pre-feasibility report of -...

PRE-FEASIBILITY REPORTOF

Total Production Capacity and augmentation of

integrating melting and rolling facilityPROPOSED BY

M/s KUNDLAS LOH UDYOG

LOCATED AT-BALIANA, TEHSIL-BADDI, DIST.-SOLAN,

STATE-HIMACHAL-PRADESH

PREPARED BY

SHIVALIK SOLID WASTE MANAGEMENT LIMITEDQCI/NABET EIA CONSULTANT ORGANIZATIONS

Registered Office:

Village Majra, Post Office Dabhota, Tehsil Nalagarh

Distt. Solan, Himachal Pradesh - 174101

CorporateOffice:

SCO 20-21, 2nd Floor, Near Hotel Dolphin, Baltana,

Zirakpur Punjab- 140 604

Phone/Telefax: 01762 – 509496

PROPOSED TOR

3(a): STANDARD TERMS OF REFERENCE FOR CONDUCTING ENVIRONMENT IMPACT ASSESSMENT STUDY FOR METALLURGICAL INDUSTRIES (FERROUS & NON FERROUS) PROJECTS AND INFORMATION TO BE INCLUDED IN EIA/EMP REPORT

A. STANDARD TERMS OF REFERENCE (TOR)

1) Executive Summary

2 ) Int roduct ion

i. Details of the EIA Consultant including NABET accreditation

ii. Information about the project proponent

iii. Importance and benefits of the project

3) Project Description

i. Cost of project and time of completion.

ii. Products with capacities for the proposed project.

iii. If expansion project, details of existing products with capacities and whether

adequate land is available for expansion, reference of earlier EC if any.

iv. List of raw materials required and their source along with mode of transportation.

v. Other chemicals and materials required with quantities and storage capacities

vi. Details of Emission, effluents, hazardous waste generation and their management.

vii. Requirement of water, power, with source of supply, status of approval, water

balance diagram, man-power requirement (regular and contract)

viii. Process description along with major equipments and machineries, process flow

sheet (quantative) from raw material to products to be provided

ix. Hazard identification and details of proposed safety systems.

x. Expansion/modernization proposals:

a. Copy of all the Environmental Clearance(s) including Amendments thereto

obtained for the project from MOEF/SEIAA shall be attached as an Annexure. A

certified copy of the latest Monitoring Report of the Regional Office of the Ministry

of Environment and Forests as per circular dated 30th May, 2012 on the status of

compliance of conditions stipulated in all the existing environmental clearances

including Amendments shall be provided. In addition, status of compliance of

Consent to Operate for the ongoing Iexisting operation of the project from SPCB

shall be attached with the EIA-EMP report.

b. In case the existing project has not obtained environmental clearance, reasons

for not taking EC under the provisions of the EIA Notification 1994 and/or EIA

Notification 2006 shall be provided. Copies of Consent to Establish/No

Objection Certificate and Consent to Operate (in case of units operating prior to

EIA Notification 2006, CTE and CTO of FY 2005-2006) obtained from the SPCB

shall be submitted. Further, compliance report to the conditions of consents

from the SPCB shall be submitted.

4) Site Details

i. Location of the project site covering village, Taluka/Tehsil, District and State, Justification for selecting the site, whether other sites were considered.

ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000

scale on an A3/A2 sheet. (including all eco-sensitive areas and environmentally

sensitive places)

iii. Details w.r.t. option analysis for selection of site

iv. Co-ordinates (lat-long) of all four corners of the site.

v. Google map-Earth downloaded of the project site.

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located within an Industrial

area/Estate/Complex, layout of Industrial Area indicating location of unit within

the Industrial area/Estate.

vii. Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation/greenbelt, in particular.

viii. Landuse break-up of total land of the project site (identified and acquired),

government/ private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (not required for industrial area)

ix. A list of major industries with name and type within study area (10km radius) shall be incorporated. Land use details of the study area

x. Geological features and Geo-hydrological status of the study area shall be included.

xi. Details of Drainage of the project upto 5km radius of study area. If the site is

within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of Flood Level of the project site and maximum Flood Level of the river

shall also be provided. (mega green field projects)

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition

process and expected time of complete possession of the land.

xiii. R&R details in respect of land in line with state Government policy

5) Forest and wildlife related issues (if applicable):

i. Permission and approval for the use of forest land (forestry clearance), if any, and

recommendations of the State Forest Department. (if applicable)

ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed

site delineating the forestland (in case of projects involving forest land more than

40 ha)

iii. Status of Application submitted for obtaining the stage I forestry clearance along

with latest status shall be submitted.

iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere

Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit

the map duly authenticated by Chief Wildlife Warden showing these features vis-à-

vis the project location and the recommendations or comments of the Chief Wildlife

Warden-thereon

v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the

State Government for conservation of Schedule I fauna, if any exists in the study

area

vi. Copy of application submitted for clearance under the Wildlife (Protection) Act,

1972, to the Standing Committee of the National Board for Wildlife

6) Environmental Status

i. Determination of atmospheric inversion level at the project site and site-specific

micro-meteorological data using temperature, relative humidity, hourly wind

speed and direction and rainfall.

