EX EC U T I V E S U M M A R Y O F EXECUTIVE SUMMARY 1.0 Introduction M/S Mahalakshmi Profiles Pvt. Ltd., established on Survey. No. 287, 288 & 289 in Kallakal village, Manoharabad Mandal, Medak District in Telangana state, is already manufacturing Steel Billets. Presently it has two induction furnaces (one stand by) with 12 tons capacity, with total production of 29,700 tons per Annum. It also has a Strip mill and Tube mill of 165tonnes per day capacity each. The existing plant is having valid Consent for Operation from TS Pollution control Board. Now the company have proposed to expand the existing plant by installing 12TPH x 6 more (total 8 No. 12TPH) Induction Furnaces along with CCM for making 621 TPD (2,04,930 TPA) of MS Billets and New roughing stand/Modernization activities for making 534 TPD (1,76,220 TPA) of MS Skelp and installation of 3 new ERW Tube mills for production of 835 TPD (2,75,550 TPA) of MS Pipes and installation of scaffolding workshop for production of 50 TPD (16,500 TPA) of Scaffolding. It will also Install continuous coil Galvanizing unit for manufacturing of 300 TPD (99,000 TPA) of Galvanized Strips /Coils and installation of Hot Dip Galvanizing unit for manufacturing of 300 TPD (99000 TPA) of Hot Dip Galvanizing of MS ERW Tubes. Project Proponent M/S Mahalakshmi Profiles Pvt. Ltd. is a Private Limited Company. The Directors of the company are as under: Directors: The company is promoted by: Mr. Ramniranjan Agarwal and Mr. Vinod Kumar Agarwal. Address: Mahalakshmi Profiles Pvt. Ltd. Private Limited has its registered office at 1-9-8, I.D.A, Azamabad, Hyderabad, Telangana. 1.1 Location M/S Mahalakshmi Profiles Pvt. Ltd.is situated at village Kallakal village, Manoharabad Mandal, Medak District in Telangana state , Latitude 17° 41' 54.3408"N and Longitude 78°29'4.8192"E. The project falls under the Manoharabad Mandal. The land area of the plant is 19 Acres and 17 Guntas (78,610.256 sq m) out of which 13.675 acres is being used for the Industrial processes and 5.75(33.0% )Acres has been allocated for green belt. a 2.0 Product and Capacities The project proposes to expand the production capacity by upgrading existing capacity as given below: Capacity S. No. Product Existing Expansion After Expansion MS Billets though 1 90 TPD 621 TPD 711TPD Induction Furnace 2 MS Skelp through 165 TPD 534 TPD 699 TPD Strip mill 3 Pipes through Tube Mill 165 TPD 835 TPD 1000 TPD 4 Scaffolding -- 50 TPD 50 TPD 5 Galvanized Strips/Coils -- 300 TPD 300 TPD Hot Dip galvanizing of 6 -- 300 TPD 300 TPD MS ERW Tubes The unit obtained CFO for Furnace on 16-08-2017 (valid up to 31-01- 2022) from State Pollution Control Board to manufacture 90 T/Day of MS Ingots ,60TPD MS Pipes and 70TPD hot Rolling strips . The unit obtained the respective Consent Orders accordingly and started its operations. Salient Features of the Project Name of Project Mahalakshmi Profiles Pvt. Ltd. Proponent( Director) Mr. Ramniranjan Agarwaland Mr. Vinod Kumar Agarwal. Nature of the Project Secondary Metallurgical Process based industry Latitude and Longitude S. LATITUDE LONGITUDE S. LATITUDE LONGITUDE NO. NO. 1 17°42'3.22"N 78°29'1.19"E 14 17°41'56.60"N 78°28'47.00"E 2 17°41'57.66"N 78°29'0.91"E 15 17°41'56.50"N 78°28'47.00"E 3 17°41'57.60"N 78°28'55.80"E 16 17°41'55.90"N 78°28'42.00"E 4 17°41'52.50"N 78°28'55.60"E 17 17°41'56.20"N 78°28'41.90"E 5 17°41'52.50"N 78°28'55.40"E 18 17°41'56.80"N 78°28'46.70"E 6 17°41'54.20"N 78°28'50.00"E 19 17°41'57.60"N 78°28'46.70"E 7 17°41'54.20"N 78°28'49.60"E 20 17°41'57.50"N 78°28'48.20" 8 17°41'54.10"N 78°28'49.10"E 21 17°42'0.80"N 78°28'48.50"E 9 17°41'55.30"N 78°28'48.80"E 22 17°42'0.70"N 78°28'50.60"E 10 17°41'55.40"N 78°28'49.40"E 23 17°42'2.00"N 78°28'50.90"E 11 17°41'56.60"N 78°28'49.40"E 24 17°42'2.30"N 78°28'56.20"E b Name of Project Mahalakshmi Profiles Pvt. Ltd. 12 17°41'56.70"N 78°28'49.60"E 25 17°42'2.20"N 78°28'56.20"E 13 17°41'56.90"N 78°28'49.70"E 26 17°42'2.79"N 78°29'0.25"E Site Location Survey. No. 287, 288 & 289 in Kallakal village, Manoharabad Mandal, Medak District in Telangana state Total land area 78,610.255 sq. m Total area of green belt developed 2,594.22 sq. m (33.0%) Nearest High way