Waryam Steel - Feasibility Report For Casting and Projections. PrefeasibilityReport

CPTL-PFR-WSCPL-129/3
PRE-FEASIBILITY REPORT
FOR
EXPANSION OF STEEL MANUFACTURING UNIT BY

REPLACING EXISTING INDUCTION FURNACE
CAPACITY
Steel Billets/Ingots- 29,750TPA to 84,000TPA
By
M/S WARYAM STEEL CASTINGS PVT. LTD.

KANGANWAL ROAD, V.P.O. JUGIANA,
LUDHIANA WEST, DISTRICT- LUDHIANA, PUNJAB.
CHANDIGARH POLLUTION TesTING LABORATORY

EIA-DIVISION
(QCI/ NABET Certificate No: NABET/EIA/1922/SA 0135)
Address: E- 126, Phase- VII, Industrial Area, Mohali, Punjab- 160055.
Contacts: 0172-4669295, 5090312
E-mail: eia@cptl.co.in / cptleia@gmail.com
Website: www.cptl.co.in
1
M/s WARYAM STEEL CASTINGS PVT. LTD. CPTL-EIA
AUGUST, 2021
INDEX
1.0 EXECUTIVE SUMMARY 4-8
2.0 INTRODUCTION OF PROJECT & PROPONENT 9-23
Introduction 9
Partner background 9
Need of the project 9
Employment Generation 11
Description of Environment 12
Environmental Impact and Management Plan 19
3.0 PROJECT DESCRIPTION 26-36

Category of project 26
Location of Project 27
Alternate site selection 34
Size & magnitude of operation 34
Manufacturing Process details 34
Raw material & product details 37
Resources optimization 37
Availability of water its source, Energy/power requirementand source 38
Quantity of waste generation 39
4.0 SITE ANALYSIS 41-42
5.0 PLANNING BRIEF 43
6.0 PROPOSED INFRASTRUCTURE 44
7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN 45
8.0 PROJECT SCHEDULE & COST ESTIMATES 45
9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 46
10.0 CER ACTIVITIES 46
2
LIST OF FIGURES:
1.0 Location of Project site. 6
2.1 Ambient Air Monitoring Locations 14
2.2 Groundwater sampling Locations 15
2.3 Surface Water sampling Locations 16
2.4 Soil sampling Locations 17
2.5 Noise monitoring location 18
3.1 Location on google imagery 28
3.2 Location Map General (500m Radius) 29
3.3 Pillar Coordinates 30
3.4 Location on toposheet 10km 31
3.5 Location of project site on master plan of Ludhiana. 32
3.6 (a) Layout plan 33
LIST OF TABLES:
1.1 Détails of the area 7
2.1 Primary data Description 12
3.1 Project Description 26
3.2 Location Co-ordinates 27
3.3 Production & Raw Material Details 37
3.3(a) Quantity of Solid/Hazardous Waste 38
3
PRE-FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
The proposed project of Waryam Steel Castings Pvt. Ltd. is located at Kanganwal Road,
V.P.O.Jugiana, Ludhiana west, District Ludhiana, Punjab. The project falls within MC
boundary of Ludhiana, which is a Critically Polluted area (CPA). There was a ban on setting
up new industries/expanding existing industries in CPAs. The moratorium was lifted on 15 th.
February 2011, and re-imposed on 17th September 2013 As per order of Hon’ble NGT dated
August 19, 2019, this is under study of CPCB and till that time, the ban on expansion/setting
of new industries in CPA/SPA may be kept in abeyance.
Location Co-ordinates: Latitude :
POINT LATITUDE LONGITUDE
A 30°51'15.64"N 75°55'48.36"E
B 30°51'11.81"N 75°55'54.92"E
C 30°51'10.59"N 75°55'53.93"E
D 30°51'14.58"N 75°55'47.41"E
ELEVATION 255m
4
TOTAL PROJECT COST: -
Total project cost: - Existing : Rs 7.30 Crores
Proposed : Rs 4.20 Crores
Total : Rs 11.50 Crores
The location of the project site is given in Figure 1.0 on map of India and other area details
are given in Table 1.1
5
Figure 1.0
Location of the Project Site
Location of Punjab State at Political Map of India Location of District on Punjab Map
Location of Project Site on District Map

