Techno Economic Feasibility Report of M/S Modern India Con-Cast Ltd

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB CONTENTS

CHAPTER-1 ...... 5 EXECUTIVE SUMMARY ...... 5 CHAPTER-2 ...... 7 INTRODUCTION OF THE PROJECT ...... 7

2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT ...... 7 2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ...... 7 2.3 NEED OF THE PROJECT AND IMPORTANCE OF THE PROJECT TO THE COUNTRY AND REGION ...... 7 2.3.1 Domestic Market ...... 9 2.4 EMPLOYMENT GENERATION...... 9 CHAPTER-3 ...... 10 PROJECT DESCRIPTION ...... 10

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTER DEPENDENT PROJECTS, IF ANY...... 10 3.2 LOCATION ...... 10 Fig 3.1 Location map ...... 10 Fig 3.2 Satellite map of M/s MICL Haldia project ...... 11 Fig 3.3 Project Layout map showing existing and proposed facilities...... 12 3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED...... 13 3.4 SIZE OR MAGNITUDE OF OPERATION ...... 13 Table 3.1 Project Configuration before and after configuration ...... 14 3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ...... 15 3.6 PROCESS DETAILS ...... 16 3.6.1 Submerged Electric Arc ...... 16 3.6.2 Briquette plant ...... 18 Table 3.2 Annual Major Net Raw material requirement in TPA ...... 18 3.7GROSS RAW MATERIAL, SOURCE AND MODE OF TRANSPORT FOR BOTH RAW MATERIAL AND FINISHED PRODUCT...... 18 3.8 RESOURCE OPTIMIZING/RECYCLERS AND REUSE ENVISAGED IN PROJECT ...... 19 3.8 AVAILABILITY OF WATER, ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE...... 19 3.9QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT/DISPOSAL ...... 20 3.9.1 Solid waste generation and management ...... 20 3.9.2 Liquid waste generation and management ...... 20 3.10 SCHEMATIC REPRESENTATION OF FEASIBILITY DRAWING WHICH GIVES INFORMATION ABOUT EIA ...... 21 CHAPTER-4 ...... 22 SITE ANALYSIS ...... 22

4.1 CONNECTIVITY ...... 22 4.2 LAND FORM, LAND USE AND LAND OWNERSHIP ...... 22 4.2.1 Land use ...... 22 4.2.2 Land ownership ...... 23 4.3 TOPOGRAPHY ...... 24 4.4 EXISTING LAND USE PATTERN OF STUDY AREA ...... 24 Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

4.5 EXISTING INFRASTRUCTURE ...... 25 4.6 SOIL CLASSIFICATION ...... 26 4.7 CLIMATIC DATA FROM SECONDARY SOURCE ...... 26 4.8 SOCIAL INFRASTRUCTURE ...... 27 4.8.1 Health infrastructure ...... 27 4.8.2 Waste disposal facilities...... 27 4.8.3 Recreation and sports infrastructures ...... 28 4.8.4 Educational infrastructure ...... 28 CHAPTER-5 ...... 29 PLANNING BRIEF ...... 29

5.1 PLANNING CONCEPT ...... 29 5.2 PERIPHERAL DEVELOPMENT PLAN ...... 29 5.3 LAND USE PLANNING ...... 29 Table 5.1: Land Use Pattern after Modernization & Expansion* ...... 29 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND ...... 30 CHAPTER -6 ...... 31 PROPOSED INFRASTRUCTURE ...... 31

6.1 INDUSTRIAL AREA DISTRIBUTION ...... 31 6.2 GREENBELT DEVELOPMENT FACILITY ...... 31 6.3 CONNECTIVITY ...... 31 6.4 DRINKING WATER MANAGEMENT: ...... 31 6.5 INDUSTRIAL WASTE MANAGEMENT ...... 31 6.5.1 Waste Management ...... 32 6.6 INDUSTRIAL POLLUTION CONTROL ...... 32 6.6.1 Air Pollution Control ...... 32 6.6.2 Water Pollution Control ...... 32 6.7 MAN POWER REQUIREMENT ...... 33 CHAPTER -7 ...... 34 REHABILITATION & RESETTLEMENT ...... 34

REHABILITATION & RESETTLEMENT ...... 34 CHAPTER -8 ...... 35 PROJECT SCHEDULE ...... 35

8.1 IMPLEMENTATION SCHEDULE ...... 35 Table 8.1: Tentative implementation schedule: ...... 35 8.2 ESTIMATED PROJECT COST ...... 36 CHAPTER-9 ...... 37 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION) ...... 37

9.1 FINANCIAL & SOCIAL BENEFITS ...... 37 9.2 SOCIAL INFRASTRUCTURE ...... 37 Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

