M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, , .

CHAPTER – 01 EXECUTIVE SUMMARY

Sl. No. Particulars Details 1 Name of the Project Reliable Sponge Pvt Ltd.

IDCO Plot No-84 2 Location Golibhanga,Kalunga Tahasil-Lathikata Sundergarh.Odisha 3 Area 26.837 Acre Revenue Land allotted by IDCO,Govt Of Odisha. Sponge Iron=4000 MT/Month 4 Product Through DRI Klins Billet-28,800 TPA TMT bars and rods. 5 Man Power Existing=240 Addl. Requirement=240 6 Topography Plain Area Present=70 KLD 7 Water Requirement Addl.=133 KLD (Permission Obtained and agreement is done with E.E,Irrigation,Sundergarh. Present=14MW 8 Power Requirement and Source Addl.=8MW Source=WESCO Agreement has been Done. 9 Cost Of the Project Existing =Rs 11.2Cr Addl=Rs 6.00Cr 4,500 Plants have been planted in 4Acre Area within plant 10 Green Belt Development 21 Acre has been developed outside of the plant Area as Green Belt & Land has been allotted by IDCO. Hindalco Industries. 11 Consumers National Aluminum Company & Other Local Industries. Presently Billet Production=28,800 TPA 12 Capacity Enhancement of Production from 28,800 TPA to 1,15,200TPA

Visiontek Consultancy Services Pvt. Ltd. Page 1 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha. (Incremental 86,400 TPA) By augumanting present 2 nos. Induction Furnace capacity 6T/H to 12 T/H and installation of an additional 2 nos. Induction Furnace of 12 T/H. Consent to operate has been obtained vide 13 Consent to Operate Letter No-17972/22-12-2016 and valid up to 31-03-2018 14 Consent to establish Consent to establish vide Letter No-15094/07- 10-2016 and valid up to 31-03-2018 15 Certification Received ISO-9001(valid up to 04/2018 and ISO 14001

Visiontek Consultancy Services Pvt. Ltd. Bhubaneswar Page 2 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

CHAPTER – 02

2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of Project and Project Proponent. In case of mining project, a copy of mining lease/letter / letter of intent should be given.

Reliable Sponge Pvt. Limited, a company incorporated in March 2004. The company was taken over by DUA group in January 2007.At present the company has 2 nos. 50 TPD Sponge Iron DRI Kilns and 1 no. 100 TPD Sponge Iron DRI Kilns and other machineries like induction Furnace, producer Gas Plant etc.. The Plant is located in Plot no. 84, Industrial Estate Kalunga, Dist Sundergarh, Odisha. The present production of billet is 28,800 TPA and it is proposed to enhance additional production of billet to 86,400 TPA by augmenting existing two nos. Induction Furnace capacity 6T/H to 12T/H and installing two nos. additional Induction Furnace of 12 T/H. The total capacity will be 1, 15,200 TPA. The company has received ISO-9001 and valid up to 04/2018 ISO-14001 Certification. The Company has obtained consent to operate and consent to establish . vide letter no. 17972 dated 22.12.16 and 15094 dated 07.10.16 and valid up to 31.03.2018 respectively.

Reliable Sponge Pvt. Ltd produces quality of billets and torque steel rods and supply to its valued customers like Hindalco Industries Limited,National Aluminium Company Limited, Phosphates Limited and others. This project is for manufacture of steel billets through Induction Furnace, Ladle Furnace and Continuous Casting Machine. The Company has been incorporated under companies Act, 1956. The Promoters are Shri Arun Kumar Dua and members of Dua families. Shri Ramakanta Dash and Shri Sarat kumar Rout acts as Directors. The Directors are having good experience in the field of Steel Industry.

2.2 Brief Description of Nature of the project

The nature of the project is metallurgical industries and fall under the category of 3 (a) under category “A” of the schedule of EIA notification sept., 2006. It is proposed for enhancement of production of billets with additional three nos. Induction furnace. There are two nos. (2x50 TPD) and one no. (1x100 TPD) DRI Kilns which produces sponge Iron 4000

Visiontek Consultancy Services Pvt. Ltd. Bhubaneswar Page 3 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha. MT/month. Steel scraps, pig iron, silico manganese coke, and ferro silicons are brought from outsides. Rolling Mills, Induction furnace (2x6 T/H) ate existing now. Billets are produced and which are used to manufacture Torque steel and rods.

