SUMMARY

FOR PROPOSED EXPANSION PROJECT

OF

C.P. RE-ROLLERS LTD.

At

J.L. No. 90 Raturia, Angadpur Industrial Area, Dist: Burdwan, – 713215,

PREPARED BY:

PACIFIC SCIENTIFIC CONSULTANCY PVT. LTD., KOLKATA

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Executive Summary C.P. Re-Rollers Ltd.

SUMMARY

FOR PROPOSED EXPANSION PROJECT

Installation of 2 No. 10 MT Induction Furnaces At J.L. No. 90, Raturia, Angadpur Industrial Area, Dist: Burdwan, Durgapur – 713215, West Bengal

1. COMPANY: C.P. Re-Rollers Ltd. is one of the distinguished manufacturers who are engaged in making of one of the most useful material, MS Ingots/ billets. The company’s corporate office is situated at 5, Nafar Kundu Road, Flat No. 2B, Kolkata-700026. The manufacturing unit is located at J.L. No. 90, Raturia, Angadpur Industrial Area, Dist: Burdwan, Durgapur – 713215, West Bengal. The company has set up 2x8 MT Induction Furnace for manufacturing of billet with annual capacity of 60,000 TPA. Now, the promoters have decided for expansion of their existing unit by installing additional 2 nos. of 10 Ton capacity Induction Furnace in the existing land.

Particulars Existing Subsequent Modification/Addition Induction Furnace 2 no 8 MT 2 no 10 MT M.S. Billets 60,000 Tonnes/ Annum 62,000 Tonnes/ Annum Continuous Caster 1 Nos. 2 strand - Reheating Furnace 2 no. 20 Ton/hr Rolling mill 90,000 Tonnes/ Annum - Section Mill 30,000 Tonnes/ Annum Ladle 4x12MT -

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2. PROJECT SITE

The factory is located at J.L. No. 90, Raturia, Angadpur Industrial Area, Dist: Burdwan, Durgapur – 713215, West Bengal at a distance of 3.0 km (Approx.) from Grand Trunk Road. The distance of site from Durgapur railway station is about 4.0 Km (Appox.). Original land surface is little undulating and irregular in shape which has been already developed. Total land area is around 8 acres (32374.9 sqm). The latitude and longitude of the project site is 23°30'41"N, 87°16'54"E respectively. The area is well connected by road to Durgapur town as well as to other industrial town like , , and other neighbouring areas by G.T. Road. The place is well connected to railway station (Easter Railway) and towns by bus, jeeps, taxi and rickshaw. All the civic amenities like market, bus stand, hospital, school, college, hotel, restaurant etc. all are available in the town which is about 5-7 km from the site.

3. PROJECT DETAILS

The proposed expansion has been planned based on the following operating condition: No of Induction Furnace 2.00 No of Crucible 4 Capacity (MT) of each Induction Furnace MT 10.00

Total Production (MT) /heat MT/heat 20 No of Heats Per day 10 Number of days available Per annum 310 Total Liquid Metal Production MT 62,000 Actual Yield of Billets @ 99.5% MT 61,690

Total Project Cost: The Project cost of the expansion project has been estimated at Rs. 1029.32 Lacs. Raw materials: The Durgapur and Ranigunj areas consists of many sponge iron, pig iron and ferro alloy plants which will ensure ample and uninterrupted supply of raw materials for the Induction furnace. Though in developed countries sponge iron or hot briquetted iron in varying

3 Executive Summary C.P. Re-Rollers Ltd. proportion being used but scrap still maintains its leading role for making steel through electric furnace route. Besides steel scrap of different grades and physical characteristics, various ferro-alloys like ferro-manganese, ferro-silicon, silico-manganese alloy, aluminium in required proportions are also needed while furnace and ladle refractories form the major consumable materials.