9.3 EMPLOYMENT POTENTIAL ...... 37 9.4 BENEFITS TO THE REGION AND THE COUNTRY ...... 37

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB CHAPTER-1

EXECUTIVE SUMMARY

M/s Modern India Con-cast Ltd (MICL) has been promoted by Modern Group of Companies, who are well known specially in the eastern India for their manufacturing activities in steel sector. The Group is in this line of business for the last four decades. The group is also engaged in exporting various types of Ferro-alloys and Iron & Steel products. Considering the future growth potential of ferro-alloys market at domestic and international level, MICL proposes to increase the installed capacity of its existing Ferro-alloy plant at Haldia in West Bengal

Spread over in an area of 15.98 ha of land in Bhuniaraichak, in Purba Medinipur district of West Bengal. The company proposes expansion through installation of 3x9 MVA Submerged Arc Furnace and at the same time proposes to add production of Fe-Cr and Fe-Si to existing Fe-Mn & Si-Mn (4 products) due increasing demand of all these Ferro-alloys.

Raw material for the expansion will be about 0.28 MTPA Mn Ore, 0.051 MTPA Cr Ore, 0.11 MTPA Coke, 0.030 MTPA Dolomite, and 0.084 MTPA Quartzite.

Fresh water requirement for the expansion project is estimated to be 800 m3/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 22.5 MW, and total power requirement is 67.5 MW

Land

The Company has in its possession 15.98 ha of land on which existing project is running and giving production. 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. 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. Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

Pollution Control Features

Following pollution control measures will be taken up for integrated steel project of M/s Bengal Energy Limited at Bhuniarichhak, Haldia

 Dust extraction & dedusting bag house at Raw material Stock house. This will result in reduction in fugitive dust emission.

 Bag filter SAFs for dust and iron particle removal from fume.

 Wastewater settling, cooling and treatment for reused/recycled in the process.

 Slag to be used for construction work/land fill, raw material

 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 70 will be regular employment plus about indirect staffs.

Project cost

The estimated expansion project is 100 crore. This will be as follows.2.5 % of the total capital cost will be spent under ESC activities.

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 Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB CHAPTER-2

INTRODUCTION OF THE PROJECT

2.1 Identification of Project & Project Proponent

M/s Modern India Con-cast Limited having its administrative office at: 6G-Everest, 46C, Jawaharlal Nehru Road, Kolkota-700071 is an ISO 9001, ISO 14001 & OHSAS 18001 Company.

The company has its 100% export oriented 6x9 MVA Ferro-Alloy manufacturing unit, manufacturing & exporting Fe-Mn and Si-Mn at-J.L.No. 122, Bhuniaraichak, in Purba Medinipur district of West Bengal, Latitude-22°05'37.56"N and longitude-88°10'19.53"E with mean sea level 4.6m.

2.2 Brief description of nature of the project

The proposed project is expansion of existing Primary metallurgical, schedule 3(a), Category-AFerro-alloy Plant, proposing to manufacture Fe-Mn, Si-Mn,Fe-Cr & Fe-Si from 9x9 MVA submersed Arc Furnace. The expansion project needs prior Environmental Clearance from MoEFCC.

2.3 Need of the project and importance of the project to the country and region

M/s MICL proposes four Ferro-alloy products, namely Fe-Mn, Fe-Si, Fe-Cr and Fe-Si from all of its 9x9 MVA SAFs and production will be from one to all the products depending upon the market demand.

Fe-Mn is mostly being used today for improving the hardness and wear resistance of steels.

Si-Mn is a preferred ferroalloy during steel making. It has emerged as a more important alloy than Fe-Mn.It is also employed as a complex deoxidant in steel making and (upon melting together with aluminium) to produce a complex manganese-silicon-aluminium (M- K-A) deoxidant.

Fe-Cr is the major alloying element in the production of stainless steel. HC Fe-Cr, produced from higher grade ore, is normally used in specialist applications such as engineering steels. Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB LC Fe-Cr is also a low-cost alternative to metallic chrome for uses in super alloys and other special melting applications.

Fe-Si increases the strength of steel and is therefore used in those steels which are required for producing wire cords for tyres and ball bearings. Fe-Si is also used for deoxidation during steel making. The other major applications of Fe-Si are in electrical steels used for transformers and dynamos, alloy steels for tools and automobile valves, and in iron castings.

A new Transparency Market Research report – ‘Global Ferro Alloy Market – Industry Analysis, Size, Share, Growth, Trends and Forecast 2020’ states that the global ferro alloy market was valued at USD 37.2 billion in 2013 and is expected to reach USD 53.5 billion by 2020, expanding at 5.4% CAGR between 2014 and 2020.

As per the report, the expansion in the global steel industry is a key growth driver for the market for ferro alloy. In addition, the rising construction industry within Brazil, Russia, India, China, and South Africa (BRICS) will also stimulate the development of the market. Furthermore, the advancement of high strength and light weight steel grades will bring in new growth opportunities in the ferro alloy market. However, the strict environmental regulations enforced by the governments of various nations and the soaring operational costs associated with ferro alloys may impede the development of the market.