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and

other parameters relevant to the project shall be collected. The monitoring stations

shall be based CPCB guidelines and take into account the pre-dominant wind

direction, population zone and sensitive receptors including reserved forests.

iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency

given in the NAQQM Notification of Nov. 2009 along with - min., max., average

and 98% values for each of the AAQ parameters from data of all AAQ stations

should be provided as an annexure to the EIA Report.

iv. Surface water quality of nearby River (100m upstream and downstream of

discharge point) and other surface drains at eight locations as per

CPCB/MoEF&CC guidelines.

v. Whether the site falls near to polluted stretch of river identified by the

CPCB/MoEF&CC, if yes give details.

vi. Ground water monitoring at minimum at 8 locations shall be included.

vii. Noise levels monitoring at 8 locations within the study area.

viii. Soil Characteristic as per CPCB guidelines.

ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation

of materials, additional traffic due to proposed project, parking arrangement etc.

x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the

study area shall be given with special reference to rare, endemic and endangered

species. If Schedule-I fauna are found within the study area, a Wildlife

Conservation Plan shall be prepared and furnished.

xi. Socio-economic status of the study area.

7) Impact and Environment Management Plan

i. Assessment of ground level concentration of pollutants from the stack emission

based on site-specific meteorological features. In case the project is located on a

hilly terrain, the AQIP Modelling shall be done using inputs of the specific terrain

characteristics for determining the potential impacts of the project on the AAQ.

Cumulative impact of all sources of emissions (including transportation) on the

AAQ of the area shall be assessed. Details of the model used and the input data

used for modelling shall also be provided. The air quality contours shall be plotted

on a location map showing the location of project site, habitation nearby, sensitive

receptors, if any.

ii. Water Quality modelling - in case of discharge in water body

iii. Impact of the transport of the raw materials and end products on the surrounding

environment shall be assessed and provided. In this regard, options for transport of

raw materials and finished products and wastes (large quantities) by rail or rail-cum

road transport or conveyor-cum-rail transport shall be examined.

iv. A note on treatment of wastewater from different plant operations, extent recycled

and reused for different purposes shall be included. Complete scheme of effluent

treatment. Characteristics of untreated and treated effluent to meet the prescribed

standards of discharge under E(P) Rules.

v. Details of stack emission and action plan for control of emissions to meet standards.

vi. Measures for fugitive emission control

vii. Details of hazardous waste generation and their storage, utilization and

management. Copies of MOU regarding utilization of solid and hazardous waste in

cement plant shall also be included. EMP shall include the concept of waste-

minimization, recycle/reuse/recover techniques, Energy conservation, and natural

resource conservation.

viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A

detailed plan of action shall be provided.

ix. Action plan for the green belt development plan in 33 % area i.e. land with not less

than 1,500 trees per ha. Giving details of species, width of plantation, planning

schedule etc. shall be included. The green belt shall be around the project

boundary and a scheme for greening of the roads used for the project shall also be

incorporated.

x. Action plan for rainwater harvesting measures at plant site shall be submitted to

harvest rainwater from the roof tops and storm water drains to recharge the

ground water and also to use for the various activities at the project site to

conserve fresh water and reduce the water requirement from other sources.

xi. Total capital cost and recurring cost/annum for environmental pollution control

measures shall be included.

xii. Action plan for post-project environmental monitoring shall be submitted.

xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency

Management Plan including Risk Assessment and damage control. Disaster

management plan should be linked with District Disaster Management Plan.

8) Occupational health

i. Plan and fund allocation to ensure the occupational health & safety of all contract

and casual workers

ii. Details of exposure specific health status evaluation of worker. If the workers'

health is being evaluated by pre designed format, chest x rays, Audiometry,

Spirometry, Vision testing (Far & Near vision, colour vision and any other ocular

defect) ECG, during pre placement and periodical examinations give the details of

the same. Details regarding last month analyzed data of above mentioned

parameters as per age, sex, duration of exposure and department wise.

iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of

hazards and whether they are within Permissible Exposure level (PEL). If these are

not within PEL, what measures the company has adopted to keep them within PEL so

that health of the workers can be preserved,

iv. Annual report of heath status of workers with special reference to Occupational

Health and Safety.

9) Corporate Environment Policy

i. Does the company have a well laid down Environment Policy approved by its

Board of Directors? If so, it may be detailed in the EIA report.

ii. Does the Environment Policy prescribe for standard operating process /

procedures to bring into focus any infringement / deviation / violation of the

environmental or forest norms / conditions? If so, it may be detailed in the EIA.

iii. What is the hierarchical system or Administrative order of the company to deal

with the environmental issues and for ensuring compliance with the

environmental clearance conditions? Details of this system may be given.

iv. Does the company have system of reporting of non compliances / violations of

environmental norms to the Board of Directors of the company and / or

shareholders or stakeholders at large? This reporting mechanism shall be detailed

in the EIA report

10) Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase.

11) Enterprise Social Commitment (ESC)

i. Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with timebound action plan shall be included. Socio-economic development activities need to be elaborated upon.

