Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Contents
CHAPTER-1 .......................................................................................................... 6
EXECUTIVE SUMMARY ........................................................................................... 6
CHAPTER-2 .......................................................................................................... 9
INTRODUCTION OF THE PROJECT ........................................................................... 9
2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT: .......................... 9
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ....................................... 9
2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR
REGION .......................................................................................................... 10
2.4 DEMAND –SUPPLY GAP ............................................................................ 11
2.5 IMPORTS VS. INDIGENOUS PRODUCTION & EXPORT POSSIBILITY ................ 11
2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT ...... 12
CHAPTER-3 ........................................................................................................ 13
PROJECT DESCRIPTION ....................................................................................... 13
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS
IF ANY. ........................................................................................................... 13
3.2 LOCATION .............................................................................................. 13
Fig 3.1 Location map of Project site M/s K I C Metaliks Ltd. ................................ 14
Fig 3.2 Satellite map showing project boundary of M/s K I C Metaliks Ltd. ............ 15
3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING
THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE
INTO SHOULD BE HIGHLIGHTED. ....................................................................... 15
Table 3.1 Project Configuration & Product Mix after Expansion ........................... 16
3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ....................................... 18
3.6 PROCESS DESCRIPTION .......................................................................... 18
3.6.1 DRI kilns .......................................................................................... 18
3.6.2 I F .................................................................................................. 18
3.6.3 EAF ................................................................................................. 19
3.6.4 TMT ................................................................................................ 19
3.6.5 DI Pipes ........................................................................................... 19
3.6.6 Oxygen Plant .................................................................................... 20
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
3.6.7 PCI Plant ......................................................................................... 20
3.6.8 CCM ................................................................................................ 20
3.6.9 R M ................................................................................................. 20
3.6.10 Cement Plant ................................................................................. 21
3.6.11 AFBC ............................................................................................. 21
Fig 3.3 Layout of the project .......................................................................... 21
3.7 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY
SOURCE & MODE OF TRANSPORT....................................................................... 22
Table 3.2 Annual Raw material requirement for expansion project .................. 22
3.8 RESOURCE OPTIMISATION/RECYCLING AND REUSE ENVISAGED IN THE
PROJECT ......................................................................................................... 23
3.9 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND
SOURCE .......................................................................................................... 23
3.9.1 WATER REQUIREMENT: ....................................................................... 23
3.9.2 POWER REQUIREMENT FOR THE PROJECT .............................................. 23
3.10 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME
FOR MANAGEMENT ........................................................................................... 24
Table 3.3 Solid Waste Generation & Its Management ..................................... 24
3.11 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE
INFORMATION OF EIA ....................................................................................... 24
CHAPTER -4........................................................................................................ 26
SITE ANALYSIS ................................................................................................... 26
4.1 CONNECTIVITY ....................................................................................... 26
4.2 LAND FORM, LAND USE LAND OWNERSHIP ................................................ 26
Table 4.1: Land Use Pattern after Modernization & Expansion .......................... 26
Fig- 4.1: Topography of the area..................................................................... 28
4.4 LAND USE PATTERN ................................................................................ 28
Table 4.2 Land use pattern of buffer zone .................................................... 29
4.5 EXISTING INFRASTRUCTURE .................................................................... 29
4.6 SOIL CLASSIFICATION: ........................................................................... 29
4.7 CLIMATIC DATA FROM SECONDARY SOURCE .............................................. 30
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
CHAPTER -5........................................................................................................ 31
PLANNING BRIEF................................................................................................. 31
5.1 PLANNING CONCEPT ............................................................................... 31
5.2 Peripheral Development Plan .................................................................... 31
Fig 5.1: MANAGEMENT HEIRARCHY ................................................................. 32
5.3 LAND USE PLANNING .............................................................................. 33
Table 5.1: Land Use Pattern after Modernization & Expansion* ........................ 33
5.4 ASSESSMENT of INFRASTRUCTURE DEMAND .............................................. 33
CHAPTER -6........................................................................................................ 34
PROPOSED INFRASTRUCTURE .............................................................................. 34
6.1 INDUSTRIAL AREA DISTRIBUTION ............................................................. 34
6.2 GREENBELT DEVELOPMENT FACILITY ........................................................ 34
6.3 CONNECTIVITY ....................................................................................... 34
6.4 DRINKING WATER MANAGEMENT: ............................................................. 34
6.5 INDUSTRIAL WASTE MANAGEMENT ........................................................... 34
6.5.1 Waste Management ........................................................................... 34
6.5.2 Solid Waste Generation & Management ............................................... 35
6.6 INDUSTRIAL POLLUTION CONTROL ........................................................... 35
6.6.1 Air Pollution Control .......................................................................... 35
Table 6.1: PROPOSED AIR POLLUTION CONTROL FACILITIES .......................... 35
6.6.2 Water Pollution Control ...................................................................... 35
6.7 MAN POWER REQUIREMENT ..................................................................... 35
CHAPTER -7........................................................................................................ 36
REHABILITATION & RESETTLEMENT ...................................................................... 36
REHABILITATION & RESETTLEMENT ................................................................... 36
CHAPTER -8........................................................................................................ 37
PROJECT SCHEDULE ............................................................................................ 37
8.1 IMPLEMENTATION SCHEDULE ................................................................... 37
Table 8.1: Tentative implementation schedule: .............................................. 37
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
8.2 ESTIMATED PROJECT COST ...................................................................... 38
CHAPTER-9 ........................................................................................................ 39
ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION) ............................................. 39
9.1 FINANCIAL & SOCIAL BENEFITS ............................................................... 39
9.2 SOCIAL INFRASTRUCTURE ....................................................................... 39
9.3 EMPLOYMENT POTENTIAL ........................................................................ 39
9.4 BENEFITS TO THE REGION AND THE COUNTRY ........................................... 39
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
CHAPTER-1
EXECUTIVE SUMMARY
M/s KIC Metaliks Ltd.,steel project is located at Raturia Industrial area, Angadpur,
Durgapur developed by Asansol Durgapur Development Authority, in Burdwan district of
West Bengal. The project site is at latitude 23
0
30’ 32’’ N and longitude 87
0
16’
39.89’’ E, MSL 450m. The project is well connected by road and rail networks. The
important Grand Trunk road connecting Kolkata & Delhi is passing only at 3 Km from the
site. The nearest railway station at Durgapur on main line Howrah- New Delhi is about 2
km.
M/s KIC Metaliks Ltd. was incorporated on 26th August 1986 and commissioned its pig
iron unit in Raturia Industrial in February 1998 by setting up one Mini Blast Furnace of
volume 215 m
3
with production capacity of 1,09,000 TPA and slag cement grinding unit
of capacity of 100 TPD utilizing the in plant waste MBF slag.