In 2013, Fe-Mn led the market with a share of more than 37%. This is due to the fact that Ferro manganese is majorly utilized in foundry activities and steel making and is among the cheapest alloys utilized globally. By volume, the market for Ferro manganese is predicted to expand at a 4.5% CAGR from 2014 to 2020 and likely to cross 2.5 billion tons by the end of 2024, growing at close to 5% CAGR. On the other hand, the market for ferro chrome is also rising exponentially owing to its growing utilization in stainless steel manufacturing. In addition, the increasing demand for anti-corrosive steel from the automotive industry is also augmenting the growth of the Ferro chrome market.

Geographically, the market is segmented into China, Europe, North America, Rest of Asia Pacific and Rest of the World (RoW). Among these, China led the market in 2013 owing to the presence of a number of steel manufacturers within this country. By volume, China constituted a share of 46.6% in the market for ferro alloy in the same year. Europe trailed China and held the second-largest share in the market owing to the development of the automotive industry in this region.

Rest of Asia Pacific is predicted to be one of the most promising ferro alloy markets due to the expansion of the steel industry here, particularly within Japan and India. On the other hand, Rest of the World and North America are poised to register a slow growth rate on the basis of demand for ferro alloys during the forecast horizon.

Ferro Alloys Corporation Limited (FACOR), Georgian American Alloys, Nikopol Ferroalloy Plant, S.C. Feral S.R.L., China Minmetals Corporation, Sinosteel Jilin Ferroalloy Corporation Limited, and OM Holdings Ltd, among others, are the chief players dominant in the market, as per this study. Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB Source: Steel 360 Magazine June’16 Issue

This being 100% export oriented company domestic market has not been taken into consideration.However, the global market scenario is indicator of the importance of Ferro alloy industry.

2.3.1 Domestic Market

Steel industries are major consumer of Ferro alloys. No alloy steel is possible without Ferro alloys. So demand of ferro alloys depend on planning for steel production.

Steel is a core industry and thus its demand is strongly linked to the overall economic activity of the nation. Given the inherent long-term potential of the Indian economy and its cyclical nature, the long-term prospects of the steel industry are fairly comfortable. The demand and production has been growing at a healthy rate for the last few years and the forecast for the next decade and half is also very promising.

It has been estimated by certain major investment houses such as Credit Suisse that India’s steel consumption will continue to grow at 16 % rate annually fuelled by demand for construction projects worth US $1 trillion. The scope for raising the total consumption for steel is huge, Per capita consumption of steel at current levels is about 65 kg. As a comparison, per capita steel consumption in China is 430 kg and the world steel consumption per capita average is 180 kg.

By 2020-21 the demand at 7 % and 8 % GDP growth is estimated to be 123 million tons and 137.5 million tons respectively. Taking a mean figure of 130 million ton, there is a need of 65 million ton in 10 years’ time. This translates into an average growth requirement of about 10 million tons per year and gives a clear-cut indication of demand of Ferro alloys.

2.4 Employment Generation

For the expansion project of 3x9 MVA Ferro alloy plant there will be generation of about 70 direct employment excluding contract labours and security guard.

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB CHAPTER-3

PROJECT DESCRIPTION

3.1 Type of Project including interlinked and inter dependent projects, if any.

Ferro alloy plant at Haldia in Purba Medinipur district of WB is a metallurgical Ferrous alloy unit of schedule 3(a), category-A, producing alloy from ore in electro thermic process. For raw material it is neither interlinked nor interdependent with any other project rather dependant on ores from mines.

3.2 Location

Location map showing general & specific location, project boundary & Project site layout with co-ordinates.

Fig 3.1 Location map

The Ferro alloy project of M/s MICL is located at village Bhuniaraichak, Haldia, district Purba Medinipur in West Bengal. The geographical coordinates are latitude 22°05'37.56"N and longitude 88°10'19.53"E with mean sea level 4.6m. Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist- Purba Medinipur, WB

Fig 3.2 Satellite map of M/s MICL Haldia project

Co-ordinates:Pt 1 -NW-2205’ 45.35” N 880 10’ 33.31” Pt 3- SW-220 5’ 45.49” N 880 10’ 20.06”

Pt 2-ENE-220 5’ 30.10” N 880 10’ 29.38” E Pt 4- ESE-220 5’ 33.19” N 880 10’ 16.54” E Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist- Purba Medinipur, WB

Fig 3.3 Project Layout map showing existing and proposed facilities

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted.

M/s Modern India Con-Cast Ltd is having its 6x9 MVA Submerges Arc Furnaces running on a land of 15.98 ha (39.50 Ac) and has vacant space to accommodate additional 3x9MVA Submerged Arc Furnaces with additional raw material and waste. Existing infrastructures will be utilised for the expansion activities. Hence expansion has been proposed on this land and no other land has been taken into consideration. More over this site is well connected with roads/rail and Haldia port is nearby for export and import of product and raw material as the unit is 100% export oriented project with raw material also imported from outside.

