KHUSHKHERA STEELS PVT.LTD. (NEW PROJECT) Location: SP-29, F 20-24, RIICO Industrial Area, Khushkhera (Bhiwadi), District: Alwar (Rajasthan) Plot Area : 5600 Sq.M

KHUSHKHERA STEELS PVT.LTD. (NEW PROJECT) Location: SP-29, F 20-24, RIICO Industrial Area, Khushkhera (Bhiwadi), District: Alwar (Rajasthan) Plot Area : 5600 Sq.m

Proposed Production Capacity: 60,000 TPA (Billets/Ingots)

PROPOSAL FOR TERM OF REFERENCE (3(a), Category ‘A’ As per, the EIA Gazette Notification 14th September’ 2006)

The Proposed projet lies within the interstate boundary of Rajasthan and Haryana, which is about 3.5 km from the site towards North. Hence, the project will be treated as ‘A’ Category and has to be dealt at MoE&F.

Authorized Signatory; Mr. Anurag Rathi, Address : R/O A-24/7, Mohan Co-operative Industrial Estate, Main Mathura Road, New Delhi email: [email protected]; [email protected] Telephone no.: 011-43155400 Proposed Project Cost: Rs. 3034.00 (in Lacs) Proposed Baseline Study Period : December 2015, January 2016 and February 2016

GLOBAL TECH ENVIRO EXPERTS PVT. LTD. (QCI-NABET, New Delhi Accredited, NABET List at S.No. 73 - June 11,2015) C-23, BJB Nagar Bhubaneswar-751014- Odisha- India Tel : 0674-2436853Fax : 0674-2433487

GLOBAL MANAGMENT AND ENGINEERING CONSULTANTS I N T E R N A T I O N A L Saharan Tower, 308, Officers Campus extensión, Sirsi Road, Khatipura, Jaipur 302012 (Rajasthan) Phone-0141-2353241 [email protected], [email protected] M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

CONTENT

1.1 SALIENT FEATURES OF THE PROJECT ……………………………………………..27 2.0 IDENTIFICATION OF THE PROJECT / BACK GROUND INFORMATION ...... 29 2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ...... 29 2.6 EXPORT POSSIBILITY ...... 32 2.7 DOMESTIC/EXPORT MARKETS ...... 32 2.8 EMPLOYMENT GENERATION (Direct and Indirect) DUE TO THE PROJECT . 33 3.0 PROJECT DESCRIPTION ...... 33 3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ...... 33 3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT BOUNDARY AND PROJECT SITE LAYOUT) WITH COORDINATES 34 3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GIVEN INTO SHOULD BE HIGHLIGHTED ...... 36 3.4 SIZE OR MAGNITUDE OF OPERATION ...... 37 3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS (A SCHEMATIC DIAGRAM/ FLOW CHART SHOWING THE PROJECT LAYOUT, COMPONENTS OF THE PROJECT ETC. SHOULD BE GIVEN) ...... 38 3.5.1 Billets manufacturing process ...... 38 After the quality of the molten iron is insured, the furnace tilts and pours it into a ladle maneuvered by a crane. The crane moves this ladle towards the caster and pours the molten iron into it. The caster then casts the molten iron into continuous Casts...... 38 (c) Billets/Billet processing ...... 38 3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEFLY OUTLINED ...... 40 3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN ...... 40 3.8.1 Water Demand & its Source ...... 40 3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND THEIR SCHEME FOR THEIR MANAGEMENT / DISPOSAL...... 42 3.9.1 SOLID WASTE ...... 42 24

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

3.10 SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PUROSE ...... 42 4.0 SITE ANALYSIS ...... 45 4.1 CONNECTIVITY ...... 45 4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ...... 45 Land Ownership: ...... 45 4.3 TOPOGHRAPHY (along with map) ...... 45 4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA UNDER SEZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN...... 46 4.5 EXISTING INFRASTRUCTURE ...... 47 4.6 SOIL CLASSIFICATION ...... 48 4.7 CLIMATE DATA FROM SECONDARY SOURCES ...... 48 4.8 SOCIAL INFRASTRUCTURE AVAILABLE ...... 49 5.0 PLANNING BRIEF ...... 49 5.1 PLANNING CONCEPT (type of Industries, facilities transportation etc.) TOWN AND COUNTRY PLANNING/ DEVELOPMENT AUTHORITY CLASSIFICATION 49 5.2 POPULATION PROJECTION ...... 49 5.3 LAND USE PLANNING (Break up along with green Belt etc.) ...... 50 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (Physical & Social) ...... 50 Social Demand ...... 50 5.5 AMENITIES/FACILITIES ...... 50 6.0 PROPOSED INFRASTRUCTURE ...... 51 6.1 INDUSTRIAL AREA (processing area) ...... 51 6.2 RESIDENTIAL AREA (non processing area) ...... 51 6.3 GREEN BELT ...... 51 6.4 SOCIAL INFRASTRUCTURE ...... 52 6.6 DRINKING WATER MANAGEMENT (source & supply of water) ...... 52 6.7 SEWERAGE SYSTEM ...... 53 6.8 INDUSTRIAL WASTE MANAGEMENT ...... 53 6.9 SOLID WASTE MANAGEMENT ...... 53