12) Any litigation pending against the project and/or any direction/order passed by any

Court of Law against the project, if so, details thereof shall also be included. Has the unit

received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant

Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s)

and present status of the case.

13) A tabular chart with index for point wise compliance of above TOR.

Pre-feasibility Report

Pre-feasibility Report of Expansion of Total Production Capacity and augmentationof integrating melting and rolling facility of M/s Kundlas Loh Udyog

Shivalik Solid Waste Management Ltd. Page 1

Table of Contents1 EXECUTIVE SUMMARY ............................................................................................................ 4

1.1 Introduction .................................................................................................................................................................... 4

1.2 Synopsis of the Report............................................................................................................................................... 5

2 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION ............................ 6

2.1 Identification of the Project and Project Proponent .................................................................................. 6

2.2 Brief Description of Nature of the Project....................................................................................................... 7

2.3 Need for the Project and Its Importance to the Country and or Region.......................................... 7

2.4 Demand –Supply Gap ................................................................................................................................................. 8

2.5 Employment Generation (Direct and Indirect) Due to Project............................................................. 9

3 PROJECT DESCRIPTION ........................................................................................................10

3.1 Type of Project.............................................................................................................................................................10

3.2 Location...........................................................................................................................................................................11

3.3 Details of Alternate Sites ........................................................................................................................................14

3.4 Size and Magnitude of operation........................................................................................................................14

3.5 Project Description with Process Details.......................................................................................................15

3.6 Source of Pollution and it’s Control ..................................................................................................................17

3.7 Selection Criteria of plant species for Green Development Plant .....................................................17

3.8 Resource optimization/Recycling and Reuse..............................................................................................18

3.9 Availability of water its source, Energy/Power requirement and source....................................18

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

Management/disposal ............................................................................................................................................................19

4 SITE ANALYSIS.........................................................................................................................20

4.1 Connectivity ..................................................................................................................................................................20

4.2 Land Form, Land use and Land ownership...................................................................................................22

4.3 Topography ...................................................................................................................................................................22

4.4 Existing Land Use pattern......................................................................................................................................23

4.5 Existing Infrastructure ............................................................................................................................................23

4.6 Soil Classification........................................................................................................................................................23

4.7 Social Infrastructure available ............................................................................................................................23

5 PLANNING BRIEF ....................................................................................................................24



5.1 Planning concept (type of industries, facilities, transportation etc.) Town and country,

planning/ development authority classification.......................................................................................................24

5.2 Population Projection ..............................................................................................................................................24

5.3 Land use planning (breakup along with green belt etc.) .......................................................................24

5.4 Assessment of infrastructure demand (physical and the social) ......................................................24

5.5 Amenities/Facilities..................................................................................................................................................24

6 PROPOSED INFRASTRUCTURE ...........................................................................................25

6.1 Industrial area (processing area) ......................................................................................................................25

6.2 Residential Area (non- Processing area)........................................................................................................25

6.3 Green Belt.......................................................................................................................................................................25

6.4 Social Infrastructure .................................................................................................................................................25

6.5 Connectivity ..................................................................................................................................................................25

6.6 Water Management (Source and Supply of Water)..................................................................................25

6.7 Sewerage System........................................................................................................................................................26

6.8 Industrial Waste Management ............................................................................................................................26

6.9 Solid Waste Management.......................................................................................................................................26

6.10 Power Requirement & Supply/source ............................................................................................................26

7 REHABILITATION AND RESETTLEMENT (R & R) PLAN ...............................................27

8 PROJECT SCHEDULE & COST ESTIMATES ........................................................................28

8.1 Total Project Cost .......................................................................................................................................................28

9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) .............................................29



List of Table

Table 2-1: Project Details................................................................................................................................... 6

Table 2-2: Employment Details ....................................................................................................................... 9

Table 3-1: Salient Features of the Project ................................................................................................ 10

Table 3-2: Coordinate....................................................................................................................................... 11

Table 3-3: List of Existing Machinery along with Capacity................................................................ 14

Table 8-1: Total Project Cost ......................................................................................................................... 28

List of Figure

Figure 3-1: Process flow sheet ...................................................................................................................... 11

Figure 3-2: Location Map of the Project Site ........................................................................................... 12

Figure 3-3: 10 km Radius Buffer Location Map ..................................................................................... 13

Figure 3-4: Water Balance Chart.................................................................................................................. 19

Figure 4-1: Map Showing 10 km Radius of Environment Sensitivity Map around Project

Location ................................................................................................................................................................. 21

List of Annexure

Annexure-I: Consent to Operate

Annexure-II: Copy of Tatima

Annexure-III: Partnership Deed



1 EXECUTIVE SUMMARY

1.1 Introduction

M/s Kundlas Loh Udyog is an existing secondary steel based industrial unit located at Kh

No. 414, 415, 416, 418 and 133 of mauza Baliana, Vill. Baliana, Tehsil- Baddi, Distt.- Solan,

State-Himachal Pradesh. The existing industrial unit has installed production capacity of

~54000 MT/Annum (~165 MT/day) of rolled steel sections using MS scrap/ingot as basic

raw material.