3.4 Size or magnitude of operation

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist- Purba Medinipur, WB Table 3.1 Project Configuration before and after configuration

Sl Existing Existing Existing Proposed Proposed Proposed Proposed Proposed Final Final No configuration products capacity Modified Modified Expansion Expansion Expansion Configuration Capacity In TPM Products Capacity configuration Products Capacity after In TPM In TPM Modification &Expansion In TPM 1 6x9MVA SAF Fe-Mn 3,846.25 Fe-Mn 1,112.08 3x9MVA SAF Fe-Mn 556.00 9x9 MVA SAF 1,668.08 Si-Mn 5,465.83 Si-Mn 6,000.00 Si-Mn 3,000.00 9,000.00 Fe-Cr 1,300.00 Fe-Cr 650.00 1,950.00 9,312.08 Fe-Si 900.00 Fe-Si 450.00 1,350.00

9,312.08 4,656.00 13,968.00

With modification in existing 6x9 MVA Submerged Arc Furnaces Fe-Mn, Si-Mn, Fe-Cr and Fe-Si will be produced and from proposed 3x9 MVA Submerged Arc Furnaces similar products like Fe-Mn, Si-Mn, Fe-Cr and Fe-Si will also be produced and production capacity will be increased from 9,312.00 TPM to 13,968.00 TPM. However as per market demand the company can reduce the quantity of one product and increase the other due to interchangeable facility. Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

3.5 Project Description with process details

Project High lights

The highlights of the proposed modification cum expansion Project of M/s Modern India Con- cast Ltd. (MICL) are as follows:

Location Bhuniaraichak, Haldia, District Purba Medinipur West Bengal

Latitude & Longitude 22°05'37.56"N and longitude 88°10'19.53"E , Avg. MSL-4.6m

Land in possession 15.98 ha

Existing Plant status 6x9 MVA running SAF

Producing Fe-Mn & Si-Mn, 9,312 TPM

Modification Proposal Modification of existing SAF to produce Fe-Cr and Fe-Si in addition to Fe-Mn & Si-Mn without change in existing capacity of 9,312 TPM.

Expansion Proposal Installation of additional 3x9 MVA SAF to produce Fe-Mn, Si-Mn, Fe-Cr and Fe-Si 4,656.00 TPM

Project capacity after modification cum 13,968.00 TPM i.e. 1,53,648 TPA of mixed expansion production

Raw water requirement& source 800m3/day, Haldia Development Authority (HDA)

Waste water management zero waste water dischargeout side plant. Furnace cooling water will be recycled. Domestic wastewater will be treated in Septic tank–Soak pit system

Air pollution control Bag filters for each SAF with ID fan and 30m stack above ground. Water sprinklers for Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB fugitive dust control

Solid waste management Fe-Mn slag raw material for Si-Mn

Si-Mn to be used for land fill and paver block (brick) manufacture

Fe-Cr slag is a refractory material for sale/road construction after alloy recovery

Expansion Power requirement & source 22.50 MW, West Bengal State Electricity Board (WBSEB). Total power including existing will be about 67.50 MW.

Man power for expansion project Direct employment-70

Expansion project cost 100 crores

3.6 Process details

Ferroalloy refers to various alloys of iron with a high proportion of one or more other elements such as manganese, silicon or Chromium. Typically, compositions are like this. Fe-Mn: Mn-70%, Si-7.5%, C-2.25%(max) Si-Mn: Mn- 60-65%, Si-14-17%, C-2.5%(max) Fe-Cr: Cr-50-70% Fe-Si: Si-70-75%, Al-1.5-2%, C-0.2%(max)

3.6.1 Submerged Electric Arc

Furnace Smelting in an electric arc furnace is accomplished by conversion of electrical energy to heat. An alternate current applied to the electrodes causes’ current to flow through the charge between the tips of the electrodes. This provides a reaction zone at temperatures of> 2000ºC. The tip of each electrode changes polarity continuously as the alternating current flows between the tips. To maintain a uniform electric load, electrode depth is continuously varied atomically by mechanical or hydraulic means. The lower part of the SAF is composed of a cylindrical steel shell with a flat bottom or hearth. The interior of the shell is lined with two or more layers of carbon black. The furnace shell is water cooled to protect it from process heat. A water-cooled cover and fume collection hood are mounted over the furnace shell. Normally, three carbon electrodes arranged in a triangular formation, extend through the cover and into the furnace shell opening. Prebaked or self - baking (Soderberg) electrodes ranging from 76 to over 100cm in diameter are typically used. Raw materials are sometimes charged to the furnace through feed chutes from above the Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB furnace. The surface of the furnace charge, which contains both molten material and unconverted charge during operation, is typically maintained near the top of the furnace shell. The lower ends of the electrodes are maintained at about 1 to 2 meters below the charge surface.