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

6.10 POWER REQUIREMENT & SUPPLY/ SOURCE ...... 53 7.0 REHABILITATION & RESETTLEMENT (R&R) PLAN ...... 54 7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABORERS ( A BRIEF OUTLINE TO BE GIVEN) ...... 54 8.0 PROJECT SCHEDULE & COST ESTIMATES ...... 54 8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION (TIME SCHEDULE FOR THE PROJECT WILL BE GIVEN)...... 54 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT ...... 54 9.0 ANALYSIS OF THE PROPOSAL ...... 55 9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON HE BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA ...... 55

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M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s Khushkhera Steels Pvt. Ltd. proposes to install a new project of manufacturing unit of MS Billets, which is situated at Plot No. SP-29, F-20-24, RIICO Industrial Area, Khushkhera, Tehsil – Tijara & District-Alwar (Rajasthan). The plant is located in the RIICO Industrial Area near Bhiwadi in Rajasthan. The company proposes to install induction furnace for manufacturing for MS Billets. The proposed capacity is 60,000 TPA MS Billets. The New proposed plot area is 5600 sq.m. The total capital cost of the project will be Rs. 3034.00 lacs. The proposed project fall under categorized A, Section 3 (a) column 4 (as per amendment dated on 01.12.09 of the Gazette Notification of Sept. 14th 2006), and its subsequent amendments, as Secondary Metallurgical processing industry and attracts general conditions as it falls within 5 Km of boundary of Haryana (i.e. 3.5 Km in NE direction), and it is mandatory to have prior Environmental Clearance (EC) from the Ministry of Environment, Forests and Climate Change (MoEF & CC), Government of India, New Delhi.

1.1 SALIENT FEATURES OF THE PROJECT

S. Parameter Description No.

1. Plant Capacity Products Proposed Remark Raw Materials 64,720 TPA MS Billets 60,000 TPA -- Induction furnace 2 Nos. Each of 10 MT 2. Total area of the 5600 sq.m plant 3. Project Cost Total Project Cost 3034.00 lacs (It includes land, plant machinery , construction and others cost) 4. Location Plot No. SP – 29, F-20-24, RIICO Industrial Area, Khushkhera, Tehsil - Tijara & Dist- Alwar (Raj.) Geographical location: NW NE 28º 06’ 46.30” N 28º 06’ 43.71” N 76º 47’ 31.88” E 76º 47’ 40.20” E SE SW

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

28º 06’ 40.57” N 28º 06’ 40.57” N 76º 47’38.93” E 76º 47’ 38.93”E The site falls in geological survey of India of Toposheet No.53 D /16. 5 Water Items Water requirement (KLD) Requirement/Sourc Industry Activity 22.0 e Domestic 4.0 Total 26.0 Daily fresh water demand 26.0 Reused Water 6.5 Green Belt Development 6.5 ( Dual Media Filtration)

6. Waste Water Industrial waste water will be treated by Dual Media Filtration. Management Domestic waste water will be routed to septic tank connected with soak pit. 7. Employment Manpower No. of Persons Remark generation Managerial staff 6 -- Supervisior 3 Local people Workers 72 will be Total 81 employed

8. Power Supply/ Particulars Details Source Start up Power Proposed Connected Load: 8 MV JVVNL GSS - Sub power Contract Demand: 5.5 Station, Bhiwadi. demand MV DG Set (1 200 kVA HSD-Authorized nos.) dealers

9 Raw Materials Proposed Requirement Particulars (TPA) Iron Scrap 51,776 Iron Sponge 12,206 Ferro Manganese 559 Ferro Silicon 179 Total 64,720

10 Products Particulars Proposed Requirement (TPA) Billets 60,000

11 SOLID WASTE AND MANAGEMENT

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

Waste Proposed Management Quantity Slag generation 4995 TPA Used in road after removal of iron contents Not leachable, hence will be used in land filling, road making / can be used in cement industry Bag Filter dust 1433 TPA can be used in cement / brick industry Used oil <1.0 KLPA Sold to authorized recycler Septic tank Sludge <1.0 KLD Sludge will be generating on periodic cleaning, (As the volume of wastewater after 5 years or more Will be used as manure. & pollution load in wastewater in low)

1.2 FINANCIAL AND SOCIAL BENEFITS

Under financial & social benefit, the project proponent will propose Rs. 75.0 lacs for the CSR activities.

1.3 CONCLUSION

M/s. Khushkhera Pvt. ltd. proposes to install induction furnace for manufacturing for MS Billets. The proposed production capacity 60,000 TPA will not only contribute the growth of Indian economy but also strengthen the socio-economic values in the area. The unit will adopt all the measures through pollution control equipments, Environment Management plan & Disaster Management Plan to prevent harm and damage to environment.

2. IDENTIFICATION OF THE PROJECT / BACK GROUND INFORMATION 2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT 2.1.1 Project Proponent

“M/s Khushkhera Steels Pvt. Ltd.” is a state of the proposed manufacturing unit of MS Billets sections proposed by Rathi group. Khushkhera Steel is fully equipped to ensure quality at every stage of production, so as to deliver perfect product. Modern and apt machinery, testing and quality checks along with qualified operators make the task easy for the company to deliver the best every time.

