SUMMARY
FOR PROPOSED PROJECT
OF
KEJRIWAL CASTINGS LIMITED At
Bamunara Industrial Area, Mouza – Bamunara, P.S – Kanksa, Durgapur – 713212, Dist- Burdwan, West Bengal
PREPARED BY:
PACIFIC SCIENTIFIC CONSULTANCY PVT. LTD., KOLKATA
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Executive Summary Kejriwal Castings Limited
SUMMARY
FOR PROPOSED EXPANSION PROJECT
Setting up DI Pipe Manufacturing Unit
OF
Capacity 48,600 MT/ Annum
At J.L.No. 58, Khatian No. 5770, Bamunara Industrial Area, Mouza – Bamunara, P.S – Kanksa, Durgapur – 713212, West Bengal
1. COMPANY: Kejriwal Castings Limited (KCL) is one of the distinguished manufacturers who are already engaged in the field of manufacturing pipes, fittings and valves in ductile iron and cast iron for the last few decades. The company’s corporate office is situated at Chatterjee International Centre, 33A, Chowringhee Road, 11th Floor, Suite No- 6 & 11, Kolkata – 700 071, West Bengal. The manufacturing unit will be located at J.L.No. 58, Khatian No. 5770, Bamunara Industrial Area, Mouza – Bamunara, P.S – Kanksa, Durgapur – 713212, Dist- Burdwan, West Bengal. To increase the production and meet the demand of DI Pipe as well as the importance of economy of scale, the management has taken a decision for setting up a 48,600 MT per annum DI pipe manufacturing unit.
2. PROJECT SITE
The company plans to start a DI pipes manufacturing unit with a capacity of 48,600 MT per annum at Durgapur in West Bengal. Therefore, it has taken over erstwhile Bhagwanji Ispat Pvt Ltd (BIPL) which had a mild steel ingots manufacturing unit located at Bamunara Industrial Area, Durgapur, West Bengal. As a result of the amalgamation, land and all other assets in the name of BIPL has been transferred to KCL. The factory is located at J.L. No. 58, Khatian No. 5770, Bamunara Industrial Area, Mouza – Bamunara, P.S – Kanksa, Durgapur – 713212, Dist- Burdwan, West Bengal at a distance of 0.6 Km (Appox.) from NH-2. The distance of site from Durgapur railway station is about 6.0 Km (Appox.). Original land surface is little undulating and irregular in shape which has been already developed.
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Total land 10.41 Acre (42127.775 sqm) has been mutated in the name of Kejriwal Castings Limited. 8.71 Acre out of 10.41 Acre has been converted into Industrial and conversion of remaining portion of land of 1.70 Acre is in process. The site is falling under Gopalpur Gram Panchayet. The latitude and longitude of the project site is 23°29'54"N, 87°22'34"E respectively. The area is well connected by road to Durgapur town as well as to other industrial town like Asansol, Raniganj, Dhanbad and other neighbouring areas by recently developed Durgapur Expressway (NH-2) and 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 project has been planned based on the following operating condition: The Installed capacity of the proposed ductile iron pipe manufacturing plant will be 162 MT per day. Total Project Cost: The Project cost of the expansion project has been estimated at Rs. 6341.81Lacs. 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 proportion being used but scrap still maintains its leading role for making steel through electric furnace route. Besides, various ferro-alloys like ferro-silicon and other in required proportions are also needed.
Pig Iron MT/Month 6560 M.S. Scrap MT/Month 1640 Ferro silicon, calcium carbide magnesium ingot, MT/Month 180 inoculants
Sand for core MT/Month 60
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Resin, hardener, catalyst, paint MT/Month 4 Zinc wire/Aluminium wire MT/Month 34 Sand for lining MT/Month 900 Portland cement MT/Month 700 Bitumen/Epoxy paint MT/Month 36
4. OTHER REQUIREMENT:
Water: There are two submersible pumps with boring depth of about 120-150 feet with 5 hp motor at two different locations to meet the present industrial as well as domestic requirements. There is one water reservoir of about 10ft x12ft x10ft RCC construction at ground level. Moreover, there are four 2,000 litre PVC tanks on the roof of the ground-plus- two-storied building and one 5,000 litre PVC tank on the roof of the labour quarters respectively. There are two water pumps exclusively for the melting furnace with 22 KW motor. Additionally, there is also one 5.9 KW 8 BHP capacity diesel engine-operated water pump for emergency operation.
The total water requirement is given below: Particulars Requirement (KLD) Cooling Water (Make up) 170 Other Industrial activity 16 Domestic purposes & Others 32 Total 218
The water will also be available from Rain Water Harvesting (RWH) system.