Ferroalloys are produced by electric arc carbothermic reduction of various ores like Manganese ore, Quartzite ore or chromiteore depending upon the ferro alloys required to be produced.

Ferroalloy production is essentially a carbothermic reduction operation taking place at high temperatures generated by electric arc formed between the tips of the electrodes in the bottom of the furnace and the furnace hearth. Oxide ores above 20000C of arc at the tips of electrodes are reduced by Carbon of Coke and thus ferro alloys are produced. In the process of smelting, huge amounts of electricity are consumed, making production in countries with high power cost very expensive.

Charging: The reactants consist of metallic (chrome) ore and a carbon-source reducing agent, usually in the form of coke, low-volatility coal or wood chips. Limestone may also be added as a flux material. Raw materials are crushed, sized, and some cases, dried, and then conveyed to a mix house for weighing and blending. Conveyors, buckets, skip hoists, or cars transport the processed material to hoppers above the furnace. The mix is then gravity-fed through a feed chute either continuously or intermittently, as needed. Smelting: Three- phase electric current arcs are formed from electrode to electrode through the charge material. Power is applied continuously. The carbonaceous material in the furnace charge reacts with oxygen in the metal oxides of the charge and reduces them to base metals. The reactions produce large quantities of carbon monoxide (CO), which passes upward through the furnace charge. In the further reaction, this carbon monoxide gets converted into carbon dioxide (CO2). Feed materials may be charged continuously or intermittently. Tapping / Pouring: The molten metal and slag are released through a tapping process. One or more tap holes extending through the furnace shell at the hearth level. Tap holes are opened with pellet shot from a gun, by drilling or by oxygen lancing. The molten metal and slag flow from the tap hole into a carbon-lined trough, then into a carbon-lined runner which directs the metal and slag into a ladle, ingot moulds, or chills (chills are low, flat, iron or steel pans that provide rapid cooling of the molten metal)

Tapping of the material from the furnace takes place intermittently. When enough smelted Ferro alloy has accumulated in the hearth of the furnace, the tap hole is drilled open and a stream of molten metal and slag rushes down a trough into a chill or ladle. The ferroalloys solidify in large castings, which are crushed for sale or further processed.

Slag tapped from furnace contains Ferroalloys due to molten alloys sticking to it. Slag solidifies after cooling, crushed and alloys removed by jigging in water bed where density variation separates alloy from slag. Alloy thus recovered is cycled back to corresponding furnaces.

Metal Recovery Plant : The ferroalloy slag consist some portion of valuable ferroalloy material which can be obtained in a directly saleable condition and can be sold at reasonably Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB good market rates as compared to the main ferroalloy product. The Metal Recovery Plant is being used to recover this portion of metal from slag. Certain portion of slag is conveyed to Metal Recovery Plant (MRP) wherein it is crushed as to extract good quality Ferrochrome from the slag waste. This process involves the following three steps;  Crushing and screening of metal containing slag.  Separation of metal from slag.  Re-crushing of middling to realize additional metal

Fe-Si is basically a slag less process however depending on quality of Quartz. A type Quartz containsSiO2 99.5% (min) and B type contains SiO2 98.5%.

For Fe-Mn production, Manganese ore is reduced by Coke in SAF, for Si-Mn production Manganese ore and slag from Fe-Mn production are reduced by Carbon of Coke in SAF,

Fe3O2 (iron ore), SiO2 (quartz) and carbon in the form of coke is used as raw material for production of Fe-Si.

For production of Fe-Cr, Chromite ore and Iron ore are reduced by coke.

3.6.2 Briquette plant

The project will make briquettes utilizing Chrome-ore fines to the extent of 70%, lump and fine ores will be used to the extent of 20% and 5-10% respectively. Utilization of briquette charge will also optimize power consumption in the furnace.

Table 3.2 Annual Major Net Raw material requirement in TPA

Product Quantity Mn ore Chromite Coke Quartz Dolomite TPA Ore Fe-Mn 18,348 44,000 - 13,750 - 6,424 Si-Mn 99,000 2,37,600 - 74,250 49,500 19,800 Fe-Cr 21,450 - 51,480 16,500 4,400 4,400 Fe-Si 14,850 - - 14,850 30,250 - Total 1,53,648 2,81,600 51,480 1,19,350 84,150 30,624

3.7 Gross Raw material, source and mode of transport for both raw material and finished product.

Material Quantity in TPA Source Mode of transport Mn Ore of different 2,90,048 Import/Barbil mines, Rail/Road/Ship grade (35-37, 38-48 Odisha/MOIL Ltd etc.) Chromite Ore both 53,025 Import/Sukinda mines, Road lump & fines Odisha Quartzite 86,675 Jharkhand, Bankura Road Coke 1,22,930 Import/Dhanbad/Durgapur Rail/Ship Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB steel/import Dolomite 31,542 Odisha, Bhutan & Import Rail/Road Electrode paste 34,000 Graphite Road India/Maharashtra Carbon Ltd

Finished products to meet export quality standard with respect to purity and export 100% of product through ship.