The Group has very strong presence in various market of the country. The domestic market is well aware of the brand “Rathi” which will give a further pushup to marketing concern.

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

In order to meet the market demands, the company now proposes to install a new manufacturing unit of MS Billets namely “Khushkhera Steels Pvt. Ltd.” at Plot No. SP-29, F-20-24, RIICO Industrial Area, Khushkhera, Tehsil – Tijara & District-Alwar (Rajasthan).

2.1.2 Identification of Project

The proposed products with its production capacity are as mentioned Table 2.1

Table 2.1M Product Profile S.No. Products Production Capacity (TPA) 1. MS Billets 60,000

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The proposed project fall under categorized A, Section 3 (a) column 4 (as per amendment dated on 01.12.09 of the Gazette Notification of Sept. 14th 2006), and its subsequent amendments, as Secondary Metallurgical processing industry and attracts general conditions as it falls within 5 Km of boundary of Haryana (i.e. 3.5 Km in NE direction), and it is mandatory to have prior Environmental Clearance (EC) from the Ministry of Environment, Forests and Climate Change (MoEF & CC), Government of India, New Delhi.

2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND REGION

As the industrial and economic development of the country gains pace, the steel industry in India is poised for faster growth in the decades ahead. India is now the 4th largest producer of steel with an annual production of around 53.9 million tonnes. The contribution of private sector and public sector is about 68 and 32 %, respectively. Indian steel industry is expected to grow by 12% annually. Steel is one of the most important metals and is widely used in automotive, construction, Infrastructure development, mechanical engineering, railway and many other industries. The steel industry in India is poised for faster growth in the decades ahead as the industrial and economic development of the country gains pace. Indian Steel industry is also

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

emphasizing its presence in the global market. The present steel scenario is favorable for expanding steel plant.

2.4 DEMAND – SUPPLY GAP

In India steel industry has a wide application and demand. The steel industry has witnessed continuous modernization of new technologies in recent years. Steel demand has been on an upsurge in India due to the continuous increment in infrastructure growth. The proposed project aims to fill the demand-supply gap through recycling of scrap iron to meet the demand effectively. The demand of Pig Iron, Sponge Iron & finished steel for last five years is given in Table 2.4 Table 2.4 Demand of Pig Iron, Sponge Iron & Finished Steel Indian Steel Industry : Production for sale (in million tonnes) Category 2010-11 2011-12 2012-13 2013-14 2014-2015 Pig Iron 5.68 5.371 6.870 7.950 9.694 Sponge Iron 25.08 19.63 14.33 18.20 20.38 Total Finished Steel 68.62 75.70 81.68 87.67 91.46 (alloy + non alloy) Source: Joint Plant Committee

*In 2014-2015, production for sale of total finished steel (alloy + non-alloy) was 91.46 MT, a growth of 4.3% over 2013-14. *Production for sale of Pig Iron in 2014-15 was 9.7 MT, a growth of 22% over 2013-14. There is demand of high quality product, which India aims to supply, in sufficient quantities for the foreseeable future. Table 2.5 Supply & Demand Gap

Per capita steel Consumption (million ton) Year India (average of rural & urban) World Average Present (2014 -15 ) 91.46 203 2020 165 285

There is a large gap between the demand of and the supply of steel in the region. The proposed project aims to marginally fill the demand – supply gap through optimum expansion to meet the demand effectively.

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

2.5 IMPORT VS. INDIGENOUS PRODUCTION The Proposed project will help substitute steel import from neighboring countries. Local villagers will be employed. The domestic production of it has been catering to the domestic market only.

2.6 EXPORT POSSIBILITY The project is not proposing for export of products.

2.7 DOMESTIC/EXPORT MARKETS Domestic Market The Indian steel industry has entered into a new development stage from 2007-08, riding high on the resurgent economy and rising demand for steel. Rapid rise in production has resulted in India becoming the 3 rd 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 12 th Five Year Plan, there exist many factors 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 600 million by 2030 from the current level of 400 million, emergence of the rural market for steel currently consuming around 10 kg per annum buoyed by projects like Bharat Nirman, Pradhan Mantri Gram Sadak Yojana, Rajiv Gandhi Awaas Yojana among others. National Steel Policy's Export Projection NSP - 2005 estimates that India’s steel production would reach approximately 110 million tons by 2019-20. To contribute in this national goal and to catapult India into a steel superpower, the existing steel plants should be allowed for expansion. Further, NSP – 2005 has set an export target of 26 million tons by 2019, which would exceed imports by 20 million tones. Following table presents the export target set in NSP, 2005 by the Government of India. Table 2.7

Indian Government’s Steel Forecasts (Unit: million tonnes)

Year Product Import Exports Consumption ‘19/ ‘20 110 6 26 90 ‘04/ ‘05 38 2 4 36 CAGR* 7.3% 7.6% 13.3% 6.3% 32

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

Note: * Compounded Annual Growth Rate

*Source: Ministry of Steel- Government of India Nov. 2005 In 2006-07 the Imports and Exports, the imports have been 4.0 million tons and the exports have been 5.0 million tons.