In competitive industrial scenario, in order to survive and sustain, there was an
imperative need for modernization and expansion of the existing set up. The company
therefore took EC vide letter F. No J -11011/556/2009-IA II (I) dt.24
th
May 2011, for
following facilities.
The company applied for a fresh proposal to set up 2x350 TPD sponge iron plant, 14 MW
power generations from its waste heat, 4x15T Induction Furnace, 1x30T EAF with LF,
2x600T CCM, 2x50T Oxygen,1x50T Nitrogen Plant& 1200T Rolling mill to meet the basic
needs to produce 0.378 MTPA TMT rods, angles and channels with 0.2 MTPA DI pipes.
The unit after expansion to be 0.598 MTPA Integrated Steel Plant.
This proposal was considered by EAC on their 14
th
meeting, held on 22
nd
December,
2016 and grant of ToR was published vide minutes of meeting; 10
th
January 2017. But
with the configuration approved in ToR the company had not taken into consideration
the dolchar from DRI kilns which has potential of generating substantial power due to its
calorific value about 1800kcal/kg.
The project is primary ferrous metallurgical unit belonging to schedule 3(a) category A
and needs EC from MoEFCC
The company also felt following modifications to its 1x215m
3
MBF to make it more
environment compatible while increasing its productivity.
1. Increase its volume from 215m3 to 245m3
2. To have facilities of injecting Pulverized Coal injection to reduce Coke
consumption and increase productivity.
3. To incorporate bell less top charging system in place of existing double bell
system which has better environment protection.
4. By enriching the air blast with 3% oxygen and charging 85% sinter into furnace
then the productivity can be increased.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
In order to meet the enhanced production from MBF the company proposes additional
1x25m
2
sinter plant also.
Utilizing Dolchar from DRI kilns and fresh boiler grade coal an AFBC of 11 MW is
proposed.
Raw material for the expansion will be about 0.38 MTPA Iron ore lumps for DRI Kilns,0.4
MTPA iron ore fines for sinter plant, 0.18 MTPA DRI grade coal, 0.08 MTPA Dolomite &
heavy melting iron scrap of 0.13 MTPA.
Fresh water requirement for the expansion project is estimated to be 5,527.2 m
3
/day.
Contaminated used water of plant will be settled, cleaned and reused in the plant and
there will be zero waste water discharge to outside project boundary. More over rain
water will be harvested and used in process, which will help in reducing fresh water
intake from river.
Power requirement for expansion project is estimated to be about 55.20 MW, whereas
captive power generation from expansion project will be only 30 MW. Balance power will
be purchased from state supply.
Land
The total land required for the project is 34.80 ha out of which the company has in its
possession 30.75 ha of land on which existing project is running and giving production
and in the process of acquiring another 4.05 ha of land. The proposed expansion units
shall be accommodated and will be suitably integrated with the existing plant units.
There is no proposal at present for further acquisition of land for expansion purposes.The
proposed expansion will advantageously utilise the existing infrastructure
facilities.Important plant facilities like SMS, MBF, Rolling Mill, and Sinter etc are laid out
considering the need for optimization earthwork, rational material flow, economy in
operations and the space requirements for rational development. The layout also takes
into account the stage wise commissioning of the plant units.The general layout of the
plant shall be developed with requisite provision for landscaping and greenbelts with a
view to avoid adverse impact on the environment.
Pollution Control Features
Following pollution control measures will be taken up for integrated steel project of M/s
KIC Metaliks Ltd at Raturia industrial area, Angadpur.
Installation of ABC for burning of CO and coal dust, ESP for dust removal from DRI
kilns flue gas. Excess heat removal from flue gas through West heat boiler
Installation of 11 MW AFBC to fully consume dolchar generated from DRI kilns
Dust extraction & dedusting bag house at DRI kiln, Sinter Plant &MBF Raw Material
Stock house. This will result in reduction in fugitive dust emission.
Fine dust collection from the off gas in Sinter ESP.
Bag filter for IF and EAFs for dust and iron particle removal from fume.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Utilization of MBF gas for MBF burners and balance gas burning for generation of
steam for 5 MW power plant.
Wastewater settling, cooling and treatment for reused/recycled in the process.
Solid waste MBF Slag shall be used for cement manufacturing in the cement unit.
Other non-hazardous solid waste like flue gas dust shall be utilized in sinter unit.
Removal of entrapped iron from IF slag and recycle to IF. Slag for construction
work/land fill
In-built noise control features in machineries & equipments like acoustic enclosure
or use of PPE by people working area.
ID fans and high stack for disposal of gases at height.
Manpower
On expansion all the existing infrastructure and man power of existing plant will be
utilized for expansion project also. However there will be additional man power skilled in
new installation will be required. Besides there will be increase in contract labor, security
and canteen personnel. It is estimated that about 742 will be regular employment plus
about 50 security staff.
Project cost
The estimated expansion project is 545 crore. This will be as follows.
Sl. No.
Cost Head
Estimated Cost, in Crore
1
Land development earth
work& civil structure
50.0
2
Plant Machinery& Pollution
control devices
430.0
3
Consultant Expenses
03.5
4
Contingency
12.0
5
Margin for WC
30.0
6
Misc. Fixed Assets
10.0
7
Prel. Expenses
04.0
8
Pre-Operative Exp/IDC
05.5
Total
545.0
Project completion schedule
After getting CTE from SPCB, WB and EC from MOEF & CC tenders will be floated for
purchase, installation and commissioning of equipment and units and earth work
activities will start parallel. It is estimated the completion of project will take 3yrs of
time.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
CHAPTER-2
INTRODUCTION OF THE PROJECT
M/s KIC Metaliks Ltd is spread over in an area of 34.80 ha of land in Raturia industrial
area in Burdwan district of WB, has an employment capacity of approx. 500 persons of
various categories.
The company is at present producing sinter from 1x25m
2
sinter plant, pig iron from its
1x215m
3
MBF, and slag cement from a 100 TPD cement grinding unit.
In order to become 0.578 MTPA Integrated Steel Plant, the company applied and
granted ToR and Base line study has already been conducted to make draft EIA/EMP
report for Public Hearing.
At this point of time the company felt that there is a scope of increasing the capacity of
existing MBF, dolchar from DRI kilns will create environmental problem if stored & not
consumed in AFBC for power generation and increase capacity of MBF will need more
sinter.
The company therefore prosing amendment of granted ToR implementing above stated
facilities.
2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT:
The project is presently a pig iron casting unit manufacturing pig iron for sale from
existing 215m
3
MBF revamped with enhanced capacity and spun pipes. The company has
also its existing 100 TPD cement plant.
The company has been granted ToR vide 14
th
meeting of EAC, dt.22
nd
December 2016 to
set up DRI Kilns, IFs, EAFs with LF, VD, CCM, PCI and Oxygen, Nitrogen plant and
Rolling mills to manufacture 0.378 MTPA TMT rods, channels, angles and 0.2 MTPA DI
pipes.