2.3 Need for the Project and its importance to the Country and/or region.

The production of sponge iron started from 2004-05 was not required for the plant. Environmental Clearance as per EIA notification dated 14th sept. 2006 & subsequent amendment in 21st Nov 2006. The plant has obtained Consent to Operate from SPCB, Odisha. Steel is one of the most important products of modern world and is of strategic importance for any industrial nation. Historically, all nations during their industrialization phase have been supported by strong steel industries of their own.

India is the fourth largest producer of steel in the world. It holds the third position in consumption of steel. There is a great Potential in Steel Industry in

During address to the nation, Prime Minister has envisaged the growth of steel sector to attain a production capacity of 300 million tonnes by 2020. From Construction, industrial machinery to consumer products, steel finds a wide variety of application. It is an industry with technologies based on the nature & extent use of raw materials.

Sponge Iron is an intermediate product used for manufacture of steel. India has installed capacity of 36.7 MTPA sponge iron and leading state in production is Odisha.

In Odisha, in Kalunga Industrial Estate, there are 2 small and 8 medium sponge iron industries and total capacity is 0.65 MTPA.

Commercial production of sponge iron started in India in 1980. Today India has installed 36.7 MTPA sponge iron. Odisha occupies the top position accounting 36% of total capacity.

Visiontek Consultancy Services Pvt. Ltd. Bhubaneswar Page 4 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha. Sponge Iron Growth

Year Production

2001-02 7.5 MTPA

2002-03 8.7 MTPA

2003-04 10.0 MTPA

2004-05 12.9 MTPA

2005-06 36.7 MTPA

2.4 Demand & Supply Gap

 In 2013 world crude steel production reached 1606 million tonnes (mt) and showed a growth of 3% over 2012.

 Indian steel industry has entered into a new development stage from 2007-08.

 Rapid rise in production has resulted in India becoming the 4th longest producer of crude steel and largest producer of sponge iron or DRI in the world.

 As per the report of working group on steel for 12th plan, there exist many factors which carry the potential of raising the per capita steel consumption in the country, currently at 59.2 kg.

 National steel policy 2005 had envisaged steel production to reach 110 million by 2019-20.

 Working group on steel for 12th plan has projected that crude steel capacity in the country is likely to be 140 mt by 2016-17.

 World Steel Association has projected Indian Steel demand to grow by more than 3.3% as compared to global Steel growth.

Visiontek Consultancy Services Pvt. Ltd. Bhubaneswar Page 5 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha. 2.5 Imports v/s Indigenous Production

Imports are not expected.

2.6 Export Possibility

Export of steel is always possible. Government of India is also encouraging export of excess steel after domestically consumption.

2.7 Domestic/export markets

Brillets & Iron Torque steels produced by the M/s Reliable Sponge Pvt. Limited is sold mainly to secondary steel producing units.

2.8 Employment Generation (Direct & Indirect) due to the Project.

Total manpower currently is 240 nos. Additional manpower about 240 will be required for incremental production. The skilled & semiskilled man power will be recruited from the nearby villages.

Visiontek Consultancy Services Pvt. Ltd. Bhubaneswar Page 6 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

CHAPTER - 3

PROJECT DESCRIPTION

3.0 Project Description

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

This project is a secondary metallurgy project falling under “B” category.

The project is manufacturing of steel billets and torque steel rods through Induction Furnace route along with setting up LRF and CCM.

The project is having two nos. 50 TPD DRI KILN and one no. 100 TPD DRI KILN along with one numbers Ladle Refine Furnace (LRF), oil fired Rolling mills, slag crusher 12 TPH (one number) and two numbers 6T capacity Induction Furnace. This project is not interlinked.

3.2 Location (map showing general location, specific location, and project boundary & project site layout) with coordinates.

The Project lies between longitude 84˚45́̒̓’26” E & latitude 22˚13’6” N. The Project is situated in Kalunga Industrial Estate, , Odisha.

The plant having area 26.371 acre is located in Kalunga village of Sunderagrh district of Odisha. The land has been allotted by Orissa Industrial Infrastructure Development Corporation, Govt. of Odisha and lease deed has been signed on 10.02.2017.