2.8 EMPLOYMENT GENERATION (Direct and Indirect) DUE TO THE PROJECT Direct Employment Total employment in the plant will be for maximum 81 people. The local villagers will be given employment. The man power requirement in the different heads of the proposed development will be as under:- Details of Technical & Managerial Personnel Manpower No. of Persons Remark Managerial staff 6 -- Supervisior 3 Local people Workers 72 will be Total 81 employed

Indirect employment Transportation and warehousing in the region would eventually be needed more therefore truckers and jobs in logistical activities will increase. The will be development of supporting facilities for the workers, petty shops (tea, repair stations for trucks etc) which will give employment opportunities to local people. The increased employment through transportation, warehousing, loading and unloading of container / material will provide indirect agency employment.

3.0 PROJECT DESCRIPTION 3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY The proposed unit is categorized A of schedule no. 3(a) column4 point II of EIA Gazette Notification dated Sep. 14 th , 2006 and its subsequent amendments. M/s Khushkhera Steels Pvt. Ltd. proposes to setup an industrial unit for manufacturing of Billets through concast process at Plot No. SP-29, F-20-24, RIICO Industrial Area, Khushkhera, Tehsil – Tijara & District-Alwar (Rajasthan). The proposed capacity is 60,000 TPA MS Billets. The New proposed plot area is 5600 sq.m. The total capital cost of the project will be Rs. 3034.00 lacs. 33

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT BOUNDARY AND PROJECT SITE LAYOUT) WITH COORDINATES General Location: The proposed project is situated at Plot No. SP-29, F-20-24, RIICO Industrial Area, Khushkhera, Tehsil – Tijara & District-Alwar (Rajasthan), the plot area is 5600 sq.m. Alwar district lies in the Eastern part of Rajasthan State. It is surrounded by Dausa in the South, Bharatpur in the East, Jaipur in the West and Haryana in the North. The plant site is located in Khushkhera village of Tijara Tehsil adjacent to SH 25 connecting to Bhiwadi to Tijara. The site falls in Geological Survey of India of Toposheet No.33D/16. The geographical location of the project is: Specific Location NW NE 28º 06’ 46.30” N 28º 06’ 43.71” N 76º 47’ 31.88” E 76º 47’ 40.20” E SE SW 28º 06’ 40.57” N 28º 06’ 40.57” N 76º 47’38.93” E 76º 47’ 38.93”E

The location map is provided as below clearly showing the project site and its study area is shown in Figure 3.2(i) and plant layout in figure 3.2(ii)

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

Figure 3.2 (i) Location Map

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT Figure 3.2 (ii) Schematic Plant layouts (showing features of the project)

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GIVEN INTO SHOULD BE HIGHLIGHTED No alternative site was examined, because of following favorable conditions of the proposed site: • Vicinity to Market. • Project site situated at RIICO industrial area. • Availability of Land Area. • Availability of Ground Water. • Availability of Raw Materials. • Local Labour is easily available. • Power is easily available. • Well developed transport route is available.

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT Figure 3.3 Site Map of 10 Km radius

3.4 SIZE OR MAGNITUDE OF OPERATION Khushkhera Steel Pvt. Ltd. proposes to set up an industrial unit of capacity 60,000 TPA for manufacturing of MS Billets through concast process at Village Khushkhera, Tehsil Tijara, of Alwar district. The proposed annual capacity of the unit shall be 60,000 TPA on 3 shifts for 300 days. Shift will last for 8 hours. Table 3.4(i) Proposed Facilities and production capacities Particulars Proposed Remark Plot area 5600 Sq.m Induction Furnace 10 Ton (2nos.) Each of 10 tons Billets 60,000 TPA --

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT Additional Cost Break up Table 3.4(ii) Cost Breakup of the Plant (Additional Cost) S.No. Description Cost (in Lacs) 1. Land 0.00 2. Building & Civil work 428.84 3. Plant & Machinery 1717.93 4. Rented Value (Rs. 0.50 Lacs Monthly) 6.00 5. Miscellaneous 736.90 6. Preliminary & Preoperative Expenses 144.33 Total 3034.00

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS (A SCHEMATIC DIAGRAM/ FLOW CHART SHOWING THE PROJECT LAYOUT, COMPONENTS OF THE PROJECT ETC. SHOULD BE GIVEN) The proposed annual capacity of the unit will be 200 TPD (60,000 TPA on 3 shifts for 300 days).

3.5.1 Billets manufacturing process (a) Melting the Charge in Induction furnace

The first step of Billets production is of procurement of sponge iron/Scrap. This sponge iron/scrap is later fed to the furnace by a giant crane. The sponge iron is melted by the induction furnace at a high temperature.

(b) Casting of Billets After the quality of the molten iron is insured, the furnace tilts and pours it into a ladle maneuvered by a crane. The crane moves this ladle towards the caster and pours the molten iron into it. The caster then casts the molten iron into continuous Casts.

(c) Billets/Billet processing The Billets from a particular cast are lifted from the cooling bank and stored separately. When cooled, they are inspected on each face for defects; surface defects are normally removed by a swing frame grinder, etc.