M/s Kundlas Loh Udyog is planning for capacity expansion and augmentation. In the

process the industrial unit will increase its molten metal generation capacity, addition of

continuous casting machine (CCM), and enhancing re-rolling mill capacity. After proposed

expansion, installed production capacity of the industrial unit will increase to ~92500

MT/Annum (~280 MT/day) along with increased quantity of raw material from 109.1

MT/Day to 310 MT/day. The existing coal based furnace would be used as standby and

same would comes in the production process during failure of induction furnaces having

total consumption of fuel i.e. Coal around 19000 kg and FO around 9216 kg for the

production of ~280 MT/day.

The industrial unit has valid “Consents to operate” for the existing setup and the renewal of

the same has applied on Date 13.03.2015 (Attached as Annexure I). The proposed

expansion will be done in the existing plant premises only.

The proposed project planning needs “Environmental Clearance” from the MoEF as

per the EIA Notification, 2006. The project is classified under Category A due to

“General Conditions” (interstate boundary) as Metallurgical Industries (primary

metallurgical processing), listed as Item 3(a) of the schedule of the EIA Notification.

Water for construction and domestic purpose will be drawn from borewell. Approximately 65

KLD water will be used for industrial and domestic purposes. Total Power load will increase

to around 11000 KVA to run the additional plant & machinery during. The electrical power

will be sourced from Himachal Pradesh State Electricity Board (HPSEB).



Total land area available with the industrial unit, presently, is around 0.778941 Ha. There

shall not be any change in the land area in the proposed project planning.

1.2 Synopsis of the Report

The pre-feasibility report includes a brief introduction of the company, need and

justification of the project, process description, required and available resources, proposed

Environment Management Systems, land-use and proposed infrastructure, project

schedule and cost estimate and proposed Terms of reference for conducting the EIA

studies. M/s Kundlas Loh Udyog has engaged M/s Shivalik Solid waste management limited

as their Environmental Consultant to conduct the EIA studies for obtaining Environmental

Clearance (EC) for the proposed Project.



2 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of the Project and Project Proponent

M/s Kundlas Loh Udyog located at Kh No. 414, 415, 416, 418 and 133 of mauza Baliana,

Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal Pradesh. The proponent plans to

enhance the production capacity of the plant due to huge demand of the same.

The existing plant has ~54000 MT/Annum (165 MT/Day) and it has planned to increase

up to ~92500 MT/Annum (280 MT/Day) (rolled sections) by increased quantity of raw

material from 109.1 MT/Day to 310 MT/day by using two induction furnaces each having

12 MT/heat capacity with increased raw material consumption around 310 MT/day.

The details of the project is given in Table below-

Table 2-1: Project Details

S. No Parameters Description

1 Identification of

project

Project falls under Metallurgical Industries Item 3(a) of

the schedule of EIA notification of Sept 14, 2006 issued by

MOEF & CC.

2 Project Proponent M/s Kundlas Loh Udyog

3 Brief description of

nature of the project

The proposed project is for the expansion of the

production capacity from ~54000 MT/Annum (165

MT/Day) to ~92500 MT/Annum (280 MT/Day) (rolled

sections) by increased quantity of raw material from 109.1

MT/Day to 310 MT/day by using two induction furnaces

each having 12 MT/heat capacity within already

established premises only.

There is a provision for the replacement of induction

furnace having 6 MT/hr to 12 MT/hr and additionally one

12 MT/hr and CCM with 20 MT/hr with re-rolling mill

with 14 MT/hr.

4 Salient Features of the Project

4.1 Proposed plant

capacity

~92500 MT/Annum (280 MT/Day) (rolled sections) by

using two induction furnaces each having 12 MT/heat

capacity and CCM with 20 MT/hr and re-rolling mill with

14 MT/hr.

4.2 Total Plot Area Total Plot Area –0.778941 Ha.

4.3 Location Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal

Pradesh



S. No Parameters Description

4.4 Water requirement Water for construction and domestic purpose will be drawn

from Borewell.

Approximately 65 KLD water will be used during

operational phase.

4.5 Source of water Borewell

4.6 Wastewater 9 KLD generated domestic waste water will be used for

the irrigation purposes.

Most of water quantity shall be used for cooling purpose in

proposed project activity and same shall be reused within

the plant premises after neutralization and addition of

makeup water.

4.7 Man Power Around 321 person

4.8 Electricity/Power

requirement

Total Power load around 11000 KVA to run the additional

plant & machinery during Construction and Operational

Phase.

Source: Himachal Pradesh State Electricity Board

(HPSEB)

In case of Power failure DG sets of 2X125 KVA Capacity

would be provided.

4.9 Alternative site The proposed addition will be established in the existing

plant premises only.

4.10 Land form, Land use

and land ownership

Private land, owned by M/s. Kundlas Loh Udyog

5.0 Project cost The estimated cost of the proposed Project is

approximately Rs. 1019.75 Lacs.

2.2 Brief Description of Nature of the Project

M/s Kundlas Loh Udyog is an existing industrial unit which plans to enhance the

production capacity up to 280 MT/day (rolled sections) by using two induction furnaces

each having 12 MT/heat capacity and rerolling mill (including reheating furnace) having

production capacity of ~14 MT/hr (while operating in single shift of 8 hours) at Vill.-

Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal Pradesh.