Details of Area:

State Odisha District Sundergarh Tehsil Lathikata Village Goibhanga Area 26.371 Acre

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Revenue Khata no. 65,67,37,14,15,67,65,37,14,15,67,65,65,67,67,67 & 65 84,84/1,84/1A,93,91,92,93/A,95/B, IDCO Plot No. 91/1,140,141,148,149(P), and 139 (P) Toposheet No. 73 B-11,12,15,16 Longitude:84˚45’26” E Geo coordinates Latitude: 22˚ 13’ 6” N

Details of Land:

Sl. No. Particulars Area in Acre 1. Sponge Iron Units 3.5 Raw material stock yard for Sponge Iron 2. 1.0 Unit 3. Rolling mill along with its stock yard 4.0 4. Structure mill along with its stock yard 3.0 Induction Furnace, continuous casting 5. 1.5 machine, slag crusher 6. Solid waste dump area 3.586 7. Proposed expansion Area 0.6 8. Area available for Green belt 8.0 9. Area for future use 1.185 Total 26.371

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KEY PLAN

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GOOGLE MAP

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TOPO MAP

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

 The area has been allotted by IDCO, Odisha. The installation of additional three nos. of Induction Furnace will be within allotted area. i.e. in the proposed expansion area of the existing plant area.

 Environmental Consideration:

 There is no national park, wild life sanctuary or biosphere reserves within 10 km fom the periphery of the plant.

Environmental Setting Sl. No. Particulars Distance & Direction from the plant WATER BODIES 1 Brahmani River 4.18 km in East direction 2 Sankha River 3.09 km in NE direction 3 Langamohan Nadi 2.05 km in NW direction 4 Vedvayas Confluence 4.88 km in NE direction 5 Pitamahal Reservoir 3.8 km in SW direction FOREST 1 Balanda Reserve Forest 2.59 km in S direction 2 Butkupiri Reserve Forest 3.74 km in SE direction 3 Sagjor Reserve Forest 4.53 km in SW direction 4 Laimura Reserve Forest 8.38 km in W direction 5 Jogisar Reserve Forest 5.5 km in N direction 6 Chadri Reserve Forest 8.51 km in N direction ROADS 1 NH-23 3.22 km in NW direction 2 SH-10 2.22 km in NE direction 3 Kalunga Railway station 2.42 km in W direction 4 Railway station 9.26 km in W direction VILLAGES NEARBY INDUSTRIES ARE 1 Kalunga village 1 km in SW direction 2 Jiabahal village 0.8 km in NW direction 3 Brahamani Taranga 1.5 km in SW direction THE INDUSTRIES AROUND RELIABLE SPONGE LIMITED ARE 1 Mahavir ferro alloys 0.2 km in NW direction 2 Utkal metallic Adjacent in N direction 3 Sita Sponge 0.2 km in SW direction 4 Puja Sponge 0.1 km in SW direction

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 12 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

3.4 Size or Magnitude of operation.

The present area is 26.371 acre has been allotted by IDCO, Govt. of Odisha. Presently 28,800 TPA billets are being produced. It is proposed to enhance the production up to 1,15,200TPA i.e. an incremental 86,400 TPA after augmenting the existing 2 nos. Induction Furnace capacity 6T/H to 12 T/H and installing an additional two nos. of Induction Furnace of 12 T/H. Rolling Mill & Structure Mill present capacity is 72,000 TPA which has been enhanced to 1,44,00 TPA.

The present consumption of the materials are as follows to produce 4000 mt/month of sponge iron.

Quantity Particulars (Metric Ton/ month) Iron Ore 9000 Coal 5000 Dolomite 400

The following equipments exist at present.

Sl. No. Product Quantity 1. Sponge Iron-DRI kiln-I &II 2x50 TPD 2. Sponge Iron-DRI kiln-III 1x100 TPD 3 Producer Gas Plant (For Rolling Mill) 4200 Nm3/hr 4. Producer Gas Plant (for Structural Mill) 6000 Nm3/hr 5. Induction Furnace 2x6 Ton/Heat Billets (Two strand continuous billet 6. 28,800 Ton/annum caster) 7. Producer Gas Plant (stand by) 6000 Nm3/hr 8. Slag Crusher 12 Ton/hour

Proposed Equipment-:

i. Augmentation of capacity of present two nos. Induction Furnace 6T/H to 12 T/H.

ii. Installation of an additional two nos. Induction Furnace having capacity 12 T/H.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 13 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

3.5 Project Description with Process Details (a schematic diagram/flow chart showing the project layout, components of the project etc. should be given)

a. Manufacturing of Sponge Iron:

2 Nos. X50 TPD and 1 no. X100 TPD DRI Kilns exist in the plant which is used for production of sponge iron of 4000 MT/ Month by iron ore, coal & dolomite.

b. Principle of Melting in Induction Furnace:

At Present there are two nos. 6T/heat capacity of Induction Furnace.The melting process involves taking sponge Iron, Pig Iron, Steel scraps, Silico- manganese coke and ferro silicon.