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT Figure 3.5(i) Manufacturing Process

3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCT/S, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT FOR BILLETS Sponge Iron, Scrap, is the main raw materials for the Induction furnace. The Sponge and Scrap will be brought into the Plant by tippers/dumpers/ trucks and unloaded in the Scrap storage bay. From there it is transported over to the Induction Furnace. The raw materials in a pre – determined recipe and of consistent quality depending upon the nature of steel to be produced are charged into the Induction furnace. The scrap is collected in skips on the working platform and is charged into the furnace through the top by tipping the skips. The larger pieces of the scrap are entered first and the smaller pieces are packed about them as closely as possible. Table 3.6 Raw Materials Requirement for Billets Production S No. Particulars Proposed Requirement (TPA)

1. Sponge Iron 51,776 2. Iron Scrap 12,206 3. Ferro Manganese 559

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4. Ferro Silicon 179 TOTAL 64,720

3.6.2 Source of Raw Material The main raw material like Iron scrap, alloys like Silica, Manganese, Copper, will be sourced from domestic market.

3.6.3 Products The proposed annual capacity of the unit will be 60,000 TPA on three shifts for 300 days. Table 3.6.3 Production Capacity of Unit Products Proposed Capacity (TPA) Billets 60,000

The finished product is / will be supplied to the market by trucks/others.

3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEFLY OUTLINED The management of unit will work hard to optimize the resource utilization. The unit will recycle the industrial process water to reduce the daily fresh water. To conserve the rain water the rain water harvesting structure will be developed at the project site which will help in conserve water resources. The unit will be recovering about 1-2% of metal from slag.

3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 3.8.1 Water Demand & its Source The requirement of water for proposed will be 26 KLD. Water requirement break up for the project is given in below table. Water for industrial process and domestic purpose will be met from RIICO Water supply/ CGWB. The water balance for proposed project is given below:

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT WATER BALANCE

Industrial Water Demand: 22.0 KLD Domestic Water Demand : 4.0 KLD Recycled/Reused water: 6.5 KLD Daily fresh water (Industrial + Domestic) Demand: 26 KLD

Billets Cooling Bed: Furnace Cooling Tower : Domestic Water : (200 KL reservoir) (800 KL reservoir) 4.0 KLD

Wastewater: Circulation Rate: Evaporation Circulation losses: 10 KLD 3.0 KLD Rate: 1000 2500 LPM LPM Septic Tank Blow Down: Connected with 7 KLD soak pit Evaporation losses : 5 KLD Sludge : 25 kg/yr. on periodic cleaning after 5 yr / more; sludge will Dual Media be utilized as manure Filtration: Treated waste water: 7 KLD

losses: 0.5 KLD 6.5 KLD Greenbelt Development TDS <2000 mg/l

Table 3.8.1 Water requirement break up for the proposed project Items Water requirement (KLD) Industry Activity 22.0 Domestic 4.0 Total 26.0 Daily fresh water demand 26.0 Reused Water 6.5 Green Belt Development 6.5 ( Dual Media Filtration)

3.8.2 Power Demand & its Source The plant will require 8000 KVA as power requirement. The unit has already applied for the required load which shall be available before commencement of the project through JVVNL. The project site is situated at RIICO Industrial area. Hence no difficulty is envisaged in obtaining required power at the proposed location. For back up in the common areas as well as for essential services 1 D.G set with capacity of 200 KVA. The fuel requirement will be about 30 lit/hr. (considering 50% connected load).

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT Table 3.8.2 Power Demand

Particulars Details Source

Proposed Connected Load: 8 MV JVVNL GSS - Sub

power demand Contract Demand: 5.5 MV Station, Bhiwadi.

DG Set (1 200 kVA HSD-Authorized nos.) dealers

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND THEIR SCHEME FOR THEIR MANAGEMENT / DISPOSAL.

3.9.1 SOLID WASTE The steel industry produces metal slags while the melting of metal. The slag quantity and quality purely depends on the type of raw material used. Proposed solid waste generated from the unit, its quantity and its management is given as under:

Table 3.9 (i) Proposed solid waste quantities waste Quantity management

Slag generation 4995 TPA Used in road after removal of iron contents Not leachable, hence will be used in land filling, road making / can be used in cement industry Bag Filter dust 1433 TPA can be used in cement / brick industry

3.9.2 Liquid waste The spent oil is being and will be sold to registered actual user. Domestic water will be treated through septic tank and disposed of in a soak pit. The industrial waste water will be treated through Dual Media Filtration and treated water will be used in plantation and process. The unit will maintain zero discharge.