The company is now proposing amendment of ToR to set up 11 MW AFBC, 1x25m
2
sinter
plant and make modification in existing 215 m
3
MBF to increase its volume to 245m
3
.
The project is primary ferrous metallurgical unit belonging to schedule 3(a) category A
and needs EC from MoEFCC
Mr. Radhesyam Jalan is Chairman and Managing Director of M/s KIC Metaliks Ltd.
addressed: “Sir RNM House”, 3B Lal Bazar street, 4
th
floor, Room No-2. The company
has IN_CIN LO14098 WB 1986 PLC 041169, I SIN INE 434C01019 and date of
incorporation 1986.
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT
The Proposed expansion project of M/s KIC Metaliks is a brown field primary
metallurgical (ferrous) project. It will be a 0.578 MTPA Integrated steel project. Mine
over burden fine iron ore & lumpy hematite ore to be processed to manufacture finished
products like TMT rods and Ductile Iron pipes for sale.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY
AND OR REGION
Steel is traditionally considered the backbone of national economic development. It is a
major input into sectors which support economic growth such as infrastructure,
machinery, power and railways, as well as being important for fast growing sectors, in
particular automobiles and consumer durables.
The steel industry in India is currently at an inflexion point brought about by ambitious
capacity expansion plans, entry of new players and increased competition on one hand
and consistently rising and shifting demand patterns on the other.
This rise in demand is expected to be driven by the construction, automobile and
consumer durables sectors
In the construction sector, Government spending in infrastructure is expected to surge
during the twelfth plan period, thus driving up demand for steel used in construction.
Most steel producers are planning major capacity expansions through both Greenfield
and Brownfield expansions. This, coupled with the entry of new players will result in a
significant rise in steel production over the next ten years.
TMT rods as proposed to be manufactured by the company are most suitable in
construction due to its high workability.
The other proposed product of M/s K I C Metaliks Ltd is Ductile Iron pipes. Ductile Iron
pipe is corrosion resistance and it has good maximum strength, it is installed for water
distribution, Industrial equipment, sewage pump, etc. With the “green movement”
growth which considers to the environmental issues, ductile iron pipe stands as natural
selection compared to its competitor, PVC. PVC pipe has negative effects to the
environmental life cycle cause of its resin matter and carbon footprint.
Ductile Iron pipe resists damage during shipping and handling, and, once installed,
withstands the most demanding operating conditions, including water hammer, frozen
ground, deep trenches, areas of high water table and heavy traffic, river crossings, pipe
on supports, rocky trenches, and areas of shifting, expansive, and unstable soils. More
over Ductile iron pipe in the developed world is normally manufactured exclusively from
recycled material including scrap steel and recycled iron. The pipe can be recycled after
use.
The above stated facts indicate importance of both the products in the development of a
country. Durgapur is steel city of West Bengal and having iron scraps available around to
be utilized. Again Iron and coal mines are also nearby with water supply from perennial
river Damodar therefore resources of the state to be utilized and employment generation
both direct and indirect main and ancillary plants will improve economy of the state,
increase tax collection of state of West Bengal and improve physical and social
infrastructure of the locality.
Thus proposed integrated steel project has make in India importance to the country &
the region.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
2.4 DEMAND –SUPPLY GAP
Due to pressure from the construction sector, the demand for longs will continue to
dominate the steel industry, while on the supply side, flats are expected to dominate
In the optimistic scenario, all crude steel capacity expansion targets announced by steel
companies are aggregated. Under this scenario, it was estimated that crude steel
capacity will be 259.11 MT in 2020-21. However, this will be possible only if the crude
steel capacity targets, as announced by steel producers are met. However, for 2020-21,
this scenario estimates a more reasonable capacity of 210.11 MT.
Base Case Scenario: The base case scenario gives a lower bound crude steel capacity
estimate. It accounts for delays in commissions of projects due to problems associated
with land acquisition, obtaining environmental clearances, raw material availability, etc.
The effect of these delays on the date of commissioning of projects was assessed
through interviews with experts and a review of secondary literature. According to this
scenario, crude steel capacity in the country in 2020-21 will be 178.8 MT.
Currently, demand for finished steel in India is estimated to be around 70 MT. This is
expected to more than double to 166 MT by 2020-21. This demand will mainly be driven
by the construction (real estate and infrastructure), automobile and consumer durables
sectors. It must be noted that this figure includes only domestic demand for steel.
Demand from international markets will further push this figure up.
2.5 IMPORTS VS. INDIGENOUS PRODUCTION & EXPORT POSSIBILITY
On liberalization of the Indian steel sector with effect from 24.5.92, iron and steel
industry was included in the list of „high priority‟ industries for automatic approval for
foreign equity investment up to 51%. This limit has since been increased to 100%.
The import regime for iron and steel has undergone major liberalization moving
gradually from a controlled import by way of import licensing, foreign exchange release,
canalization and high import tariffs to total freeing of iron and steel imports from
licensing, canalization and lowering of import duty levels. Export of iron and steel items
has also been freely allowed. Import duty on capital goods was reduced from 55% to
25%. Duties on raw materials for steel production were reduced. These measures
reduced the capital costs and production costs of steel plants.
Imports
Iron & steel are freely importable as per the extant policy.
Data on import of total finished steel (alloy + non alloy) is given below for last five
years:
Indian steel industry : Imports (in million tonnes)
2010-
11
2011-
12
2012-
13
2013-
14
2014-
15
6.66
6.86
7.93
5.45
9.32
Source: Joint Plant Committee
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Exports
Iron & steel are freely exportable.
Data on export of total finished steel (alloy + non alloy) is given below for last five
years:
Indian steel industry : Exports (in million tonnes)
Category
2010-11
2011-12
2012-13
2013-14
2014-15
Total Finished Steel (alloy + non alloy)
3.64
4.59
5.37
5.98
5.59
Source: Joint Plant Committee
Above figures are indicative of constant increase of steel export from India and likely to
increase further in coming years.
The New Industrial policy opened up the Indian iron and steel industry for
private investment by (a) removing it from the list of industries reserved for public
sector and (b) exempting it from compulsory licensing. Imports of foreign technology as
well as foreign direct investment are now freely permitted up to certain limits under an
automatic route. Ministry of Steel plays the role of a facilitator, providing broad
directions and assistance to new and existing steel plants, in the liberalized scenario.
2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE
PROJECT
As on 31
st
March the regular man power strength of M/s K I C Metaliks Ltd. was 500 and
with commissioning of all the approved facilities of existing EC and thereafter on
implementation of this proposed expansion the regular employment will be about 742+
50 security staff. There will be contract labor for canteen, road sweeping/water
sprinkling jobs etc.