Location of Project Site on Google Earth Map
6
TABLE – 1.1
DETAILS OF THE AREA
S. No. Particulars Details
A. Location details
1. Location
a Village/ Town/Plot No. Kanganwal road, V.P.O. Jugiana
b Tehsil Ludhiana west
c District Ludhiana
d State Punjab
e Latitude 30°51'15.64"N
30°51'11.81"N
30°51'10.59"N
30°51'14.58"N
f Longitude 75°55'48.36"E
75°55'54.92"E
75°55'53.93"E
75°55'47.41"E
2. Topo sheet No. H43J13, H43K1
3. Project Area Existing Land = 9112.36m2
C. Production Capacity Existing:

Steel Billets-29,750TPA
After Expansion:
Steel Billets-84,000TPA
D. Environmental settings
1. Nearest Village Jugiana 943m, SE
2. Nearest City Ludhiana, approx. 3 km in W
direction from the project site
3. National Highway/State Highway/ NH-44New Delhi-Ludhiana is
Express Highway approx700m in north direction
from the project site.
4. Nearest Railway Station Ludhiana, approx..3 km in west
direction from the project site
7
5. Nearest Airport Ludhiana – 3 km W
Chandigarh - 75km E
6. National Parks/ Wild Life Sanctuaries/ Nil
Biosphere Reserves within 10 km radius
7. Reserved / Protected Forest within 10 km No Reserved Forests exists within
radius (Boundary to boundary distance) 10 km radius.
8. Nearest water bodies Sidhwan Branch (Sirhind canal)
about 7.8 km S
9. Source of Water Ground water Existing tube-well
10. Seismic Zone Seismic Zone – IV
D. COST DETAILS
1. Capital Cost of the project Existing -Rs. 7.300 Cr
Proposed -Rs. 4.20 Cr
Total -Rs. 11.50 Cr
2. Total cost for Environmental Management Rs . 100 lacs
Plan (EMP)
8
2.0 INTRODUCTION OF THE PROJECT
M/s Waryam Steel Castings Pvt. Ltd. is already manufacturingSteel Billetsat Kanganwal road, V.P.O.
Jugiana, Ludhiana west, District Ludhiana, Punjab.It is proposed to enhance the capacity of unit by
replacing existing 1 no. furnace of capacity of 8TPH with one no. Induction furnace of 15TPH
capacity. The total project cost of the unit after expansion will be Rs 11.50 Crores.The unit has
9112.36m2 land and no additional land is required for expansion. The capacity of the unit after
expansion will be 84,000 TPA steel Billets/Ingots.
As per G.O.I Notification dated 14/09/2006 any change in product/expansion required Environmental
Clearance. Accordingly, it is mandatory to submit Form No- I along with Pre-Feasibility Report and
other relevant documents for getting Environmental Clearance. Further, the project site falls in the
“critically polluted areas” Ludhiana as notified by the Central Pollution Control Board, categorizing
the project as Category ‘A’ and the environmental clearance accorded by the Central Govt. in the
MoEF&CC New Delhi. This Prefeasibility report has, therefore, been prepared to assess the likely
impact of the proposed expansion on various factors which may be affected with the implementation
of the programme and to suggest remedial / precautionary measures, if any.
I. Partner’s Background:
M/s Waryam Steel Castings Pvt. Ltd. is a private firm managed by following directors: -
1. Sh. Maharaj Krishan Gupta
2. Sh. Ashish Gupta
3. Sh. Rajat Gupta
All directorshave vast experience in various industries and trades including Steel industry.
II. Need for the project and its importance to the country and or region.
The economy of India is the seventh-largest economy in the world measured by nominal GDP
and the third-largest by purchasing power parity (PPP). The country is classified as a newly
industrialized country, one of the G-20 major economies, a member of BRICS and a
developing economy with an average growth rate of approximately 7% over the last two
decades. This growth rate has a great impact on domestic consumption of steel as well as
export potential to other countries. As a result of this, the demand for iron & steel remains
9
extremely good, this would continue for next 10 years if not less, since the per capita
consumption of steel in India is still very low compared to other developed countries. For
rapid development of economy and infrastructure of the country it is necessary to increase the
production of steel within the country.
National Steel Policy – 2005 has the long-term goal of having a modern and efficient steel
industry of world standards in India. The focus is to achieve global competitiveness not only
in terms of cost, quality and product-mix but also in terms of global benchmarks of efficiency
and productivity. The Policy aims to achieve over 100 million Metric Tonnes of Steel per year
by 2020-21 from the 2004-05 level of 38 mt. This implies an annual growth of around 7.3%
per year since 2004-05.
The above strategic goal is justified on the ground that steel consumption in the world, around
1000 Million Metric tonnes in 2004, is expected to grow at 3.0 percent per annum to reach
1,395 Million Metric Tonnes in 2020, compared to 2 percent per annum in the past fifteen
years. China will continue to have a dominant share of the world steel demand. At home, the
Indian growth rate of steel production over the past fifteen years was 7.0 percent per annum.
The projected growth rate of 7.3 percent per annum in India compares well with the projected
national income growth rate of 7-8 percent per annum, given an income elasticity of steel
consumption of around 1.
10
III. Employment Generation (Direct and Indirect) due to the project.
The proposed project shall generate direct employment for 60 persons as per the details
below:
S.No. Description Nos.