3.10 SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PUROSE As per the EIA Notification dated 14 th September, 2006, it is mandatory for the proposed activity to get Environmental Clearance before setting any project or Expansion/modernization of any project. The detailed chart delineating the process is given in figure 3.10

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT The purpose of this Environmental Impact Assessment (EIA) study is to provide information on the nature and extent of environmental impacts arising from the operation of the project and related activities taking place concurrently. The study also focuses on the sensitive issues. For the purpose of the EIA study, the impact zone for the implementation shall confine within a radius of about 10 km from the center of the project site. The objectives of the EIA study are as follows: i) To describe the proposed and existing project and associated works together with the requirements for carrying out the development. ii) To identify, predict and evaluate environmental and social scenario of the project surroundings. iii) To identify and describe the elements of the community and environment likely to be affected by the developments. iv) To identify, predict and evaluate environmental and social impacts expected to raise during the operation of the plant. v) To develop mitigation measures so as to minimize pollution, environmental disturbance and nuisance during construction and operations of the plant. vi) To design and specify the monitoring and auditing requirements necessary to ensure the implementation and the effectiveness of the mitigation measures adopted. In terms of the EIA Notification of the MoEF dated 14 th September, 2006, the generic structure of EIA documents shall be as under: Introduction Project description Analysis of Alternatives (Technology & Site) Description of the Environment Anticipated Environmental Impact & Mitigation Measures Environmental Monitoring Program Additional Studies Project Benefits Environmental Cost Benefits Analysis EMP Summary & Conclusion Disclosure of Consultant Engaged

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT Figure 3.10 Process of Environmental Clearance Procedure

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT 4.0 SITE ANALYSIS 4.1 CONNECTIVITY The proposed site has well developed transport infrastructure, which has all basic amenities that are feasible for industrial projects viability.

Table 4.1 Basic Amenities S. Distance & Direction Nearest Name No. (From plot Boundary) 1. Railway Station Rewari R.S 21.19 km, NW

2. Airport IGIA, New Delhi 58.42 km , NNE 3. Highway SH-25 2.78 km, NE

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP Land Form: The proposed project is new project at barren land has been converted to industrial purposes. The company has acquired the new land of total 5600 Sq.m. Initial agreement is herewith attached as annexure. Land Use: The detailed Land area break up is shown in Table 4.2 Table 4.2 Land Area Breakup S. No. Particulars Area (sq.m)

1. Plant area 2,632 2. Roads/ Corridors 6,72 3. Plantation 1,848 4. Open area 4,48 TOTAL 5600

Land Ownership: The proposed project is situated at Plot No. SP-29, F-20-24, RIICO Industrial Area, Khushkhera, Tehsil – Tijara & District-Alwar (Rajasthan). The land is allotted on private lease by under the name of M/s Khushkhera Steel Pvt. Ltd. The total land area is 5600 Sq.m. 4.3 TOPOGHRAPHY (along with map) The Topography of the Study Area (10 km radius) is flat. In 10 kilometre buffer area there is no hilly area and there is no undulation. There is no major nallah or drainage

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT system in the area. There is no perennial river within the study area except a seasonal Sahibi Nadi . There is no Wild Life Sanctuary/National Park within the study area of 10 km radius. The site is located in Zone III (moderate risk zone) as per the seismic map and prone to moderate intensity earthquake with MSK VIII zone.

Figure 4.3 Topographical Map (10 Km area)

4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA UNDER SEZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN. The study of 10 km around the plant boundary is considered in the land use pattern study. The geographical area of all settlements covered within the study area as recipients. The land use is classified into 4 classes – viz. Built-up Area, Hill Area, Forest Area and Agriculture/others land. There is no national park, wild life sanctuary, eco sensitive areas in surrounding 10 km of the plant boundary.

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

Table 4.4 Land use classification in 10 km buffer area from the project site S.No. Class Area (in Sq. Km) 1. Built-up Area 66.87 2. Hill Area 6.13 3. Forest Area 3.56 4. Agriculture/Others land 237.71

The land use pattern of district is show in following figure Figure 4.4 Land use Map

4.5 EXISTING INFRASTRUCTURE 4.5.1 Water Supply

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT The requirement of water for proposed project will be 26 KLD. Water requirement break up for the project is given table 3.8.1. The water requirement for the plant is met from water tanker/PHED supply.

4.5.2 Power Requirement The plant will require 8000 KVA as power requirement. The unit has already applied for the required load which shall be available before commencement of the project through JVVNL. The project site is situated at RIICO Industrial area. Hence no difficulty is envisaged in obtaining required power at the proposed location. For back up in the common areas as well as for essential services 1 D.G set with capacity of 200 KVA.

4.5.3 Connectivity The proposed site has well developed transport infrastructure, which has all basic amenities that are feasible for industrial projects viability . Table 4.5.3 Basic Amenities

S. Distance & Direction Nearest Name No. (From plot Boundary) 1. Railway Station Rewari R.S 21.19 km, NW 2. Airport IGIA, New Delhi 58.42 km , NNE 3. Highway SH-25 2.78 km, NE

4.6 SOIL CLASSIFICATION Soils play an important role in agricultural development and planning of a region. Various types of soils are found in Rajasthan. The soil of the Alwar district is classified into three classes, viz., Older Alluvial Soils, Red Grey-valley Soils and Red Sandy Soils. Older Alluvial Soils are found in Tijara tehsil, large part of Lachhmangarh tehsil and some parts of Ramgarh, Kherli, Behror, Rajgarh, Itarana and Kishangarh tehsils. Red Grey-valley Soils are found in large part of Alwar tehsil and Thanagazi, small patches in Kishangarh and Ramgarh tehsils, north-east part of Rajgarj and north-west part of Lachhmangarh tehsils. Red Sandy Soils are found in large part of Bansur tehsil, mid part of Thangazi and some parts of Rajgarh.