Ancillary industries, business centers will develop which will engage substantial amount
of manpower for various activities.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
CHAPTER-3
PROJECT DESCRIPTION
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND
INTERDEPENDENT PROJECTS IF ANY.
The project is a primary metallurgical (ferrous) expansion project of M/s K I C Metaliks
Ltd. Coming under category-A, schedule 3(a).
This project is independent plant without any interlink or interdependence.
3.2 LOCATION
Maps showing general location, specific location and project boundary of existing plant
of M/s K I C Metaliks Ltd have been shown below with co-ordinates of project boundary.
The acquired land area is 34.80 ha in which existing project is running and in the
available vacant space of which expansion project will be accommodated.
The Project site is located in Raturia Industrial area, Durgapur, Dist. Burdwan, in the
state of West Bengal. It is situated by the side of Kolkata-Delhi Grand Trunk road. The
nearest Broad-gauge rail link is at Durgapur on main line Howrah- New Delhi which is
only 2 km away from the proposed site. Railway link for passengers and transportation
of goods is also available there
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Fig 3.1 Location map of Project site M/s K I C Metaliks Ltd.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Fig 3.2 Satellite map showing project boundary of M/s K I C Metaliks Ltd.
The corner co-ordinates of project site are as follows.
NW: 23
0
30‟ 40.31” N and 87
0
16‟ 31.22” E
NE: 23
0
30‟ 41.00” N and 87
0
16‟ 53.56” E
SW: 23
0
30‟ 25.30” N and 87
0
16‟ 29.89” E
SE: 23
0
30‟ 24.85” N and 87
0
16‟ 49.56” E
3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF
SELECTING THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL
CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED.
The existing site is located near the famous Raniganja coal belt area. The other
important minerals like iron ore, limestone, dolomite, manganese and chromites ore are
available in the neighbouring mineral rich states like Odisha & Jharkhand.
The site is in the famous Durgapur –Asansol industrial region where its product, by-
product can be transported and marketed and the required accessories and inventories
needed for the production for the processes are also available.
An important utility like water is to be supplied by M/s DPL from the nearby river
Damodar. Uninterrupted Power supply from WB State Grid is available at project site.
With these facilities at the existing premises and the vacant space available in it for
accommodating expansion, no other site has been considered. The plantation and green
belt developed by the organisation will be added advantage.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At: Raturia,Durgapur, Dist: Burdwan, West Bengal
3.4 SIZE OR MAGNITUDE OF OPERATION
The Project after this proposed expansion will be a 0.598 MTPA integrated steel project manufacturing 0.378 MTPA TMT rods/angles etc.
0.02 MTPA pig iron and 0.2 MTPA Ductile Iron pipes.
Table 3.1 Project Configuration & Product Mix after Expansion
Sl.
No.
Facilities
EC granted F. No.
J-
1011/556/2009-
IA II (I) dt. 24
th
May, 2011 for
facilities
EC
implementati
on status
Facilities
granted in
existing ToR
Facilities
proposed In ToR
amendment
Final
Configuration
After expansion
Final Capacity
in TPA
Product
1
MBF
Modernisation of
existing MBF to
enhance capacity
of 1x215 m
3
to
0.210 MTPA Pig
Implemented
Nil
Increase MBF
Volume from
215 to 245m
3
1x245 m
3
MBF
2,35,000
Hot metal/Pig
For internal use
& sale
2
DRI
-
NA
2x350 DRI
Kilns
No change
proposed
2x350 DRI Kilns
2,24,000
Sponge Iron
3
SMS
Steel Melting
shop
Not
Implemented
1x30 T EAF
No change
proposed
1x30 T EAF
3,84,000
Liquid metal for
manufacture of
billets
1x50TEAF, 1x50
T LRF,1x50 T VD
4x15T IF With
LF& V D
4x15 T IF With LF
& V D
With Matching C
C M
1200 TPD CCM
1200 TPD CCM
4
Rolling
Mill
-
NA
1200TPD R M
No change
proposed
1200 TPD R M
3,78,000
TMT rods,
angles etc.
5
Ferro
Alloy
Ferro Alloy plant
2x9 MVA (Fe-Cr,
Fe-Mn & Si-Mn)
Not
Implemented
Nil
No change
proposed
Nil
Nil
Nil
6
Sinter
Plant
Sinter Plant
1x25 m
2
Implemented
Nil
1x25m
2
2x25m
2
Sinter
Plant
3,60,000
Sinter
agglomerates
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At: Raturia,Durgapur, Dist: Burdwan, West Bengal
7
WHRB
BF gas based CPP
5 MW
Implemented
14 MW (DRI
WHRB)
No change
proposed
5 MW CPP
14 MW CPP
19 MW CPP
Electric power
for Internal use
8
AFBC
-
NA
Nil
11 MW AFBC
1x11 MW
11MW
Electric power
for Internal user
9
DI Pipe
Spun pipe
24,000 TPA
Not
Implemented
2x20 T IF
No change
proposed
2x20 T IF
2,00,000
D I spun pipe
2x0.11 MTPA
CCM(centrifuga
l)
2x0.11 MTPACC M
(centrifugal)
10
Cement
Grinder
Cement Grinding
Capacity increase
to 1,00,000 TPA
In Progress
Nil
No change
proposed
Nil
1,00,000
Cement
11
Oxygen
Plant
-
NA
1x50T &
1x100T
Oxygen Plant
No change
proposed
1x50T & 1x100T
Oxygen Plant
2,80,000Nm
3
/day
Oxygen gas
12
Nitrogen
Plant
-
NA
1x50T Nitrogen
Plant
No change
proposed
1x50T Nitrogen
Plant
80,000Nm
3
/day
Nitrogen gas
13
PCI plant
-
NA
1x100 TPD PCI
P
No change
proposed
1x100 TPD PCI
Plant
32,000
Pulverised Coal
*Out of the facilities for which EC has been accorded 1x50T EAF with LF & VOD, 2400 TPA DI spun pipe and 2x9 MVA Ferro Alloy plants
have not been installed.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS
The expansion project will have 2x25m
2
sinter plant to manufacture sinter agglomerate
from iron ore fines, dust of coal, lime stone power & mill scale etc. Sinter will be fed to
MBF. Coke, PCI, dolomite and oxygen rich blast of air will melt sinter in MBF to produce
hot metal and BF slag. Pulverized coal injection in MBF will reduce valuable coke
consumption. BF gas after cleaning shall be used as fuel in tuyeres of MBF to provide
heat for melting of Iron from sinter. Excess BF gas will be burn to generate steam in
boiler and there by generate 5 MW power.