i) Quality In charge 2
ii) Marketing In charge 2
iii) Shift Engineers 3
iv) Supervisors 4
v) Foreman 4
vi) Workers 37
vii) Clerks 6
viii) Accountants 2
Total 60
The required manpower for the proposed expansion can be classified into categories such as
managerial, supervisory, highly skilled, skilled, semi-skilled and unskilled. The direct
employment figure presented above is for the regular plant operations at full capacity.M/S
WARYAM STEEL CASTINGS PVT. LTD. has informed that their present direct
employment is 50 persons. With the addition, total employment after Expansion will
be60persons.
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IV DESCRIPTION OF THE ENVIRONMENT
1. INTRODUCTION:
The main objectives of describing the environment, which may be potentially affected, are (i)
to assess present environmental quality and the environmental impacts and (ii) to identify
environmentally significant factors that could preclude project development.
This chapter contains information on existing environmental scenario for the following
parameters.
1. Land Environment
2. Meteorology
3. Air Environment
4. Noise Environment
5. Water Environment
6. Soil Environment
7. Biological Environment
8. Socio-economic Environment
2. ENVIRONMENTAL MONITORING SCHDULE:

Collection of Baseline data for the proposed plant will be started as per Standard TOR of MoEF&CC
Guidelines. Primary data will be collected by monitoring & surveying of various environmental
components/ parameters during the study period, details of which are given in Table - 2.1.
TABLE-2.1
PRIMARY DATA DESCRIPTION
S. PARAMETERS DESCRIPTION
NO.
1 Meteorology Meteorological parameters on hourly basis at project
site. Parameters: Temperature, Relative humidity, Wind
Speed & Wind Direction.
2 Air Ambient air quality monitoring (24 hourly), twice a
12
week. Parameters are PM10, PM2.5, SO2, NO2& CO.
No. of Locations: 8 locations in core and buffer zone.
3 Noise Noise level monitoring (Day & Night time), once in a
season.
No. of Locations: 5 locations
4 Water Ground water sampling, once in a season.
Tested for physical and chemical parameters.
5 Soil Soil sampling, once in a season.
6 Biological Biodiversity survey, once in a season.
Factors Location: Core and buffer zone.
7 Socio-economic Socio-economic survey, once in a season.
Environment Location: Core and buffer zone.
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Fig-2.1 Ambient Air Monitoring Locations
14
Fig-2.2 Groundwater Sampling Locations
15
Fig-2.3 Surface water Sampling Locations
16
Fig-2.4 Soil Sampling Locations
17
Fig-2.5 Noise Monitoring Locations
18
3. ENVIRONMENTAL IMPACT AND MANAGEMENT PLAN
Located in critically polluted area (CPA) of Ludhiana, the industry is committed to follow
environmentally sound practices for the abatement and control of pollution during the entire
operation of plant. Ludhiana city is one of the highly industrialized town in north India having
all categories of industries located within the city limits, prominent being electroplating dying
& secondary metallurgical having high pollution potential. Govt. of Punjab through PPCB has
identified 10 industrial clusters within the jurisdiction of (CPA)of Ludhiana city. The main
emission are particulate matter, Sulphur dioxide, oxides of nitrogen, VOC, acid mist, process
/fugitive emissions. The emission standard from each industrial unit falling with MC limits
varies with capacity of boiler/furnace and type of fuel. Besides being surrounded by
agriculture fields, the burning of wheat & rice straw by farmers is affecting the ambient air
quality. Further, the operations of D.G. sets to cope with the erratic power supply are
significantly affecting the air quality due to the release of uncontrolled emissions. The
cumulative impact of all these resources has resulted in the deterioration of ambient air
quality. The cumulative environmental air pollution index (CEPI) as calculated by CPCB in
2018 stands at 73.48 for Ludhiana.
In compliance of the Hon’ble NGT order dated 19-08-2019 in O.A. no 1038 2018 Reg.,
MoEF& CC has evolved mechanism for new/expanding activities by Red & Orange category
industries in CPA/SPA.