Induction Sponge Iron MT 37200 Pig Iron MT 9300 Scrap MT 13640 Ferro Manganese MT 620 Ferro Silicon MT 1240

4. OTHER REQUIREMENT:

Water: Water requirement in the plant is for cooling (make-up) and domestic & other purposes. The required water will be sourced from Durgapur Municipal Corporation. The total water requirement is given below: Particulars Requirement for Proposed Plant (KLD)

Water for cooling (Make up) 40 KLD

Domestic purposes & other uses 6 KLD

Total 46 KLD

Manpower: The total requirement of manpower for the proposed Steel Melting shop is estimated at 138 numbers. The required manpower will be available locally. The implementation of industrial laws and regulations and locational factors of labour employment will also have to be considered. Power: 13 MVA power is already available in the factory with the help of DPL. Power (approx. 10000KVA for expansion project) can be enhanced with the help of them (DPL).

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Apart from this there are one D.G. set of 500KVA as backup unit. Fuel Requirement: The only fuel required is Diesel. It will be used for D.G. sets @ 50L/hr.

5. MANUFACTURING PROCESS:

FLOW SHEET OF MANUFACTURING PROCESS AS A WHOLE

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At the beginning, in tilted condition of the crucible, M. S. Scrap / pig iron is charged with the help of magnet crane and the furnace crucible is heated up till it is in molten condition. Again the crucible will be tilted for next charging of Cast Iron Scrap and again heating up is continued till the C I Scrap is totally melted. Next, Sponge is charged when some boiling is observed due reaction of oxygen available from FeO of Sponge Iron & Carbon from Cast Iron & Pig Iron. Slag, so formed out of above reaction, which being the lighter material floats up & the same is continuously skimmed of by the furnace crews with the help of long spoon. Around 30 minutes before the tapping of the molten steel, flash sample are taken for finding out the carbon level. Depending on the bath sample carbon is adjusted by adding of Met Coke or CPC. Finally, around 10 minutes before the tapping of the molten steel, required Ferro Alloy addition (silica Manganese/ Ferro Manganese/ Ferro Silicon) are done depending on the chemical composition required for bottom pouring of the pencil ingots. The molten metal is then trapped in a ladle refining furnace for teeming purpose and finally converted to billets of sizes ranging from 80 mm sq. to 125 mm sq by using a 4/7 M radius 2 stand continuous casting machine.

6. ENVIRONMENTAL CONSIDERATIONS:

The factory is planned as far as practicable as an inherently non polluting unit. o Air Pollution from Induction Furnace has been taken care of by installing Flue air duct to 30 mt. height steel chimney via Bag filter and ID fan. o There will be no generation of effluent water from process and the domestic sewerage about 5KLD will be discharged in the local Govt. Body’s Sewerage system after treated as per PHE rules. o The solid waste generated will be in the form of slag. Slag would be collected from the point of arising and proper slag handling and disposal system will be maintained. Slag will be crushed and after recovery of iron, the inert material will be used in road construction and remaining amount will be planned to dump in an environmental friendly manner in a separate area. o To attain the guide line standards all the dust generating areas will have dust suppression systems to contain the fugitive dust with in the limits of the plant.

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Auto sprinkler system Following control rooms are proposed to be fitted with Auto Sprinkler system with smoke Detection Equipment. i) Induction Furnace ii) Raw Material Handling section

AIR POLLUTANTS

The sources of air pollution from the plant activities are as follows: a) The emission from Induction furnace during transfer of raw materials b) Fumes from the Induction furnace c) Fugitive emission during breaking of ferro-alloys and packing. In steel melting shop, there would be anti-pollution system namely bag filters. The cleaned gas would be discharged through stack. The dust emission from Induction Furnace would be controlled through dust extraction (DE) system by bag filters. The dust concentration level in the chimney will be periodically monitored. Corrective steps will be taken, if the concentration is not as per the acceptable limits. The particulate concentration from the bag filters will remain within 50 mg/Nm3. Raw material handling can cause dust generation at the point of storage and transportation. The fugitive dust can have adverse impact on air quality inside the plant and its immediate surrounding. This would be prevented by spraying water at storage yard area. Ambient air quality monitoring stations in and around the premises will done as per direction by West Bengal Pollution Control Board (WBPCB).

For 2x10T Induction furnace there will be bag filter with chimney. The clean gas is then disposed through a 30 m high chimney.