3.6 PROCESS DESCRIPTION
3.6.1 DRI kilns
M/s K I C Metaliks Ltd. is proposing 2x350 TPD coal based DRI kilns for production of
Sponge iron as scrap substitute for IFs and 1x30T EAF. Lumpy Hematite ores will
undergo direct reduction by carbon of coal with the help of lime stone to produce spongy
sponge iron, Char will come out as co-product which will be used as fuel in proposed
22MW AFBC power plant.
3.6.2 I F
The company proposes 4x15T Core less Induction Furnaces to produce liquid metal on
melting DRI, pig iron and scrap by electric eddy current of Induction Furnace. Slag will
float over molten metal and will be scooped out. Molten metal will be refined in L F and
will join with molten metal of 1x30 T EAF for production of TMT rods etc.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Iron about 15% comes out sticking to surface of slag. This slag will be cooled down,
ground and Iron part will be separated from it magnetically to get slag equivalent to
river sand and can be used for construction purposes. Recovered iron will be recycled
back to IF for remelting.
3.6.3 EAF
The company has proposed 1x30T EAF. This will melt pig iron, DRI and hot metal from
MBF which after removal of excess carbon, Sulphur and Phosphorous on oxidation by
Oxygen will be casted to billets.
3.6.4 TMT
Coal based DRI kilns will produce sponge iron utilizing lumpy hematite iron ore, DRI
grade coal and dolomite. Sponge iron will be melted in Induction Furnace along with Pig
iron from MBF and heavy melting iron scraps purchased from market and in plant
generation. A part of hot metal from IF will be utilized to manufacture DI pipes for sale.
In MBF iron sinter will be melt in combustion heat of coal and hot metal will be mostly
used to manufacture DI pipes and balance to be cast to pig iron in PCM. Pig iron will be
utilized in IF and EAF.
EAF will melt DRI, Pig iron and scrap to produce hot metal. Hot metal from IF will join
with it and refined in LF. Phosphorus the enemy of steel and Sulphur will be removed on
oxidation, carbon will be reduced and Ferro alloys may be added to impart quality and
thus required grade steel melt will be prepared. This melt will be cast in CCM to produce
hot billets. Finally hot billets will pass through series of rolling mills and iron rods and
angles will be produced which on short period water quenching will be converted to TMT
rods, highly suitable for construction purpose.
Adequate size Vacuum Degassing unit is to be provided for alloy addition and production
of special grade steel.
Since the liquid steel is largely continuously cast in the present day practice, precise
control of temperature is absolutely essential for smooth casting and better surface
quality . This is achieved by the application of ladle metallurgy technology.
3.6.5 DI Pipes
Ductile iron pipe is a pipe made of ductile cast iron commonly used for potable
water transmission and distribution. This type of pipe is a direct development of
earlier cast iron pipe, which it has superseded. The ductile iron used to manufacture the
pipe is characterized by the spheroidal or nodular nature of the graphite within the iron.
Typically, the pipe is manufactured using centrifugal casting in metal or resin lined
moulds.
1,70,000 TPA hot metal from MBF shall undergo Spheroidization in a special ladle at
about 1500 °C by tundish treatment and 2.1 % of Fe=Si & Mg metal will be added to it.
molten iron will then pass through Centrifugal Casting machine for production of Ductile
Iron Spun pipes.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
In the beginning of casting cycle a core is placed in the bellend of the moulds. The
moulds moves to the pouring position encompassing a long narrow pouring through,
which is then sprayed to the wall of the moulds. Then the pipe extractor is actuated to
remove the pipe from the moulds.
To remove the rust in the internal surface of a mold, it will be grounded with sand wheel
before its dotted with peening head to increase its crack resistance. Annealing
process consists of heating section, heat holding section, slow cooling section and fast
cooling section. Ductile iron pipe will be entered to a long machine and rolled on it.
Certainly its temperature will be controlled.
Adhesive molten zinc will be coated to external surface of pipe. It is mandate that a
minimum zinc content of 135 g/m
2
and a minimum average finishing layer thickness of
70 µm to be adhered to.
Protective internal linings is applied to ductile iron pipes to inhibit corrosion, the standard
internal lining is cement mortar.
The pipe then tested with hydraulic pressure of 30 to 60 kg/cm
2
depending on nominal
bore. The company proposes to manufacture DI pipes of NB 80 to 1100 mm and length
of 5.5 to 6.0m
3.6.6 Oxygen Plant
There will be requirement of Oxygen in project mainly for MBF and EAF, of course
refining, cutting of billets etc. will also require Oxygen. There will be requirement of
nitrogen for purging of equipments and for use in low heating burners to reduce NOx.
Nitrogen will be required as grinding and conveying media of PCI unit. 1 X 50 TPD
Oxygen plant in Phase I & 1 X 100 TPD Oxygen plant in Phase II has been proposed.
3.6.7 PCI Plant
In order to reduce costly coke consumption in MBF and that to when there is scarcity ok
Coking coal in the country it is mandatory to use pulverized coal injection in MBF as fuel
supplement. This will reduce coke consumption per ton of hot metal production in MBF.
80kg use of PCI reduces coke consumption by 72 kg/THM production. Therefore, there
will be closed circuit grinding of coal in PCI unit where conveying and grinding
environment will be Nitrogen. Vertical rolling mill unit of 100TPD has been proposed.
3.6.8 CCM
2x600T Continuous Casting Machines have been proposed for KIC Metaliks Ltd. This unit
will cast molten metal from LF and Vacuum Degasser units to billets. Hot billets will be
cut to required length by Oxygen cutters and fed to series of rollers to manufacture rods
and angles or channels.
3.6.9 R M
1200T Rolling mills have been proposed. After getting required size and length the rod
while steel red hot will be passed through a water bath. This will suddenly quench
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
surface while core is steel red hot. This heat will be slowly migrate to surface and relieve
stress. Thus TMT rods will be manufactured which have extensive use in construction
work for its greater workability.
3.6.10 Cement Plant
BF slag will be granulated and utilized to manufacture slag cement in 300 TPD cement
Plant.
3.6.11 AFBC
Dolchar coming out of DRI kilns still have calorific value in the tune of 1800kcal/kg, a
potential source of heat to generate steam for power generation.
This dolchar with additional support of fresh boiler grade coal will be subjected to grate
firing in AFBC boilers. The combustion will sustain with 50% support of fresh coal to
dolchar and it is estimated that about 11 MW power can be generated from the steam
produced on combustion.
Project Layout
Fig 3.3 Layout of the project
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
3.7 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY,
LIKELY SOURCE & MODE OF TRANSPORT.
Table 3.2 Annual Raw material requirement for expansion project
Sl.
No.