The plant site approached by small road which connect NH-7 and Industry Nearest Rly Stn Dabilpur Rail Way Station is 2.8 Km from the site Nearest Air Port Rajiv Gandhi International Airport, Shamshabad, Hyderabad is 70 km from the site Nearest fire station Narsapur 21 km (North –West) Nearest village Kallakal Village North 1km Nearest surface water bodies Pond near Gomaram 9.0 km (West-North West) Water body near Meenjipeta 5.5 km(North East) Water body near Tunki Makta 8.0 km (NE) Medchal Lake 8.63 km (South) Nearest Reserve Forest Ellampet Reserve Forest 2.0 km South –South West Any ecologically sensitive areas None Fresh Water Requirement Industrial: 16 KLD; Domestic: 3.6 KLD (Existing) Industrial: 57KLD; Domestic: 16 KLD (Proposed) Source of Water Telangana: Gram Panchayat and tanker supply Man Power 500 Members to be employed directly and around 100 people may be employed indirectly Power Demand 15500 KVA and is supplied by Telangana Electricity supply board DG Set Existing one DG set of 380 kVA Project Cost The cost of the project is Rs 150 crores (15000 lakhs) along with all the accessories 3.0 Requirement of the Proposed Project 3.1 Raw Materials c The existing unit is using the MS Scrap; Sponge Iron and Alloying metals for the MS Billets. It is proposed to increase the production capacity of MS Ingots/Billets from 27,000 TPA to 213,300 TPA, thus the raw material requirement will also increase which is mentioned below. Raw Materials Requirement for Existing Unit S.N Raw Source Transportation Quantity o Material TPD TPA For Existing (90 TPD) 1 Sponge Iron Local/adjacent States By Road 63.54 19,062 2 Iron Scrape Local/Imported By Road 9.9 2,970 3 Pig Iron Local/adjacent States By Road 18.63 5,589 4 Ferro Alloys Local/adjacent States By Road 0.81 243 Strip mill Conveyors and In plant generation and 1 Billets By Road 165TPD purchased from Market (Covered trucks) High grade Imported/Purchased from By Road 2 9 TPD coal thermal Traders (Covered trucks) Tube Mill By Road 1 MS Skelp In plant generation 166 TPD (Covered trucks) Material Balance for Existing Billets 90 27,000 Slag 2 600 Cutting& Scaling 1.5 450 Raw Materials Requirement for Expansion of the Unit Source of Raw Method of Transport S.No. Raw Material Consumption Materials Induction Furnaces with concast From Sponge iron 1 Sponge Iron 551 TPD By Road (covered trucks) plants 2 Scrap 164 TPD Local By Road (covered trucks) 3 Ferro Alloys 6 TPD Local By Road (covered trucks) Strip mill 1 Billets 587 TPD In plant generation Conveyors High grade coal Imported/Purchased 2 32 TPD By Road (Covered trucks) thermal from Traders Tube Mill d 1 MS Skelp 699 TPD In plant generation By Road (Covered trucks) Purchased from 2 HR Coil 354 TPD SAIL/TATA/JSW/ By Road (Covered trucks) Other Manufacturers Scaffolding 1 MS Tubes 47 TPD In plant generation By Road (Covered trucks) Accessories/ Purchased from local 2 3 TPD By Road (Covered trucks) Components Manufacturers Continuous Coil Galvanizing 1 MS Skelp 150 TPD In plant generation By Road (Covered trucks) Purchased from 2 HR Coils 150 TPD By Road (Covered trucks) SAIL/TATA/JSW Hindustan Zinc/ Other 3 Zinc By Road (Covered trucks) reputed Manufacturers Hot Dip Galvanizing 1 MS ERW Tubes 300 TPD In plant generation By Road (Covered trucks) Hindustan Zinc/ Other 2 Zinc By Road (Covered trucks) reputed Manufacturers 3.2 Water requirement Fresh Water Industrial: 15KLD; Domestic: 3 KLD (Existing) Requirement Industrial: 75KLD; Domestic: 15KLD (Proposed) Source of Water Gram Panchayat and tanker supply 4.0 Manufacturing Process Billets Sponge iron, scrap and metal alloys are charged to furnace. Small quantity of silico-manganese and flux chemicals will be added to molten metal. The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting process compared to most other means of metal melting. Raw materials for the process are scrap, fluxes and Ferro alloys. Sponge iron can substitute e scrap up to 50%. The 16”x16” size Scrap bundles will be Lifted and Transported by Overhead cranes and fed to Induction Furnace. Scrap/ sponge iron, fluxes, Ferro alloys are melted in an Induction furnace, wherein electric current is passed through it.