3.8 Resource Optimizing/recyclers and reuse envisaged in project

Following Resource Optimizing/recyclers and reuse measures are proposed

 Solar lighting in internal roads, LED bulbs in control rooms

 Variable frequency drive, ID fans and blowers will draw less power for same output

 Installation of capacitor band to increase power factor up to 0.99

Recycling measures:

 Utilization of Ferro manganese slag as a raw material for silico manganese production

 Recovery of Ferro alloys from their slag and recycle to process

 Waste water treatment and recycling to reduce fresh water drawl

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

WATER SUPPLY FACILITIES

Fresh water requirementfor existing as well as expansion project of M/s MICL taken together has been estimated to beabout 800 KLD, whichwill be usedfor industrial as well as domestic purpose after expansionof project. The raw water will be supplied by Haldia Development Authority (HDA).

The fresh water requirement is to compensate evaporation loss through slag and alloy quenching and furnace cooling.

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

3.9Quantity of waste to be generated (liquid and Solid) and scheme for their management/disposal

3.9.1 Solid waste generation and management

Following solid waste will be generated during production of Ferro alloys from 9x9MVA Submerged Arc Furnaces.

Sl. Solid waste Quantity Management No In TPA 1 Fe-Mn slag 20,000 To be fully used as raw material for Si-Mn production 2 Si-Mn slag 1,09,000 Can be sold for land fill and paver block manufacture 3 Fe-Cr slag 23,600 It is a refractory material for sale/road construction after alloy recovery & TCLP test 4 Fe-Si slag 750 Process is slag less, however small amount generation depending on impurities in Quartz-to be used Si- Mn production

3.9.2 Liquid waste generation and management

Zero discharge norm to be adhered to.Ferro alloy plant circulating water to be cooled in CT and blow down to be used for green belt watering and dust suppression.

Domestic waste water to be discharged to soak pit after septic tank. Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB 3.10 Schematic representation of feasibility drawing which gives information about EIA

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

CHAPTER-4

SITE ANALYSIS

4.1 Connectivity

The site is well connected by roads and railways. It is approachable from the Kolkata-Haldia National Highways (NH-41 starts at Haldia near the Haldia refinery and meets NH-6 linking Kolkata to Mumbai at Mecheda). It is also connected with Howrah through Panskura-Haldia branch (69 km.) of the South-Eastern Railways. Panskura-Durgachak Road is another road, which connects Haldia to Main SouthEastern Railway line at Panskura. Haldia is about 130 km from Kolkata by road (Through NH-41 and NH-6). Haldia is also connected with Kolkata through the shortest route of Diamond Harbour Road and regular ferry services operating from Raichak to Kukrahati over the Hooghly river. The nearest commercial airport is at Kolkata.

Nearest Railway Station is Durgachak which is 4.0 KM away in SW direction from the project site. Hooghly river is within 1 km distance from the project site towards East and Haldi river is about 13.5 km away from the project site towards SW. NH - 41 is about 5.0 km away in south-west direction from the site. Haldia town is about 4.0 km in SW direction from the project site and Tamluk (Dist. HQ) is about 34.0 km in NW direction from the project site.

4.2 Land Form, Land use and land ownership

The Haldia Township is bordered by the Haldi river an offshoot of the Ganges river. Haldia is the coastal area of Medinipur. It was formed in the last few thousands of years by the continuous supply of sediments loaded from a huge catchment which is deposited into a subsiding basin, partly fluvial and partly marine, under varying energy conditions.

The most conspicuous and important litho unit in the area is laterite. Laterite is underlain by semi consolidated and unconsolidated sediments.

About 90 km long stripe between Haldia and Digha is the out-fall area of the rivers Kasai and Subarnarekha. The area is occupied by 2000 m thick column of Quaternary and Tertiary sediments comprising alternations of graded sand, silt and clay sequence.

4.2.1 Land use

The general conditions of the EIA Notification, 2006 applicable to set up the proposed Ferro Alloy plant been adhered to while selecting the present site. The location of the proposed Plant is not within 10 km from the outer periphery of the following: 1. Metropolitan Cities 2. National Park and wildlife sanctuaries 3. Ecologically sensitive areas like tropical forests, important lakes, coastal areas rich in coral formation, etc. 4. The chimney does not fall in the approach funnel of a runaway of any airport 5. No forestland or prime agricultural land is being taken for setting up the plant 6. The site is not in the vicinity (15 km) of places of archaeological, religious or tourist importance. Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB The company has acquired 15.98 ha of land and the entire land will be used for the project. Distribution of land will be as follows.