List of Raw Materials
Required Quantity
in TPA
Source
Mode of
Transport
1
Hematite Iron Ore
Lumps
3,85,500
Odisha/ Jharkhand
Rail/ Road
2
Iron ore Fines
4,00,000
Odisha/ Jharkhand
Rail/ Road
3
Non Coking Coal (DRI)
1,77,000
Raniganja /South Africa
Rail/ Road /
Import
4
Boiler grade coal for
AFBC
72,000
Raniganja
Rail/ Road
5
Coal for PCI
23,500
Australia
Import
6
Lime stone/Dolomite
8,960
Sundergarh (Odisha)
Rail/ Road
7
Scrap
1,30,000
Local Purchase
Road
In addition to the above raw materials LDO/HSD, Electrode paste, Bentonite &
lubricating oil will also be required.
Product marketing area
TMT rods, DI pipes and cement has market all over India and Finished products are to be
transported through pollution compatible vehicles and fully covered to avoid flying with
air force or spillage on the public roads,
Raw Material Receipt & Store
Most of the raw material shall be received by rail or road. Separate store yard for the
major raw materials such as iron ore and coal exists and will be done by the
requirement.
Mode of Transport (Raw materials & products)
Transports will be done by the environmentally compliant trucks and covered trains also.
Bharat-III/ Euro-III trucks will be used in the transportation system. The raw materials &
products shall be covered fully during the transportation to avoid spillage & fugitive
emissions on the road & rail line.
Raw Material Storage & Handling
Separate store yard for the major raw materials such as iron ore lumps, iron ore fines
lime stone/ dolomite, coal and Cr & Mn Ore etc are done. The material shall be unloaded
manually from the trucks in the stock yard. The yard shall have provision to store around
one months‟ stock of material.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
3.8 RESOURCE OPTIMISATION/RECYCLING AND REUSE ENVISAGED
IN THE PROJECT
The project is an integrated steel project. The final products are 0.378 MTPA TMT rods,
channels, angle, 0.02 MTPA pig iron& 0.2 MTPA DI pipes. Total power generation from
the project will be 41 MW which shall be produced from WHRB, BF gas and AFBC boilers.
Total product mix after the expansion cum modification of the project is given in the
following table.
Following optimization, recycle &reuse measures have been proposed.
1) Steps proposed for optimization of power
a) Utilization of waste heat from DRI kiln to produce steam there by generation of
own power and reduction of power draw from state grid.
b) Surplus BF gas to be burnt to generate 5MW power
c) Utilization of waste dolchar to generate power thereby reduce power drawl
d) MBF top gas pressure recovery turbine to be set up to generate about 30kwh
e) Solar lighting on internal roads to optimize power consumption
f) Variable Frequency drive ID fans and blowers will draw less power for same
output.
g) Silicon-controlled rectifier to dimmer high voltage for ESPs used for DRI kilns.
h) Use of capacitor Bank to increase power factor.
3.9 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER
REQUIREMENT AND SOURCE
3.9.1 WATER REQUIREMENT:
Fresh water requirement for the expansion project is estimated to be 5527.2 m
3
/day,
water will be drawn from Durgapur Project Limited (DPL).Contaminated used water of
plant will be settled, cleaned and reused in the plant and there will be zero waste water
discharge to outside project boundary. More over rain water will be harvested and used
in process, which will help in reducing fresh water intake from river.
3.9.2 POWER REQUIREMENT FOR THE PROJECT
Facilities
Power consumption in MW
2x350 DRI Kilns
2.40
4x15 T & 2x20 T IFs
16.00
1x30 T EAF
15.00
1x245m
3
MBF
0.84
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
2x25m2 Sinter plants
5.00
1200 TPD Rolling Mill
7.50
2x600 TPD CCM
3.20
2x0.11 MTPA Centrifugal CM
1.20
30 MW CPP internal consumption
3.00
Total
54.10
Power requirement for expansion project is estimated to be about 54.10 MW, whereas
captive power generation from expansion project will be only 30 MW. Balance power will
be purchased from DVC supply.
3.10 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID)
AND SCHEME FOR MANAGEMENT
Table 3.3 Solid Waste Generation & Its Management
Sl.
No.
Plant
Facilities
Waste
characterization
Quantity in
TPA
Utilization/ Control
Measures
1
BF
Sludge
8,000
2
BF
Slag
72,000
Cement plant
3
EAF & IF
Slag
33,600
Construction work &Low land
filling
4
RM
Scrap
6,000
Used in EAF
5
DRI
Char
44,800
To be used in AFBC boilers to
generate steam for power
6
DRI Kilns
ESP fly ash
32,000
To be supplied free of cost to
fly ash brick manufacturing
agencies
LIQUID WASTE GENERATION & MANAGEMENT
Domestic waste water will be treated in STP and reused as flush water and partly for
green belt watering. Industrial waste water will pass through settling primary and
secondary treatment and reused in the process.
3.11 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING
WHICH GIVE INFORMATION OF EIA
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
CHAPTER -4
SITE ANALYSIS
4.1 CONNECTIVITY
M/s KIC Metalliks has its existing Steel Plant at Raturia, Durgapur in Burdwan district of
West Bengal.The Latitude of the place is 23º30‟32"N and longitude is 87º16'39.89"E.
Average altitude of the place is 73 m.
The location is well connected by road and Rail. The site is only 0.4 km away from the
bypass road of road to Waria. Durgapur railway station is 4.32 km away. DCL bus stop is
only 1 km away. Grand trunk road is 3.47 km away from the site.
4.2 LAND FORM, LAND USE LAND OWNERSHIP
The total land available for the proposed project is about 34.80 hectares. Out of the total
30.75 ha land has already been acquired and possession for balance land is in progress.
Table 4.1: Land Use Pattern after Modernization & Expansion
Sl. No.
Units
Area in hectares
1
Existing Plant facilities
14.60
2
Raw Material storage
1.00
3
Water storage and rain water harvesting
1.00
4
Product handling /storage
1.00
5
Solid waste disposal
5.00
6
Internal roads/buildings
0.80
7
Green belt development
11.40
Total
34.80
4.3 TOPOGRAPHY
The topography is undulating. The area has thin alluvial cover and the soil is mainly
reddish and not very much fertile. It is a transitional zone having hard rock as well as
alluvial terrain which are flat and gently sloping.
In the eastern part of the city the thickness of the alluvial cover increases. The soil is
acidic in nature. The area is heavily forested and still has remains of the dense
vegetation. Burdwan district with its varied tectonic elements and riverine features is a
transitional zone between the Jharkhand plateau which constitutes a portion of
peninsular shield in the west and Ganga-Brahamaputra alluvial plain in the north and
east. In general the Jharkhand plateau consists of the meta-sedimentary rocks of
precambrian age, Gondwana sedimentary rocks, Rajmahal basalts and upper tertiary
sediments. Laterite has developed on these older rocks as well as on early Quaternary
sediments. Towards south, the alluvial plain merges with Damodar-kasain-Subarnarekha
deltaic plains.