2.3 Need for the Project and Its Importance to the Country and or Region

India is the world’s third-largest producer of crude steel (up from eighth in 2003) and is

expected to become the second-largest producer by 2016. The growth in the Indian steel

sector has been driven by domestic availability of raw materials such as iron ore and cost-



effective labor. Consequently, the steel sector has been a major contributor to India’s

manufacturing output.

The Indian steel industry is very modern with state-of-the-art steel mills. It has always

strived for continuous modernization and up-gradation of older plants and higher energy

efficiency levels. While plant closures and privatization are rare in India, the private sector

is considered to be the engine of growth in the steel industry and technological changes

and modernization are taking place in both the public and the private sector integrated

steel plants in India.

2.4 Demand –Supply Gap

Steel production of India accounted for 14.33 million tons in 1990-91, which gradually

increased to 36.12 million tons in 2003-04. Rapid rise in production has resulted in India

becoming the 3rd largest producer of crude steel in 2015 and the country continues to be

the largest producer of sponge iron or DRI in the world. As per the report of the Working

Group on Steel for the 12th Five Year Plan, there are many factors exists which carry the

potential of raising the per capita steel consumption in the country. These include among

others, an estimated infrastructure investment of nearly a trillion dollars, a projected

growth of manufacturing from current 8% to 11-12%, increase in urban population to 700

million by 2030 from the current level of 400 million, emergence of the rural market for

steel currently consuming around 10 kg per annum. At the time of its release, the National

Steel Policy 2005 had envisaged steel production to reach 110 Million Metric Tonnes

(MMT) by 2019-20. However, based on the assessment of the current ongoing projects,

both in greenfield and brownfield, the Working Group on Steel for the 12th Five Year Plan

has projected that domestic crude steel capacity in the county is likely to be 140 MT by

2016-17 and has the potential to reach 149 MT if all requirements are adequately met. The

National Steel Policy 2005 is currently being reviewed keeping in mind the rapid

developments in the domestic steel industry (both on the supply and demand sides) as well

as the stable growth of the Indian economy since the release of the Policy in 2005. India is

expected to become the world's second largest producer of crude steel in the next 10 years,

moving up from the third position, as its capacity is projected to increase to about 300 MT



by 2025. Huge scope for growth is offered by India’s comparatively low per capita steel

consumption and the expected rise in consumption due to increased infrastructure

construction and the thriving automobile and railways sectors.

2.5 Employment Generation (Direct and Indirect) Due to Project

Total manpower of the proposed project would be around 321. The detail is given below-

Table 2-2: Employment Details

S. No. Type of Employment Total

1. Managerial/Office Staff 07

2. Skilled/Supervisory 74

3. Un-skilled/Workers 240

Total Employment 321

During Construction phase the labors and workers will be hired from nearby areas.



3 PROJECT DESCRIPTION3.1 Type of Project

M/s Kundlas Loh Udyog is an existing industrial unit. The existing setup included induction

furnace and re-rolling mill (including reheating furnace) having production capacity of ~

14 MT/hr (while operating in single shift of 8 hours). After expansion, the proposed

capacity of the plant would be around ~280 MT/Day (rolled sections) by using two

induction furnaces each having 12 MT/heat capacity within the existing plant premises.

The proposed project belongs to expansion of production capacity and augmentation of the

existing unit. During failure of induction furnace, existing coal based furnace would be

utilized with total coal (fuel) consumption around 19000 kg and FO around 9216 kg for the

production of 280 MT/Day (rolled sections). The existing coal based furnace used as

standby along with the induction furnaces. Salient feature of the plant is given in Table

below-

Table 3-1: Salient Features of the Project

S. No. Particulars Existing Proposed expansion Total

1. Coal based Furnace 6 MT/heat - 6 MT/heat

2. Induction Furnace - 2X12 MT/heat 24 MT/heat

3. Installed

production capacity

~165 MT/day ~115 MT/day ~280 MT/day

4. Fixed capital

investment

719.24 Lacs 300.51 Lacs 1019.75 Lacs

5. Fuel consumption Pulverized Coal-

19000 kg

Furnace Oil-9216 kg

- Pulverized Coal-

19000 kg

Furnace Oil-9216 kg

6. Electrical power

requirement

4210.53 KVA 6789.47 KVA 11000 KVA

7. Raw material

requirement

109.1 MT/Day 200.9 MT/Day 310 MT/Day

8. Land area 0.778941 Ha. 0 0.778941 Ha.

9. Manpower

requirement

54 267 321

10. Gross water

requirement

0.5 KLD (Domestic) 64.5 (Domestic +

Industrial)

65 KLD (Domestic +

Industrial)



S. No. Particulars Existing Proposed expansion Total

11. Solid waste

generation

Slag

Mill scale

20 MT

3 MT

12. Hazardous waste

APCD dust

Spent lubricant

600-800 kg/day

400 kg/year

Source: Project Report

* Existing induction furnaces with 6 MT/hr would be replaced with 12 MT/hr and

provision for additional induction furnaces with aggregate capacity of around ~24 MT/hour.