Electrical Coil surrounds the cylindrical crucible acts as primary and metallic changes as secondary. When an electrical current is passed through primary coils, electromagnetic field causes inducted current to pass through metallic charges and makes melt.

As soon as the molten pool is formed, a pronounced stirring action takes place which helps in accelerating the melting. Deoxidizing agents and sometimes specific alloying elements are added at suitable interval during melting.

After completion of melting cycle, the homogeneous molten metal mass is poured hydraulically into ladle. c. Ladle Refining Furnace

Subsequent to the production of molten steel the production of quality requires refining.(Refining means – Reduction of undesirable elements like Sulphur, Phosphorous, etc). In Ladle Furnace fluxes are added. Arcing is done through three electrodes. On metal interface to refine the steel.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 14 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

Ladle Furnace is used to de-sulpurise(if required). Ferro alloys addition to adjust carbon, silicon and manganese. It also raises the temperature to the required casting at CCM.

d. Continuous Caster Machine

Ladle Preheaters are provided to heat the ladle to about 1100˚C. Addition of silicon manganese, etc. are done manually.

e. Casting

The crane will lift the ladle from ladle furnace and bring it to ladle stand of Billet casting machine.Liquid steel flow from ladle to a tundish below by controlled opening. Liquid steel flows on to curved mould which shapes and forms billet. The hot billet goes through water spray cooling chambers. Then billet comes to straightening cum with drawl machine which is a set of individually driven & hydraulically pressed rollers. There is a manually oxy- fuel cutting torch which cuts the billets. Then the crane with a magnet removes the billet from CCM cooling bed and stones.

Existing Pollution Control Measures -:

Unit Details

Sponge Iron Bag Filters ESP-2 nos.

Induction Furnace Bag Filter

Slag Crusher Bag Filter

In addition to the above

1. Approach roads are sprinkled with Water

2. Regular maintenance of Vehicles & Machineries.

3. Green Belt Development

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3.6 Raw Materials required along with estimated quantity, likely source, marketing area of final products. Mode of transport of raw material and finished product.

(a) (Ton/Annum)

Additional Total Due to Sl. No. Particulars Existing Incremental Production

1. Steel scrap 3800 11400 15,200

2. Pig Iron 500 1500 2000

3. Sponge Iron 28,500 85,500 1,14,000

4. Silico Manganese 405 1215 1620

5. Coke 430 1290 1720

6. Ferrosilicon 6 18 24

(b) Presently sponge iron is 4000 T/month. The following materials are required for production of sponge iron

Particular MT/Month Iron Ore 9000 Coal 5000 Dolomite 400

Dolomite is an important ingredient and acts as a desulphurizer for removing sulphur from the feed mix during the reduction process. It is mixed in small proportions along with other raw materials before changing to kiln.

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 Consumers

Billets are self used to produce TMT bars & Torque steels. The finished products are taken by nearby small scale industries and as well as local sell. NALCO, PPL, Hindalco & other Industries.

3.7 Resource Optimization/recycling and reuse envisaged in the project, if any, s hould be briefly outlined.

 Funace slags are used for metal recovery.

 Waste water generated is used for dust suppression.

 Slag from Induction Furnace are non-hazardous solid waste. Used for dumping low laying area/road making.

3.8 Availability of water its source, energy/power requirement

The total requirement of water will be 6100 m3/month i.e. 203 m3/day. The total water will be drawn from ground water. An agreement has been done with irrigation Division, Sundergarh.

(in KLD)

Sl. Additional Purpose Existing Total No. Requirement 1. Domestic 5 5 10 2. Cooling & Process 55 108 163 Dust Suppression & 3. 10 20 30 Others Total 70 133 203

The cooling involves sponge iron scrubber , DRI cooler, IF Cooling Tower, Rolling mill cooling Tower & Structure mill cooling.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 17 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

3.8.1 Power Requirement

Presently power is being drawn from WESCO. Consumption is 14 MW at present. Additional 8 MW will be required for the enhancement of production.Agreement has been done with the Chief Operating Officer ,WESCO Utility,Burla.