The mechanism has to be evolved by concerned SPCB/PCB.
Following, the directive, Govt. of Punjab through the Directorate of Environment& climate
change, Department of Science, Technology of Environment has in April 2019 formulated on
‘Action Plan for Clean Air, Ludhiana’ (copy enclosed)
On part of industry, all the environmental safeguards listed in the ‘Action plan’ and those
prescribed under the Terms of Reference and those likely to be formulated in future shall be
implemented in letter & spirit.
The following is being/shall be practiced:
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 Plantation is min. 40% of plot area with density of trees @ 2500 per/hectare and
plantation as per CPCB/local forestry norms
 Employing cyclone separators before bag filter to bring down the particulate emissions
to <30 mg/nm3
 Side suction hood on furnace
 Use of CNG as and when made available and practicable.
 Carrying on regular good housekeeping
 Vacuum cleaning of moulding and casting shops
 Proper design of handling and ducting to capture fumes arising from hot metal and
tapping
 Roofline collection of fugitives
 Training for effective operation of air pollution control device
 All the time compliance with discharge standards
 In house/third party monitoring of stack emission /air quality and noise
 Limiting the operation of furnace in day time only
IMPACT & MITIGATION PLAN:

PARTICULARS DETAILS
Impact on Air
Construction/ Air emissions both gaseous and fugitive from Existing/proposed
Operational Furnaces are being/will be treated by Bag Filters followed by side
Phase suction hoods. The mitigation measure adopted as under:
 The main raw material and product is being/will be
brought in and dispatched by road in covered enclosures.
 All the vehicle owners will have valid PUC Certificate
 All vehicles are being/will be loaded up-to prescribed limit
during transportation.
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 Dust suppression on haul roads is being/will do at regular
intervals.
 Adequate Air Pollution Control Equipment’s like bag filter
will be provided for proposed furnace.
 APCD dust is being/will also be sent to TSDF site/
Madhav Alloys for final Disposal.
Air Quality Management:
Emissions  A stack of adequate height equipped with Bag filter
Management
already been installed with the Induction furnaces to
control the particulate &their proper dispersion.
 All the roads are asphalted to control the fugitive dust
emissions
 Proper servicing & maintenance of vehicles will be carried
out.
 Green Belt around the periphery and within premises will
be provided as per norms of CPCB/MOEF & CC i.e. 40%.
Monitoring Ambient air quality and stack emission is being/will be regularly

Management
monitored to ensure that ambient air quality standards and
suggested limits on stack emission loads would be met honestly
at all the time.
Impact on water
Construction/ Water requirement of the plant will be meeting from tube well.
Operational
Roof top (office block) rain water will be recharged to
phase
compensate ground water.
Water Management
21
 Fresh water requirement of the project for industrial
purpose will be met by tube well.
 Domestic waste water generated from the plant will be
treated in Septic Tank and treated water will be used in
green belt development.
 The cooling water is being/will be re-circulated and
cooling blow down is being/will be dispose of through
STP and reuse for cooling purposes after expansion.
Impact on Noise
Construction/ The expected noise levels of some of the proposed equipment like
Operational Pumps (82-95 dB (A), Induction furnace (95-105 dB (A), DG sets
Phase (100-120 dB (A).
The above noise levels worked out are without mitigation
measures. With the mitigation measures the noise levels will be
further restricted within very short distance from the source point.
The operators/personnel working near the noise sources in the
Plant will be provided with earmuffs and earplugs
Green belt 33% will be developed around the plant premises
which will act as noise abatement measures.
Noise Management
 There will be no danger of noise pollution from plant. The