Figure 3-1: Process flow sheet

3.2 Location

The proposed project site is located at Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-

Himachal Pradesh. The coordinate is given in Table below-

Table 3-2: Coordinate

Latitude 30°54'59.27"N

Longitude 76°50'01.02"E

Pre-feasibility Report of Expansion of Total Production Capacity and augmentation of integrating melting and rollingfacility of M/s Kundlas Loh Udyog


Figure 3-2: Location Map of the Project Site



Figure 3-3: 10 km Radius Buffer Location Map



3.3 Details of Alternate Sites

No alternate site is examined the details of land is as follows-

Land requirement and availability:

Land is already available in plant premises at Vill.- Baliana, Tehsil- Baddi, Distt.- Solan,

State-Himachal Pradesh.

Land ownership Details:

Land is already belongs to M/s Kundlas Loh Udyog at Vill.- Baliana, Tehsil- Baddi,

Distt.- Solan, State-Himachal Pradesh.

Tatima is attached as Annexure II.

3.4 Size and Magnitude of operation

M/s Kundlas Loh Udyog is an existing industrial unit at Village Baliana. The proposed

project is for expansion of production capacity and augmentation of the existing plant. The

plant is running with ~165 MT/Day of production capacity and rerolling mill (including

reheating furnace) and it has proposed to enhance the capacity up to ~280 MT/Day by

increased quantity of raw material from 109.1 MT/Day to 310 MT/day by using two

induction furnaces each having 12 MT/heat capacity with increased raw material

consumption around 310 MT/day within the plant premises.

The list of existing machinery is given in Table below-

Table 3-3: List of Existing Machinery along with Capacity

S.No.

Machinery Capacity

1. Induction Furnace(with 2 Pots) 6 M.T

2. Reheating Furnace Thermocouple 14 Ton /Hour

3. Roughing Mill 370 MM (3i)

4. Intermediate Mill 370 MM (2i)

5. Finishing Mill 360 MM (2i)

6. Reduction Gear 5.5:1

7. Pinion Gear 1:1



S.No.

Machinery Capacity

8. Electric Motor 1250

9. Electric Motor 500

10. Electric Transformer 1500 KVA

11. E.O.T Crane 5 M.T

12. Mobile Crane 15 M.T

13. Cooling Bed 13.71x6.09 Mt.

14. Shearing/ Cutting Machine 10 Ton/ Hour

15. Striating Machine 12 Ton/ Hour

16. Lathe Machine 8 Ft




20. Shaper Machine 24 Inches

21.Roller of equal Angles & Channel of size 35, 40, 50,

65, 75 & 100, 75

22. Drill Machine 50 MM

23. Grinder 2800 RPM

24. Welding Machine 4 KW

25. Electric Generator 125 KW

26. Weight Bridge 50 Ton

3.5 Project Description with Process Details

The industrial unit is planning for capacity expansion/augmentation integrating melting

and rolling facility and also increasing overall production capacity. Firstly the preparation

of stored scrap would be carried out with sized, classified and accordingly stocked sent to

the induction furnace shell via overhead with the help of traveling crane equipped with



hydraulic grab having capacity of 2m3. Induction melting system has two shells and

operated with same electrical line. During operation of one shell, another one is fed with

scrap to decrease the process time. The induction furnaces are driven by transformer.

The melted scrap is tilted from hydraulically operated induction furnaces into liquid steel

ladle having capacity 35 ton. The liquid steel is transferred to ladle furnace to adjust the

final analysis and temperature, suitable for billets with the help of installed sliding gate

mechanism on bottom of each ladle and the liquid steel is stirred with a inert gas such as N2

or Ar.

After reaching the desired analysis and temperature, it will take on to the casting platform

by casting machine with the help of casting carne, capable to cast square billets from 100 to

165 mm. the melt shop also includes one (2) strands continuous machine where the casting

of the billets would be done.

In caster the sliding gate is opened and liquid steel starts to flow into 2 strand tundish

located on tundish car through the tundish nozzles into caster moulds where liquid steel

start to solidify by re-circulating water. The steel billet is completely solidified by water jets

through the strand. After the straightening and withdrawal mechanism produced billets

are cut into desired length. A flat type cooling bed is used to cool down the hot billets.

At the end of cooling bed, the billets would be transferred by forklifts or by crane to make it

stacking.

A laboratory, equipped with a sample preparation equipment spectrometer analyzer is

incorporate to check the conformity of products with the chemical and quality standards

required.

Water is treated in the water treatment facilities and used as the makeup water. The

industrial cooling water is cleaned, cooled and re-used in the water facilities. A de-dusting

plant, equipped with high temperature filters is provided to the dust content of furnace exit

gas.



3.6 Source of Pollution and it’s Control

A) Flue Gas management

The flue gases generated during melting of scrap are the major source of air pollution.

Quality and quantity of flue gases mainly depends upon type of Scrap used in Furnace, i.e.

degree of contamination in the Scrap. These flue gases need proper treatment for removal

of dust particles before being discharged into the atmosphere. Major pollutants generated

in the process will be Carbon Dioxide, Carbon Monoxide, Suspended dust (PM10, PM2.5,

Heavy metals like As, Cr, Pb, Cd, Zn & Mn), Sulpher Dioxide (traces), Oxides of Nitrogen (in

low concentration, depending on the temp of the process) and emissions from DG sets.