Sl. No Facilities Use of land in ha 1 Existing plant facilities including internal roads 2.5 2 Proposed plant facilities 1.0 3 Raw water reservoir & rain water harvesting pond 3.2 4 Raw material, Waste & Finished product yard 4.0 5 Green Belt 5.28 Total 15.98

4.2.2 Land ownership

Excepting river, all the lands are private lands. M/s MICL has acquired 15.98 ha of land and converted to industrial land on which existing plant is running and proposed expansion has been proposed.

The proposed development will be confined within the boundary of the allocated land only, earmarked for the industrial purpose, so there will not be any significant impact on the land use pattern of the area.

The land has been leased from HDA as industrial land.

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB 4.3 Topography

4.4 Existing Land use pattern of study area

An analysis of the land use within the study area indicates that River & other Water bodies occupy a significant portion of 33.8% of the total study area. The areas under agriculture is about 25% and the settlements account for around 21% of the total study area. 12.8% of the study area falls under the category of the barren land, whereas wetland accounts for around 6.9% of the total study area.

There is no national park, no wild life sanctuary, no eco sensitive zone, no forest within buffer zone of project area. Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

Water bodies wet land Agricultural land settlement Barren land

4.5 Existing Infrastructure

Many of the villages and urban area have primary schools, middle schools, secondary schools and Colleges under study area. Medical facilities (primary health centre, allopathic & homeopathic dispensary, maternity and child welfare centre) are not enough in the rural area. Haldia Municipal area has all types of infrastructure facilities. Water supply in the study area is mainly from supply, tank, well, bore well and hand pumps. Electricity is being supplied for domestic, agriculture, and public lighting purposes. Post Office, Electricity and telephone connections are available within the study area.

The site is accessible from NH-41. The site is also approachable from Haldia Railway Station through a road. Nearest Railway Station is Durgachak which is 4.0 KM away in SW direction from the project site. Hooghly river is within 1 km distance from the project site towards East Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB 4.6 Soil classification

The soils of the study area are formed through alluvial deposits and overlain by more recent back swamp deposition. The soils are light to dark coloured and poor in calcareous materials. Considerable quantity of decayed vegetation is reported to occur particularly in the silty clay strata.

Soils in the area are mostly clay loam and silt or clay in texture and contain large percentage of silt and clay and hence possess high water holding capacity and good fertility status. Only in areas close to rivers, soils are sandy clay which is typical of river banking areas.

Agricultural land is spread over a substantial area of the entire study area. However, canal irrigation facilities being few and far between, irrigation is mostly done from tube wells, rivers and ponds through lift irrigation. Most of the irrigational tube wells are driven through electricity.

The prevailing edaphic, hydrological and climatological conditions favour production of paddy, jute and quite a good number of other crops. The prime agricultural crop paddy is grown during both of the kharif and rabbi seasons. Betel (Pan) is another significant agricultural crop of this area which is harvested throughout the year. Coconuts and bananas are grown abundantly throughout the area.

Major kharif crops include rice (Aman), pulses (mainly chickling and kesari), vegetables and jute, while major rabbi crops are rice,oilseeds (mainly mustard), vegetables, potato and other tuber crops.

4.7 Climatic data from secondary source

Nearest Meteorological station of project site is Midnapore (42803) was the secondary source of climatic data.

Haldia has a typical moderate climate with winter temperatures ranging from a low of around 7 degrees Celsius to a high of 22 degrees Celsius. Summers can be very hot and humid. Usual summer temperatures in May, the hottest month range from a low of 24 degrees to highs around 40 degrees Celsius. Although summers are hot and humid, Kalbaishakhis (mango rain) provide a relief to the people. Rainfall is heavy during South- West monsoons, with an average rainfall of 1451mm and the rainy months are from mid- June to mid- October.

Rain fall occurs on almost all months but the least amount of rainfall occurs in December. The average in this month is 1 mm. Most of the precipitation here falls in September, averaging 326 mm.

Relative Humidity varies from 34 to 84%, annual avg.59%.

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

4.8 Social Infrastructure

A well-connected road network with good condition of the roads is extremely important for an industrial region to prosper. This has motivated HDA to engage in construction of new roads along with widening of existing roads in full swing. The port city is traversed by a good network of roads and highways connecting different parts of the industrial area. Haldia Development Authority ensures that every industrial, residential and commercial plot has an access through an approach road. At present, all the roads in Haldia are in good condition.

4.8.1 Health infrastructure

The township is well equipped with medical facilities to take care of emergencies, routine check-ups, and chronic and complex cases. There is a 250-bed Sub-Divisional Hospital with specialized health care, prevention and treatment, diagnostic and pathology facilities. Also a 100 bed Eye care centre, 300 bedded Dr. B. C. Roy Hospital cum Dental College, Government run health centres, primary health units and clinics. Apart from these the Indian Oil Refinery and Port have their own hospitals and clinics equipped with all modern facilities. A 300 bedded Medical College is also coming up under ICARE - an NGO.