Source APC System Concentration of dust Inlet Outlet Induction furnace Bag filter 1 - 2 gm/Nm3 <50 mg/Nm3 D.G Proper stack with exhaust - <150 mg/Nm3

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Solid Waste Management As solid wastes, Furnace slag will be generated. In the proposed unit there will be one number of crusher cum magnetic separator. The slag will be crushed into coarse and segregated into metallic and non-metallic contents. Metallic parts will be recycled back as raw material for captive utilization where as non-metallic parts will be disposed off for land filling or road construction. From Induction furnace ore slag will be generated. The quantity of slag will be 800 Tonnes/month (approx) which will be disposed for land filling and road construction. Generation of dust from Air pollution control system will be approx. 50 Tonnes /month which will be utilized in making the fly ash bricks. Scrap (Approx. 20 Tonnes /month) from Induction furnace will be reused. Mill scale from rolling 20 Tonnes/month (approx) will be recycled in Induction furnace. Liquid Effluent Generation and Control There will be no generation of effluent water from process. There will be liquid effluent (approx 5KLD) from domestic section. Part of this effluent will be taken into septic tank and to soak pit; other part will be discharged to Panchayet drain. The Domestic waste water (5KLD) will be treated as per PHE norms. So there will be no such risk of contamination of ground or surface water. Noise Pollution Control Proper acoustic enclosure for rotating equipment and providing silencers for DG set will help in keeping noise level within CPCB norms.

GREENBELT An extensive plantation within the boundary limits of the plant is considered during expansion project work by planting about 2300 saplings making a two row deep green belt along the periphery (spacing 2.0 m x 2.0 m) and all along internal roads iron ore storage areas, ground hoppers and dumps leaving only adequate truck access. The total land area covered for greenbelt will be 33% of the total area i.e., 10956.51 sq. mt.

Lit of big trees for proposed plantation is given below.

No. Common name Scientific name Family 01. Arjun, Arjuna Terminalia arjuna Combretaceae

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No. Common name Scientific name Family 02. Ashwatha Ficus religiosa Moraceae

03. Akashmoni Acacia moniliformis Mimosaceae

04. Aam Mangifera indica Anacardiaceae

05. Bot Ficus benghalensis Moraceae

06. Chatim Alstonia scholaris Apocynaceae

07. Debdaru Polyalthia longifolia anonaceae

08. Ghoranim Melia azedarch Meliaceae

09. Jhaun Casuarina equisetifolia Casuarinaceae

10. Jarul Lagerstroemia speciosa Lythraceae

11. Karanj Derris indica Fabaceae

12. Krishnachura Caesalpinia pulcherrima Caesalpinaceae

13. Nim Azadirachta indica Meliaceae

14. Pakur Ficus infectoria Moraceae

15. Radhachura Delonix regia Caesalpinaceae

16. Tantul, Tentuli Tamarindus indica Caesal pinaceae

17. Sisso Dalbergia sissoo Papilionaceae

18. Sirish Albizia Lebbeck Mimosaceae

7. ENVIRONMENTAL MANAGEMENT COST

An initial budget of Rs. 25.0 lacs to be made on the following heads as included in the project cost in the proposed project. The recurring cost is estimated to be around Rs. 3.0 lacs. Capital Recurring cost (lac) cost (lac) Air Pollution Control Equipment 21.0 2.0 9 Executive Summary C.P. Re-Rollers Ltd.

Water harvesting system 2.0 0.25 Water sanitation and septic tank 1.0 0.25 Plantation 0.5 0.25 Miscellaneous safety including fire fighting purpose 0.5 0.25

This budget provision may be reviewed at the time of commissioning of the unit.

8. ENVIRONMENTAL SETTING OF THE PROJECT SITE:

Land- The selected and purchased site has already been converted to Industrial land after proper recording of mutation in BL & LRO.

Air Quality –Industrial and Residential Air Quality is important for the area.

Water Quality – Zero discharge will be attempted to minimize water pollution so that there is no impact on local water resources.

Ecology - Not significant, no reserve forest area or sensitive place is around.

Social – Significant for job and development.

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