Currently the Air Pollution Control Device (APCD) unit with cyclone & bag filters is

installed at the facility & its capacity will be increased in accordance with the proposed

expansion to control the emissions within permissible limit will be let-out through stack.

B) Hazardous Waste Management

Around 20 MT Slag would be generated. The disposable waste would be around 18 MT out

of 20 MT which would be stored along with generated Slag dust from cyclones and Bag

filters around 600-800 kg and transported to TSDF. The rest 2 MT would be reusable for

recovery of metal and same would be recycled for the production process.

C) Green Belt

Green belt will be developed as per CPCB guidelines. Plants of the various species will be

planted in the plant and peripheral areas of the project site.

3.7 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 will be locally available

5. Species tolerances to air pollutants like PM, SO2, and NOx should be preferred.

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.

3.8 Resource optimization/Recycling and Reuse

Various steps shall be taken for recycle/ reuse in the proposed project is as mentioned

below:

Waste water generated shall be mainly from cooling and same shall be reused

within the plant premises by neutralizing.

Slag from furnaces, Dust from cyclones & Bag filters are hazardous materials

generated on site, will be stored and transported to TSDF site.

3.9 Availability of water its source, Energy/Power requirement and source

Water for construction and domestic purpose will be drawn from borewell. Approximately 65

KLD water will be used for industrial and domestic purposes. Water balance is given in Figure

below-

Total Power load of 11000 KVA will be used to run the additional plant & machinery during

construction and operational phase.

Source: Himachal Pradesh State Electricity Board (HPSEB). In case of power failure two DG

sets of 125 KVA provided.



Figure 3-4: Water Balance Chart

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

Management/disposal


of 20 MT which would be stored along with generated Slag dust from cyclones and Bag

filters around 600-800 kg and transported to TSDF. The rest 2 MT would be reusable for

recovery of metal and same would be recycled for the production process.

Solid waste management will be done as per MSW 2000 rule & amended thereof. Water

shall be for cooling purpose in proposed project activity. Waste water generated shall be

mainly from cooling shall be reused within the plant premises. Generated domestic waste

water will be sent to septic tank.



4 SITE ANALYSIS4.1 Connectivity

The Plant site is located at Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal

Pradesh. The Plant is located at Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal

Pradesh. Project location is about 2.3 km away from National Highway-105. The project

site is around 447 m above MSL.

The site is well connected by road and railways and the neighboring city and town is

Chandigarh and Baddi around 31.5 km and 10.8 km away from project site respectively.

The nearest railway station is Chandigarh Railway station about 34.8 km, S. Chandigarh

Airport is around 42.6 km, S away from the project site.

The study area map is given in Figure below-



Figure 4-1: Map Showing 10 km Radius of Environment Sensitivity Map around Project Location



4.2 Land Form, Land use and Land ownership

Land is already available with M/s Kundlas Loh Udyog located at Vill.- Baliana, Tehsil-

Baddi, Distt.- Solan, State-Himachal Pradesh. The land is hilly terrain, utilized for the

cultivation, forest and industrial purposes.

4.3 Topography

The topography of the district is mountainous with elevation ranging from 300 meters to

3000 meters from above sea level. The mountain ranges of the district lie on the outer

Himalayas and are a part of Shivalik ranges. Doon valley is the most fertile tract in Nalagarh

tehsil. The Saproon valley in Solan tehsil and Kunihar valley in Arki though small in size,

are also fertile. The district by and large is also climatically suitable for growth of

temperate fruits.

Climate:

The climate of the district is sub-tropical in the valley and tends to be temperate on the

hilltops. There are four major seasons. The winter season commences from November to

February and ends in March; summer season extends from March to June, followed by the

monsoon period extending from July to September. Maximum precipitation occurs during

July to September. Average annual rainfall in the district is about 1140.86 mm, out of which

85% rainfall occurs during June to September. In the winter season, precipitation as

snowfall also occurs in the higher reaches up to 1000 m elevation and as rainfall in low hills

and valleys of the district. Mean maximum and minimum temperature ranges between

32.2°C (May) and 0.6°C (January).

Geology:

The state of Himachal Pradesh is covered by the rocks ranging in age from Precambrian to

Recent. The normal order of super-position of the rocks in the Lesser Himalaya has been

affected by later events of thrusting. Owing to its complex tectonism and geological

evolution, establishing an unanimously-accepted geology and stratigraphy of Himalaya

remained mired with debate and controversy- posing a natural deterrent.



4.4 Existing Land Use pattern

The land is hilly terrain, utilized for the cultivation, forest and industrial purposes. The

existing land is used as industrial purposes. The land of the area is flat plain having slight

slope and well developed industrial area.

4.5 Existing Infrastructure

The infrastructure amenities available in the area denote the economic wellbeing of the

region. The project area is connected with NH-105 and SH-9. Educational facilities up to

Senior School, College, Hospital & Banking facilities are available at Baddi about 10.8 km

away from the project area. The existing building comprise of rolling mill shed, Workshop

shed & Competitive administrative block along with office quarters at the existing

premises.