4.8.2 Waste disposal facilities

West Bengal Waste Management Ltd. (WBWML) is a JV project on PPP mode which has a fully integrated waste management complex in Haldia. It has fully functional Industrial, Hazardous and Bio-Medical Waste Management plant. The domestic and municipal waste Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB management facility is under construction. HDA has offered land (about 100 acres) for this project

4.8.3 Recreation and sports infrastructures

The Haldia Development Authority has constructed a huge stadium at Durgachak with a seating capacity of 12000 people to encourage the sports activities in the township. The township also houses parks properly developed and maintained. The riverfront along the Haldi river is being developed with facilities for all water sports activities in the recent future. An amusement park is also to be constructed within the township. One Sports city with a stadium is being developed by Haldia Municipality on 65 acres plot of land.

4.8.4 Educational infrastructure

Country's leading schools and educational institutions have started their branches here to impart good quality education. St. Xaviers, Assembly of God Church, KendriyaVidyalaya, Bharatiya Vidya Bhawan are only a few to name. Co-educational and women's colleges have also been started. Besides the seats for general learning, there are engineering and polytechnic colleges likeDental College, Golden Regency (Hotel Management Institute), Haldia Law College, Marine Institute, Paramedical Institute, Management Institute, Haldia Institute of Technology, MeghnadSaha Polytechnic Institute and Central Institute of Plastics Engineering Technology. An Industrial Training Centre has come up that ensures readily available skilled manpower. The foundation stone for Apeejay Knowledge Park has just been laid which will further enhance the academic level in the town.

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB CHAPTER-5

PLANNING BRIEF

5.1 Planning concept

It is a labour intensive project. However, depending on the production schedule, there will be additional technical labour 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 Bengal Energy 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.

5.3 Land Use Planning

The total land of 15.98 ha is available for the project and its expansion will be carried out within the existing plant.The detailed breakup of the land is given in the following table:

Table 5.1: Land Use Pattern after Modernization & Expansion*

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB 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 Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB 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 15.98 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 5.27 ha of land will be demarcated for green belt purpose.

6.3 Connectivity

The site is well connected by roads and railways. It is approachable from the Kolkata-Haldia National Highways (NH-41) starts at Haldia near the Haldia refinery and meets NH-6 linking Kolkata to Mumbai at Mecheda). It is also connected with Howrah through Panskura-Haldia branch (69 km.) of the South-Eastern Railways. Panskura-Durgachak Road is another road, which connects Haldia to Main SouthEastern Railway line at Panskura. Haldia is about 130 km from Kolkata by road (Through NH-41 and NH-6). Haldia is also connected with Kolkata through the shortest route of Diamond Harbour Road and regular ferry services operating from Raichak to Kukrahati over the Hooghly river. The nearest commercial airport is at Kolkata.

6.4 Drinking Water Management:

Around 15 KLD of water will be used for drinking purposes and sanitation purposes. The required water will be sourced from Haldia Development Authority

6.5 Industrial Waste Management

Sl. Solid waste Quantity Management No In TPA 1 Fe-Mn slag 20,000 To be fully used as raw material for Si-Mn production 2 Si-Mn slag 1,09,000 Can be sold for land fill and paver Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB block manufacture 3 Fe-Cr slag 23,600 It is a refractory material for sale/road construction after alloy recovery & TCLP test 4 Fe-Si slag 750 Process is slag less, however small amount generation depending on impurities in Quartz-to be used Si- Mn production

6.5.1 Waste Management

The wastes which will be generated from the process are some used oil,sludge and slag from Submerged Arc Furnace. The utilization and disposal of Arc furnace slag has been discussed in this chapter. 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 as because the amount is too low for any treatment in STP .Canteen waste water will be treated in a separate ETP consisting of O & G trap, settling tank, anaerobic treatment system & gravity sand filter.

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

Raw Material Handling

1 Raw Material Handling, Raw - Water sprinkling will be provided at the Material Processing Transfer transfer points of material at RMHP. Points, Junction Houses - Bag filter

2 SAF - Bag Filter

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 sent to soak pit. Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB 6.7 Man Power Requirement

The total man power requirement for plant operation on completion of the proposed expansion will be around 70

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB 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 Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB 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. Activities Duration No.

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 Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB

Receipt of equipment 230 days

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 from SPCB, WB.

8.2 Estimated Project Cost

Project Cost

The estimated expansion project is 100 crore. This will be as follows.

Sl. No. Cost Head Estimated Cost, in Crore

1 Land development earth 12.0 work & civil work

2 Plant Machinery& Pollution 78.5 control devices

3 Enterprise Social 2.5 Commitment

3 Engineering &Consultant 7.0 Expenses

Total 100

Techno Economic Feasibility Report of M/s Modern India Con -cast Ltd Expansion cum modification Project At: Haldia, Dist - Purba Medinipur, WB 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 centre 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 70 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 MICL shall produce steel billets that are to be utilized in construction activities. The products are in demand and production shall contribute to the GDP growth of the country.