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

Sl. Solid Waste Quantity (TPA) Composition Nature No. Present Additional Total Silicate of Slag from Induction calcium Non- 1. Furnace & LRF 6100 18300 24400 embedded with hazardous residual stack Dust released from Mainly metal Non- 2. fumes extracted from 310 930 1240 oxides hazardous induction furnace 3. Char 20,000 - 20,000

 Slag is crushed and used for road construction & filling of low laying areas.

 A clear water settling pond ensures continuous cleaning of contaminated water for its reuse in operation.

 Char is used for filling of low laying areas and also used by power plants.

 Concrete flooring has been laid inside the plant area. Continuous water spraying cleans the floor and helps the dust to flow into the nearby drain where sludge is collected.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 18 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

3.10 Details of Flow Chart

DRI KILN ADDITION OF IRON ORE, DOLOMITE & COAL

SPONGE IRON

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Flow Chart of Induction Furnace

EXISTING PROPOSED

INDUCTI HOT ON WAT INDUCTION HOT WATER COOL COOL WATER WATER FURNAC ER FURNACE E

LADLE

CONTINOUS CASTING MACHINE

BILLET MOULD

BILLET TO YARD

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CHAPTER-04

SITE ANALYSIS

4.0 Site Analysis

4.1 Connectivity

The land has been allotted by IDCO, Govt. of Odisha. The area is well connected by all weather metallic road from at a distance of 3 kms. The nearest railway station is Kalunga, of South Eastern Railway at a distance 4 km from the plant.

4.2 Land form, Land use and Land ownership.

The land has been allotted by IDCO. The land has already been acquired by the company. IDCO has allotted 26.371 acre of land in industrial estate of kalunga. An agreement has been done with odisha Industrial Infrastructure Development Corporation on 10th Feb 2017.

4.3 Topography

The area is plain. Longmohan nadi flows at a distance of 2.05 km in NW direction from the plant. Brahmani River flows at a distance 4.18 km in east direction from the site. The elevation varies from 200 to 211 m above MSL. Surface run off flows to Brahmani river.

4.4 Existing Land Use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive area, 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 detail of Land schedule is given in annexure. No additional land is required for the enhancement of production . Installation of additional furnace will be within the existing area. The land is revenue land allotted by IDCO. There is no national park, wild life sanctuary, eco sensitive area within the buffer zone. However, there are some forest lands and water bodies within the buffer zone.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 21 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

4.5 Existing Infrastructure

First-aid Center, Rest Shelter for the employee. Canteen, Parking space, Rest shelter for the contractual transport vehicle persons, exist in the plant.

4.6 Soil Classification

Alluvial and Lateritic soils are found in the area.

4.7 Climatic data from secondary sources

The area is characterized extremely hot in summer and cold in winter. The Maximum temperature 45˚C & minimum 24˚C in summer and in winter maximum 30˚C & minimum 9˚C. Humidity found in summer 97% maximum & 4% minimum. During winter season humidity is found 94% as maximum and 15% as minimum. Average rainfall in August is 419 mm.

4.8 Social Infrastructure available

Hospitals, Schools, Colleges and Community facilities are available in and around the Industrial Area.

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4.9 Schematic representations of the feasibility drawing which give information of EIA purpose.

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CHAPTER-05

5.0 Planning Brief

5.1 planning concept (type of industries, facilities, transportation etc., ) town and country planning/development authority classification

Presently the company (in 2016-17) has production of 46080 tonnes. The consent to operate has been obtained from State Pollution Control Board which is valid up to31.03.2018.

At present the Industry proposes to enhance the production from 28,800 TPA to 1,15,200 TPA (Incremental 86,400 TPA) by augmenting existing two nos. Induction Furnace capacity 6T/H to 12T/H and installing two nos. additional Induction Furnace of 12 T/H.

Sponge Iron production in metric tonne per year

Year Particulars 2016-17 46079 2015-16 31850 2014-15 30521 2013-14 33670 2012-13 22917

5.2 Population Projection

At present total manpower is 240. Additional manpower will be required for incremental of production. About 240 persons will be recruited. Skilled & semi-skilled will be recruited nearby villages.

5.3 Land Use Planning (breakup along with greenbelt etc.,)

An area, 8.0 acre will be developed for green belt. About 8100 trees will be planted in the plant site. About 4500 plant has been planted inside the plant area of 4 acres. In addition to Reliable Industries has been allotted 30 acres of land Kucheita village for plantation by IDCO. 21.0 acre has been planted out of 30 acres.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 24 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

5.4 Assessment of Infrastructure Demand (physical & social)

Hospitals, Educational facilities, drinking water facilities, communication facilities are available in Kalunga Industrial Area.