4.7 CLIMATE DATA FROM SECONDARY SOURCES The climate of the District is semi-arid and very hot in summer and extremely cold in winter. The monsoon season is of very short duration. The cold season starts by the middle of November and continues up to the beginning of March. The summer season follows thereafter and extends up to the end of the June. The south-west monsoon

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT continues from July to mid-September. The period from mid-September to mid- November forms the post monsoon season. The rainfall during the south-west monsoons constitutes about 80 % of the annual rainfall. 577.7 mm is the annual average rainfall.

4.8 SOCIAL INFRASTRUCTURE AVAILABLE Social infrastructure like hospitals, educational facilities, temple, community centre, roads, telecommunication and others similar are available within 10 km radius.

5.0 PLANNING BRIEF 5.1 PLANNING CONCEPT (type of Industries, facilities transportation etc.) TOWN AND COUNTRY PLANNING/ DEVELOPMENT AUTHORITY CLASSIFICATION The demand for the steel due to the increasing infrastructure development and growing economic development has led to the increased consumption of steel. Steel is a key ingredient in ensuring the strength of infrastructures. A definite growth in the steel industry in India is required. In view of this and seeing bright future of steel industry in country the management of M/s Khushkhera Steels Pvt. Ltd. proposes to set up an industrial unit for manufacturing of Billets through concast process at Village Khushkhera, Tehsil Tijara of Alwar district. The site is having roads and means of transportation to the towns are by Bus, Jeeps, Truck and Tractors etc. Alwar City is 64 Km away from site. Water requirement for the proposed project will be 26 KLD. The source of water supply for the project will be RIICO water supply /CGWB . Power requirement for the proposed project will be 8000 kVA and one 200 kVA DG set having 30 Lit/hr (considering 50% connected load) requirement.

5.2 POPULATION PROJECTION The total population of Tijara Tehsil is 13, 28,864. The population data of Khushkhera village and the village around it has been collected from secondary source. According to Census of India 2011, the population of the few selected villages is given below. The detail population in the study area is submitted in EIA/EMP report.

Table 5.2 Population of Khushkhera & Surroundings Villages S.No. Village Name Male Female Total Population 1. Badibawal 2289 2113 4902 2. Karoli 1467 1203 2670 3. Barrera 1287 788 2075

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

4. Khushkhera 264 229 493 Source: Census of India, 2011

5.3 LAND USE PLANNING (Break up along with green Belt etc.) The proposed project is new project at barren land has been converted to industrial purposes. The company has acquired the new land of total 5600 Sq.m. Plantation is proposed in an area of 33 % of plot area. It is proposed to plant approx. 1500 plants per hectare. Table: 5.3 Land use break up along with green belt

S. No. Particulars Area (sq.m) Percentage (%) 1. Plant area 2,632 47 2. Roads/ Corridors 6,72 12 3. Green Belt Area 1,848 33 4. Open area 4,48 8 TOTAL 5600 100

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (Physical & Social)

Social Demand Khushkhera RIICO Industrial area is developed with all facilities. It is situated in the North of Bhiwadi town. This site is close to SH-25. The health, infrastructure of the Industrial area requires improvement. Physical Demand The project requires the following Water: Additional water demand is been met from RIICO water supply / Tanker supply. Electricity : The increase power demand has been already taken from existing JVVNL sub-station located in Plant Area. Materials & Other: The increased supply will be met by local, off site & other markets. Other general utilities facilities are available in the area. Machinery: The expansion will include the installation of following machinery • Induction furnace (2Nos.) - 10 Ton Capacity each. • D.G Set (1 Nos.) – Capacity 200 KVA

5.5 AMENITIES/FACILITIES

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT The project site office, small workshop, first aid room, stack yard & rest shelter will be established. Clean drinking water will be provided. The toilets will be provided separately for males and females. Following facilities are provided for Plant worker:-

S.No. Particulars Recurring cost In Rs

1 Medical facilities 15000

2 Rest Rooms 5000

3 Hygiene & Sanitation 15000

4 Awareness program & Training 15000

6.0 PROPOSED INFRASTRUCTURE 6.1 INDUSTRIAL AREA (processing area) The industry processing area consists of shed area covering the induction furnace, pollution control equipment, product storage area, solid waste storage area, and laboratory.

6.2 RESIDENTIAL AREA (non processing area) As such no individual area is proposed in this project. Only rest room for workers will be provided at site. The work force shall be put in the town nearby, which has all facilities like water; power etc.

6.3 GREEN BELT The green belt has been developed on about 1848 Sq.m land. This is 33% of the total land area (5600 Sq.m) as per the pollution control board norms.