4.6 Soil Classification

Soils of the area have been classified under three Orders i.e. Alfisols, Entisols and

Inceptisols and all the thirty two Soil Series identified in the area have been further

classified into four Suborders; five Great Groups; six Subgroups and fourteen Families.

Soil testing will be done and will be submitted at EIA (Baseline study) stage.

4.7 Social Infrastructure available

Schools, colleges, hospitals & healthcare centers, shops & bazaars, community centers etc.

are all available on nearby area.



5 PLANNING BRIEF

5.1 Planning concept (type of industries, facilities, transportation etc.) Town

and country, planning/ development authority classification

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

envisaged. The nearby towns have the modern facilities.

5.2 Population Projection

There would not be any significant development/increase in the population of surrounding

area. Workers for the proposed project will come from the local residents in the

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

project.

5.3 Land use planning (breakup along with green belt etc.)

The open space inside the plant area will suitably landscape and covered with the

vegetation of indigenous variety. Green Belt area will be developed as per the CPCB

guidelines.

The proposed expansion and augmentation of the unit will be done within existing plant

premises having total area around 0.778941 Ha, already acquired by the project

proponent.

5.4 Assessment of infrastructure demand (physical and the social)

The proposed expansion and augmentation of proposed project within well developed

industrial unit and falls in industrial area therefore all facilities/amenities like medical,

educational, housing, transportation, communication, shopping etc are available nearby

places. Local workers will be employed for the construction during proposed expansion; no

long term infrastructure will be required.

5.5 Amenities/Facilities

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

transportation facility etc are well developed in the surrounding area. All the amenities

related to project on the site will be installed.



6 PROPOSED INFRASTRUCTURE

6.1 Industrial area (processing area)

Site Infrastructure:

The site already having administrative and site control office with latest equipment

like computers, walkie‐talkie & computerized weigh‐bridge, printers, fax, Xerox

machine, etc.

Sufficient power load exists to meet the current requirement.

Water for construction and domestic purpose as well industrial purposes will be

drawn from borewell.

6.2 Residential Area (non- Processing area)

The employee quarters are provided within the plant premises. During construction

period, the manpower would be hired from nearby areas.

6.3 Green Belt

The main objective of the green belt is to provide a barrier between the plant and

surroundings areas. Green belt will be developed according to CPCB guidelines.

6.4 Social Infrastructure

Schools, colleges, hospitals & healthcare centers, shops & bazaars, community centers, etc.

are all available in nearby area.

6.5 Connectivity

The Plant is located at Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal Pradesh.

Project location is about 2.3 km away from National Highway-105. The site is well

connected by road and railways and the neighboring city and town is Chandigarh and

Baddi around 31.5 km and 10.8 km away from project site respectively. The nearest

railway station is Chandigarh Railway station about 34.8 km, S. Chandigarh Airport is

around 42.6 km, S away from the project site.

6.6 Water Management (Source and Supply of Water)

Water consumption for the unit will be as small as the requirement for the cooling system

where water will be re-circulated in the closed circuit. About 65 KL water will be required



on daily basis out of which 10 KL is used for the domestic and same would be drawn from

borewell.

6.7 Sewerage System

Around 9 KLD domestic waste water would be generated and same would be disposed off

through soak pit.

6.8 Industrial Waste Management


of 20 MT which would be stored along with the dust around 600-800 kg and transported to

TSDF. The rest 2 MT would be reusable for recovery of metal and same would be recycled

for the production process.

6.9 Solid Waste Management

Generation of solid waste will be minimum. Generated waste shall be sold to recycler. Solid

waste management will be done as per MSW 2000 rule & amended thereof.

6.10 Power Requirement & Supply/source

Total power load around 11000 KVA would be required, met from HPSEB. In case of Power

failure two DG sets of 125 KVA capacity will be provided.

Source: Himachal Pradesh State Electricity Board (HPSEB).



7 REHABILITATION AND RESETTLEMENT (R & R) PLAN

No, Rehabilitation and Resettlement (R & R) Plan required.



8 PROJECT SCHEDULE & COST ESTIMATES

The Project is envisaged to be undertaken immediately after getting statutory approvals.

8.1 Total Project Cost

Total estimated Project cost is approximately Rs. 1019.75 Lacs. The details of the breakup

is given in Table below-

Table 8-1: Total Project Cost

Existing (Lacs) Proposed (Lacs) Total (Lacs)

719.24 300.51 1019.75



9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

This project is for expansion of production capacity and augmentation of existing plant for

the production of steel related products. Due to huge demand, it has proposed to enhance

the capacity of the plant up to 280 MT/Day with the implementation of the proposed

project, the socio-economic status of the local people will improve substantially. The land

rates in the area will improve in the nearby areas due to the proposed activity. This will

help in upliftment of the social status of the people in the area. The proposed project will

also help to increase the natural beauty of the area by developing and planting new plants

along with road as well plant premises.

Annexure

Annexure-I

Annexure-II

Annexure-III

pre-feasibility report of -...

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