The western half of the district resembles a promontory jutting out from the hill ranges
of Chotonagpur plateau and consists of barren, rocky and rolling country with a laterite
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
soil rising into rocky hillocks, the highest being 227 m. These diversify the otherwise
monotonous landscape and lend a special charm to the skyline around Asansol
subdivision.
Ajay-Barakar divide is a convex plateau, the average altitude being 150 m. The gradient
is westerly to the west and to the east it is northerly towards Ajay and southernrly
towards Damodar below the latitude. The Ajay- Damodar inter-stream tract is made up
of several stows consisting of vales and low convex spurs which run in almost all
directions except north-east and thus lends a very complicated character to local relief.
Toposheet of M/s KIC Metaliks project site
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Fig- 4.1: Topography of the area
4.4 LAND USE PATTERN
The project area is present at Raturia, Burdhwan district of West Bengal. It is also noted
that the core zone i.e. the project boundary or the battery limit does not belong to part
of any National Park, wild life sanctuary or Natural/ Biosphere reserve. It also does not
contain any features of archaeological/ historical and cultural/aesthetic importance.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Table 4.2 Land use pattern of buffer zone
LANDUSE CATEGORY
AREA IN KM
2
PERCENTAGE
Rural settlement
94
29.9
Urban settlement
27.3
8.7
Agricultural land
67.1
21.4
Double crop
23.4
7.5
Dense forest
11.3
3.6
Open forest
14.1
4.5
Scrub forest
6.8
2.2
Land with scrub
16.5
5.3
Land without scrub
1.6
0.5
Fallow land
11.6
3.7
Industrial area
15.5
4.9
River
12.6
4.0
Sand
5.6
1.8
Water body
3.1
1.0
Canal
3.5
1.1
Total
314
100.0
4.5 EXISTING INFRASTRUCTURE
The site is located at Raturia, Durgapur, and Dist: Burdwan, in the state of West Bengal.
The location is well connected with road and rail. NH-2 is only 2 Km away from the
proposed site. The nearest cities Raniganja and Asansol are 3 km away from the
proposed site. The nearest railway station is about 9 Km away. The nearest Airport
Netaji International Airport is located at Kolkata.
4.6 SOIL CLASSIFICATION:
This soil is of reddish color, medium to coarse in texture, acidic in reaction, low in
nitrogen, calcium, phosphate and other plant nutrients. Water holding capacity of this
soil increases with depth as well as with the increase of clay portions. Some alluvial soil
is also observed. This alluvial soil is formed of alluvium brought down by the Ajay,
Damodar, Bhagirathi and numerous other rivers. These soils are sandy, well drained and
slightly acidic in nature. Different types of soil are encountered in different topographical
biological and hydrological as well as geological condition within the Burdwan district. In
the west coarse gritty soil blended with rock fragments is formed from the weathering of
pegmatites, quartz veins and conglomeratic sandstones, whereas sandy soil
characteristic of granitic rocks and sandstones. This soil is of reddish colour, medium to
coarse in texture, acidic in reaction, low in nitrogen, calcium, phosphate and other plant
nutrients. Water holding capacity of this soil increases with depth as well as with the
increase of clay portions. Towards the east alluvial soil attains an enormous thickness in
the low-level plains to the east. This alluvial soil is formed of alluvium brought down by
the Ajay, Damodar, Bhagirathi and numerous other rivers. These soils are sandy, well
drained and slightly acidic in nature.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Agriculture is the main occupation in the study area. Hence it is essential to determine
the agriculture potential of the soil from the area and identify the impacts of urbanization
and the industrialization in the area.
4.7 CLIMATIC DATA FROM SECONDARY SOURCE
The district experiences Hot Summer from March to May. July, August, September and
October are rainy days. November to January are cold winter. The cold season starts
from about the middle of November and continues till the end of February. March to May
is dry summer intervened by tropical cyclones and storms (mango shower). June to
September is wet summer while October and November is autumn.
Secondary information on meteorological conditions has been collected from the nearest
IMD station Durgapur (32734) and IMD Book (1970-2000).
Wind direction is SE-S-SW in Summer and rains and NW-N in winter. Wind speed goes
up to 13.5 kmph in the month of May.
Temperature of the area varies from 11.5
0
c in winter to 40
0
C in Summer. Maximum
temperature has gone upto 44.5
0
C
Relative humidity varies from 40% in April to 84% in August. During winter months
relative humidity remains 55 to 65%.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
CHAPTER -5
PLANNING BRIEF
5.1 PLANNING CONCEPT
The plant is an integrated steel plant having semi-mechanized operation. It is a labor
intensive project. However, depending on the production schedule, there will be
additional technical labor engaged for operation.
The raw materials shall be transported through covered trucks by road up to the nearest
siding for further transportation by rail. And the finished products will be transported by
both rail and road. The transportation load will not add much to the existing load on the
said road system.
Appropriate plantation program shall be undertaken along with the developmental
program to at least cover the boundary areas with thick and tall plants for containment
of the air borne pollutants within the premises, which is duly reflected in the land use
plan.
There will not be any further infrastructural development other than needed for the
commissioning of the total project component machineries. This expansion-cum-
modification shall utilize the existing infrastructural facilities for all purposes.
5.2 Peripheral Development Plan
M/s KIC Metaliks Limited will make sincere efforts to improve the socio-economic status
of the local habitants. A welfare scheme will be prepared by the company for the socio
economic development of the area. The scheme will envisage promotion of education in
the adjoining villages by giving aid to the local schools, providing drinking water facility
and organizing health check up programs. Local people will be given free seedlings to
develop greeneries all around. The progress of the scheme will be reviewed periodically
and further action will be taken as deeming fit.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Fig 5.1: MANAGEMENT HEIRARCHY
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
5.3 LAND USE PLANNING
The total land available for the proposed project is about 34.80 hectares. Out of the total
30.75 ha land has already been acquired and possession for balance land is in progress.
The detailed breakup of the land is given in the following table:
Table 5.1: Land Use Pattern after Modernization & Expansion*
Sl. No.
Units
Area in hectares
1
Existing Plant facilities
14.60
2
Raw Material storage
1.00
3
Water storage and rain water harvesting
1.00
4
Product handling /storage
1.00
5
Solid waste disposal
5.00
6
Internal roads/buildings
0.80
7
Green belt development
11.40
Total
34.80
5.4 ASSESSMENT of INFRASTRUCTURE DEMAND
The proposed expansion is project will put negligible amount of load on existing
infrastructure in terms of physical and social. So, demand for additional infrastructure is
not anticipated.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
CHAPTER -6
PROPOSED INFRASTRUCTURE
6.1 INDUSTRIAL AREA DISTRIBUTION
Proposed project will be planned in the existing plant premises. So, the area has already
been demarked as an industrial area. The expansion project will be accommodated
within the existing premises of 34.80 hectares of land.