Recommended Plants for greenbelt development: S.No. Plant -Common name Botanical name 1. Neem Azadirachta indica 2. Kachnar Bauhinia variegata 3. Shisham Dalbergia sissoo 4. Desert date of Hingoli Balanites roxburghii 5. Kiker or Babool Acacia nilotica 6. Reonja or Safed babool Acacia leucophloea 7. Palash Butea monosperma 8. Khejri Prosopis cineraria 9. Shrubs and Grasses

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT

10. Munja grass Saccharum munja 11. Kans grass Saccharum spontaneum 12. Kaner Nerium Indicum 13. "Red (Yellow, Wild) Sage" Lantana camara 14. Sarphonka Tephrosia hamiltonii 15. Bui Aerva tomentosa

6.4 SOCIAL INFRASTRUCTURE On the basis of the preliminary site visit, the proposed infrastructures are as follows:

The PP proposes facilities in the village school including books for the library, separate toilets facilities in primary & secondary schools. Few village schools were told of not having working fans and cooling facilities. The PP also proposes unavailable medicines, fans, coolers and beds in the (govt.) hospitals & health centers of the Region. On the basis of need and priority there is high infrastructure demand in the villages for water tankers in summers. Scholarship to underprivileged students at nearby village.

The assessment will be identified in the socio economic survey, after the grant of TOR and will be submitted at the time of final presentation regarding EC.

6.5 CONNECTIVITY (traffic and transportation road, rail, metro/water ways etc.) The proposed site is located in RIICO industrial area, Khushkhera, Tehsil- Tijara & Dist- Alwar (Raj.) and is well connected with all means of transport.

S. Nearest Name Distance & Direction No. (From plot Boundary) 1. Railway Station Rewari R.S 21.19 km, NW 2. Airport IGIA, New 58.42 km , NNE Delhi 3. Highway SH-25 2.78 km, NE

6.6 DRINKING WATER MANAGEMENT (source & supply of water) The requirement of water for proposed project will be 26 KLD. The water requirement for the project will be fulfil by RIICO/Tanker supply. The water balance for proposed project is given above in Table 3.8

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT 6.7 SEWERAGE SYSTEM The domestic waste water will be treated in a septic tank followed by sock pit.

6.8 INDUSTRIAL WASTE MANAGEMENT The industrial wastewater effluent will be treated in the settling tank; treated water will be reused in industrial process and plantation. All effort has been done to optimize the use of water.

6.9 SOLID WASTE MANAGEMENT The steel industry produces different type of solid waste. All efforts are taken to prevent any contamination. The industrial solid waste will be manage in such a way that it will not lead to any contamination of environment. Proposed solid waste generated from the unit, its quantity and its management is given as under: Table 6.9 Solid Waste quantity and management Waste Proposed Management Quantity Slag generation 4995 TPA Used in road after removal of iron contents Not leachable, hence will be used in land filling, road making / can be used in cement industry Bag Filter dust 1433 TPA can be used in cement / brick industry Used oil <1.0 KLPA Sold to authorized recycler Septic tank Sludge <1.0 KLD Sludge will be generating on (As the volume of wastewater & periodic cleaning, after 5 years pollution load in wastewater in or more Will be used as manure. low)

6.10 POWER REQUIREMENT & SUPPLY/ SOURCE The plant will require 8000 KVA as power requirement. The unit has already applied for the required load which shall be available before commencement of the project through JVVNL. The project site is situated at RIICO Industrial area. Hence no difficulty is envisaged in obtaining required power at the proposed location. For back up in the common areas as well as for essential services 1 D.G set with capacity of 200 KVA. The fuel requirement will be about 30 lit/hr (considering 50% connected load).

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT Power Demand

Particulars Details Source Proposed Connected Load: 8 MV JVVNL GSS - Sub power demand Contract Demand: 5.5 MV Station, Bhiwadi. DG Set (1 200 kVA HSD-Authorized nos.) dealers

7.0 REHABILITATION & RESETTLEMENT (R&R) PLAN 7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABORERS ( A BRIEF OUTLINE TO BE GIVEN) The proposed project is coming up in notified industrial area of Bhiwadi Alwar (Rajasthan). Thus rehabilitation and resettlement plan in not applicable in this particular project.

8.0 PROJECT SCHEDULE & COST ESTIMATES 8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION (TIME SCHEDULE FOR THE PROJECT WILL BE GIVEN).

Presently the project is only under planning stage & therefore likely date of starting and completion is not been formulated. The construction activity will be started only after obtaining EC. The schedule of construction and commissioning will be formulated only after obtaining EC

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT The estimated cost for the proposed project will be Rs. 3034.00 (in lacs)

Table 8.2 (i): Estimated Project Cost and Economic Viability

Particulars Details Project Cost Total Project Cost: Rs. 3034.00 Lacs, (It includes land, plant machinery , construction and others cost) Economic As per market trend and large demand of steel induced us for viability production capacity expansion of our unit, the economic viability of the project is well anticipated

M/S KHUSHKHERA STEELS PVT. LTD. PRE-FEASIBILITY REPORT 9.0 ANALYSIS OF THE PROPOSAL 9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON HE BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA As a Corporate Social Responsibility, following activities along with budget provision are proposed for improving the conditions in and around the project area. Plantation on road side. Contribution in development of infrastructure for public use such as Bus Stop, Sheds, Public Toilet etc. Contribution in towards health awareness Programmes. Contribution in books distribution to children in nearby village. Contribution in providing better medical infrastructure in nearby area of Alwar district.

9.2 BUDGETARY ALLOCATION FOR SOCIAL WELFARE IN THE AREA The project proponent will propose Rs. 61.0 lacs for the CSR activities.

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