Manpower: The total requirement of manpower for the proposed plant is estimated at 411 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.
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Power: The site presently has power facility of 3.5 MV, which has been scaled down to 0.25 MV on account of limited requirement. The company intends to scale this facility up to 9.50 MV once the commercial production commences. Durgapur is a power surplus region and thus it is expected that the company will be granted the necessary approval to scale up its current power facility. The required power will be procured from Durgapur Projects Limited. Apart from this there will be one D.G. set of 300KVA as backup unit. Fuel Requirement: Diesel will be used for D.G. sets @ 15 L/hr. CBM or furnace oil will be used for the following section.
Section CBM Furnace oil Annealing furnace 9000 Cubic Mtr / Day OR 8000 Ltrs / Day Ladle and hopper heating 300 Cubic Mtr / Day 280 Ltrs / Day
5. MANUFACTURING PROCESS:
The Installed capacity of the proposed ductile iron pipe manufacturing plant will be 162 MT per day. While estimating the plant capacity, the following have been taken into consideration: Total no of Furnaces Nos 5 Capacity per Furnace MT 4.00
No of working furnaces at a time Nos 3 Rated Capacity per Furnace MT/ Hr 3.00 No of working hour/ Day Hrs 18 Rated Installed Production Capacity/ Day MT 162 No of Working Days Days 300 Annual Installed Capacity MTPA 48,600
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FLOW SHEET OF MANUFACTURING PROCESS AS A WHOLE
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 Air Pollution from Annealing Furnace has been taken care of by installing Flue air duct to 30 mt. height steel chimney via Scrubber and ID fan. o Cement slurry is taken to the Effluent Treatment Plant from which the water is recycled and used for gardening and the solid is used to manufacture brick/cement tiles. Domestic sewerage about 10 KLD 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
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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 within the limits of the plant. 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. 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 be done as per direction by West Bengal Pollution Control Board (WBPCB). For 2x7T 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 Annealing furnace Scrubber 500-800 mg/Nm3 <50 mg/Nm3 D.G Proper stack with exhaust - <150 mg/Nm3 7 Executive Summary Kejriwal Castings Limited
Solid Waste Management As solid wastes, from Induction furnace slag will be generated. The quantity of slag will be 200 Tonnes/month (approx) which will be disposed for land filling and road construction. Generation of dust from all Air pollution control system will be approx. 100 Tonnes /month which will be utilized in making the fly ash bricks. Scrap (Approx. 10 Tonnes /month) from Induction furnace will be reused. From Magnesium converter, slag (approx 100 Tonnes/month) also will be generated which will be utilized for Road Filling and Land Reclamation. Core sand in Casting Area as well as the same from the Annealing Furnace will be used in Land Filling and reclamation and will be recycled. Zinc Dust will be sold to certified Paint manufacturer. Cement slurry (Approx. 10 Tonnes /month) is taken to the Effluent Treatment Plant from which the water is recycled and the solid is either be used to manufacture brick/cement tiles. Waste oil, used oil and other hazardous wastes will be safely stored in drums/tanks/covered shed and sold to authorized recyclers. Organic waste will be used as organic manure in the green areas. The municipal waste will be given to authorized agencies for suitable disposal. Liquid Effluent Generation and Control Extensive recycling has been adopted in the design of plant water systems. Cement slurry (Approx. 10 Tonnes /month) is taken to the Effluent Treatment Plant from which the water is recycled and used for gardening and the solid is used to manufacture brick/cement tiles. The Domestic waste water 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 and dumps leaving only adequate truck access. The total land area covered for greenbelt will be 33% of the total area i.e., 13902.166 sq. mt.
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Lit of big trees for proposed plantation is given below.
No. Common name Scientific name Family
01. Arjun, Arjuna Terminalia arjuna Combretaceae
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
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7. ENVIRONMENTAL MANAGEMENT COST
An initial budget of Rs. 20.0 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. 4.0 lacs. Capital Recurring cost (lac) cost (lac) Air and Water Pollution Control Equipment 14.0 2.0 Water harvesting system 4.0 0.50 Water sanitation and septic tank 1.0 0.50 Plantation 0.5 0.50 Miscellaneous safety including fire fighting purpose 0.5 0.50
This budget provision may be reviewed at the time of commissioning of the unit.
8. ENVIRONMENTAL SETTING OF THE PROJECT SITE:
Land- is in the Bamunara Industrial Area. 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 as this is close to an industrial Estate.
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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