6.2 GREENBELT DEVELOPMENT FACILITY
In order to combat the air pollution, noise pollution and also to improve the aesthetic,
the company proposes to develop greenbelt, landscaping and avenue plantation. 33% of
the total area i.e. about 11.40 ha of land will be demarcated for green belt purpose.
6.3 CONNECTIVITY
M/s KIC Metaliks Ltd. has its existing Steel Plant at Raturia Industrial Area, Durgapur in
the district of Burdwan, West Bengal. The project is located at latitude: 23
0
30‟ 32‟‟ N
and longitude 87
0
16‟ 39.89‟‟ E, with 450m AMSL.
The location is well connected by road and Rail. The site is only 0.4 km away from the
bypass road of road to Waria. Durgapur railway station is 4.32 km away. DCL bus stop is
only 1 km away. Grand trunk road is 3.47 km away from the site. The nearest Airport
Netaji International Airport is located at Kolkata. The transportation load will not add
much to the existing load on the said road system.
6.4 DRINKING WATER MANAGEMENT:
The drinking water will be met through existing over head tank from ADDA supply.
Around 50 KLD will be used for drinking purposes.
6.5 INDUSTRIAL WASTE MANAGEMENT
6.5.1 Waste Management
The wastes which will be generated from the process are some used oil and sludge and
slag from Induction Furnace. The induction furnace slag being equivalent to river sand
can be used as land filling. The hazardous waste will be sold to recyclers and dealers.
The waste water from canteen and office toilets will be sent to a soak pit. Canteen waste
water will be treated in a separate ETP consisting of O & G trap, settling tank, anaerobic
treatment system & gravity sand filter. Sewage from toilets will be treated in septic tank
and discharged to soak pit.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
6.5.2 Solid Waste Generation & Management
Sl.
No.
Plant
Facilities
Waste
characterization
Quantity in
TPA
Utilization/ Control
Measures
1
BF
Sludge
8,000
2
BF
Slag
72,000
Cement plant
3
EAF & IF
Slag
33,600
Construction work &Low land
filling
4
RM
Scrap
6,000
Used in EAF
5
DRI
Char
44,800
To be used in AFBC boilers to
generate steam for power
6
DRI Kilns
ESP fly ash
32,000
To be supplied free of cost to
fly ash brick manufacturing
agencies
6.6 INDUSTRIAL POLLUTION CONTROL
6.6.1 Air Pollution Control
It is envisaged to install state of the art air pollution control measures in the proposed
project, as given below.
Table 6.1: PROPOSED AIR POLLUTION CONTROL FACILITIES
Sl No
Plant/ Area
Proposed Pollution Control Measures
1
Raw Material Handling
Raw Material Handling,
Transfer Points, Junction
Houses
- Water sprinkling will be provided at the
transfer points of material at RMHP.
- Bag filter
2
Induction Furnace & EAF
- Bag Filter
3
DRI
- ESP
6.6.2 Water Pollution Control
The waste water from canteen and office toilets will be sent to a soak pit.Canteen waste
water will be treated in a separate ETP consisting of O & G trap, settling tank, anaerobic
treatment system & gravity sand filter. Sewage from toilets will be treated in septic tank
and discharged to soak pit.
6.7 MAN POWER REQUIREMENT
The total man power requirement for plant operation on completion of the proposed
expansion will be around 742 and extra 50 nos. for Security.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
CHAPTER -7
REHABILITATION & RESETTLEMENT
REHABILITATION & RESETTLEMENT
The proposed expansion units will be implemented in the existing plant premises. The
existing lands were already derived as industrial land. As settlement will not be affected
so, no R&R facility is anticipated.
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
CHAPTER -8
PROJECT SCHEDULE
8.1 IMPLEMENTATION SCHEDULE
Time schedule for completion of various activities is given below in Table 8.1. The zero
date will commence after getting EC and consent to establish from SPCB.
Table 8.1: Tentative implementation schedule:
Sl.
No.
Activities
Duration
1
Engineering
Concept Design
15 days
Basic Engineering
30 days
Detailed Engineering
150days
2
Civil Work
Land development
215 days
Finalization of layout & drainage
90 days
Construction of plant & auxiliary facilities
300days
3
Statutory Clearance for establishment
State clearance for establishment
20 days
State EC Clearance
90 days
4
Procurement
Place orders for long lead Equipments
90 days
Place orders for commodity items
30 days
Receipt of equipment
230 days
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
Installation of equipment & items
180 days
5
Erection & Commission
Inspection before commissioning
80 days
Commissioning & production trial run
40 days
Some works will proceed parallel and some in series. Critical Path Method (CPM) and
Project Evaluation & Review Technique (PERT) will be followed for completion of project
work.In short construction job will be completed within two years of time after getting
consent to establish/EC from SPCB, WB.
8.2 ESTIMATED PROJECT COST
Project Cost
The estimated expansion project is 545 crore. This will be as follows.
Sl. No.
Cost Head
Estimated Cost, in Crore
1
Land development earth
work & civil structure
50.0
2
Plant Machinery & Pollution
control devices
430.0
3
Consultant Expenses
03.5
4
Contingency
12.0
5
Margin for WC
30.0
6
Misc. Fixed Assets
10.0
7
Prel. Expenses
04.0
8
Pre-Operative Exp/IDC
05.5
Total
545.0
Techno Economic Feasibility Report of M/s K I C metaliks Ltd At:
Raturia,Durgapur, Dist: Burdwan, West Bengal
CHAPTER-9
ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION)
9.1 FINANCIAL & SOCIAL BENEFITS
The proposed expansion project is expected to bring socio-economic and environmental
benefits both at local and global level as listed below:
9.2 SOCIAL INFRASTRUCTURE
Social awareness programs will be further improved by the local authority such as
sanitation and hygiene, HIV Prevention Program.
Through this project, adult education and female education will be provided to the
illiterate adults and backward females of the villages in the project surrounding
area.
The proposed expansion project will set up training center for the male and
female youth group by considering their skills and qualification which will support
the people for self-employment.
9.3 EMPLOYMENT POTENTIAL
The project is going to create substantial employment and income. Due to this project
activity, some persons in the project area will be recruited as skilled and semi-skilled
workers by the company as per its policy. Therefore, substantial amount of employment
and income is likely to be generated for the local people. So, the project will contribute
in a positive manner towards direct employment in the project area. Some employment
potential benefits are given below:
Long term employment of up to additional 80 people in the operation phase of
the proposed expansion project.
Generating additional associated jobs due to establishment of the project.
9.4 BENEFITS TO THE REGION AND THE COUNTRY
M/s KIC Metaliks Limited shall produce TMT channels and angles & Spun pipes that are
to be utilized in construction activities. The products are in demand and production shall
contribute to the GDP growth of the country.