Education

Kalunga has a government high school. In addition to St. Gregorius school is also located. Diploma College namely Institute of Technology is also located.

Hospitals

Primary health centre exists in Kalunga Industrial Area. In addition to PHC, there is a 750 beded hospital of Rourkela Steel Plant, at a distance of 10 km from plant site.

Communication

Kalunga is well approached through rail and road. Nearest railway station is 1.0 km from the area.

5.5 Amenities/Facilities

All facilities are available.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 25 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

CHAPTER-06

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (processing area)

The enhancement of production and installation of additional Induction Furnace will be within existing area (within plant premises).

6.2 Residential area (Non-processing area)

No colony is envisaged.

6.3 Green Belt

33% of the total plant area will be developed as green belt area. Already 4.0 acre of area has been developed as green belt with local species in addition to 21.0 acre outside of the plant area.

6.4 Social Infrastructure

Basic amenities are available in the area. School, College, Hospitals, Communication road network are available.

6.5 Connectivity (traffic and transportation road/rail/ metro/water ways etc.,)

Rail & Road facilities are available. Railway station is 15 km from the plant site. All weather road is approachable to plant site.

6.6 Drinking water management (source & supply of water)

Existing drinking water is met through bore wells. 3.0 KLD is being drawn through bore wells. Additional water will be met from the existing bore wells. 10 KLD will be used for additional man power.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 26 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

6.7 Sewerage system

There is no residential accommodation. Only septic soak pit combination has been provided. Domestic waste will be generated from plant office. The Sewage from the Plant is taken to the soak pits and waste water is utilized for dump yard dust suppression. The plant will follow the zero discharge principle.

6.8 Industrial waste management

Klin accretion area waste generation. This is filled in low-laying area.

6.9 Solid waste Management

Solid wastes generated are:

Slag from induction furnace and LRF, dust released from fumes extracted from Induction Furnace. About 7510 TPA is being generated which are non-hazardous and non-pollutant. These materials are taken outside with covered trauplin lorries and dumped in low areas designated for this purposes.

6.10 Power requirement & supply/ source.

At present 14 MW is being used. Power is siurced from WESCO. Additional 8 MW will be necessary for operation of two additional Induction Furnace and will be sourced from WESCO.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 27 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

CHAPTER-07

REHABILATION & RESETTLEMENT (R&R) PLAN

7.0 Rehabilation & 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 laboureres (a brief out line to be given).

The land for setting up industry has been provided by Industrial Development Corporation of Odisha. Rehabilation & Resettlement is not applicable.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 28 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

CHAPTER-08

PROJECT SCHEDULE & COST ESTIMATES

8.0 Project Schedule & Cost Estimates

8.1 Likely date of start of construction and likely date of completion (time schedule for the project to be given).

Additional of three numbers of Induction Furnace (2x12 T/H) will be installed after obtaining Environmental Clearance.

Cost of Project

Existing cost of the Project= Rs.11.2 Crore.

Particulars Amount Civil Construction & Structures Rs. 4.10 Crore Plant & Machinery Rs. 5.3 Crore Electrical Rs. 1.8 Crore Total Rs. 11.2 Crore

Additional cost (For enhancement of Production)= Rs 6.0Cr

Particulars Amount in Rs(Cr) Civil Construction & Structures 1.83 Plant & Machinery 3.00 Electrical 1.17 Total 6.0

8.2 Estimated project cost along with analysis in terms of economic viability of the project.

The Project is Viable.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 29 M/s. Reliable Sponge Pvt. Limited Pre- Feasibility Report for enhancement of production from existing 28,800 TPA to proposed production 1,15,200 TPA with Augmentation of Existing 2 Nos. Induction Furnace Capacity 6T/H to 12 T/H & Installation of an Additional 2 Nos. Induction Furnace Capacity of 12T/H At Kalunga , District, Sundergarh, Odisha.

CHAPTER-09

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.0 Analysis of Proposal (final recommendations)

9.1 Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area.

This enhancement of production will improve the economic growth of local people. Engagement of local people will also upgrade prosperity of the region.

Visiontek Consultancy Services Pvt. Ltd Bhubaneswar Page 30