green belt (plantation of dense trees across the boundary)
helps in reducing noise levels in steel plant as a result of
attenuation of noise generated due to plant operations and
transportation.
 Earmuffs will be used while running the equipment’s of the
22
plant.
 D.G sets will be provided with acoustic to control the noise
level within the prescribed limit.
 A high standard of maintenance will be practiced for plant
machinery and equipment’s, which helps to avert potential
noise problems.
 Personal Protective Equipment like earplugs and earmuffs
will be provided to the workers exposed to high noise level.
 Regular monitoring of noise level will be carried out.
Solid Waste Management
Management  APCD dustis being/will be sent to TSDF site and slag from
process is sent to cement plant for final disposal.
Green belt Management
Management  Green belt development in and around the plant site helps to
attenuate the pollution level.
 Out of the total plant area approx. 20% land is already
developed as green belt and it will be increased up to 40%.
 Green belt has been developed as per Central Pollution
Control Board (CPCB) guidelines.
 Native species have been planted in consultation with the
local DFO.
23
4. Additional Management Approach as per the Ministry’s OM vide F. No. 22-
23/2018- IAIII(Pt) dated 31.10.2019
In order to ameliorate the adverse environmental impacts of project for scientific
development a comprehensive Environmental Management Plan (EMP) shall be prepared
based on the existing environmental conditions, impacts appraisal and environmental
prediction. The EMP will take care of formulation, implementation and the monitoring of
environmental protection measures during the construction and operation of project. The
project is located in CEPI area, the terms for EIA study shall be as per the Ministry’s OM
vide F. No. 22-23/ 2018-IAIII(Pt) dated 31.10.2019. following are the additional measures
taken as per the above-mentioned OM: -
Air pollution control measures
i. Particulate matter (PM) standard at stack emission will be considered as 30 mg/ Nm3 in
place of 150 mg/Nm3.
ii. Continuous emissions monitoring system (CEMS) will be installed with recording and
proper calibration facilities. The online monitoring results shall be linked to SPCB &
CPCB portals.
iii. For fugitive emissions during furnace charging side suction hood will be provided,
emissions like smoke, gas and heat around the furnace will be taken care of by proper
exhaust ventilation, duct is provided over the furnace as an exit for the gases through
stack, opening on rooftop is provided to remove indoor pollution. Paving the usage area
within the premises.
iv. Transportation of materials by rail/conveyor belt, wherever feasible will be followed.
v. Induction furnace will run on electricity, fuel for reheating furnace will be furnace oil
& coal.
vi. Best available Technology like Induction furnace is proposed in place of cupola
furnace, in case of APCD, Pulse jet bag filter with spark arrestor is proposed which will
have side suction hood in place of canopy hood.
24
vii. Green belt cover of 40% of the total land has been proposed.
viii. The industrial premise is having 20’ wide road, proper passage and moving area for
inside traffic movement.
Water pollution control measures
i. Treated domestic waste-water will be used for plantation within the premises.
ii. This industry doesn’t use water in manufacturing process. Water is only required for
domestic purpose and cooling tower make-up.
iii. The management of the M/s Waryam Steel Castings Pvt. Ltd. desire to harvest rain
water falling on various rooftops of the building during monsoon & non-monsoon
period to reuse that water for green belt within the industry and also will adopt one
pond.
iv. No waste-water will be thrown out-side the premises, it will follow ZLD system.
v. Domestic waste-water generation is more than 2.4 KLD. The waste water will be
treated in septic tank and will be reused for plantation.
Land pollution control measures
i. Green belt cover of 40% of the total land has been proposed.
ii. Slag is being/will be sent to cement manufacturing plant for final disposal.
iii. APCD dust will be sent to M/s. Madhav Alloys Ltd./TSDF site for recovery of Zn
metal.
25
3.0 PROJECT DESCRIPTION:
I. Category & type of project including interlinked and interdependent projects, if any.
It is originally Category ‘B’ project. As situated within 5km radius of critically polluted area
boundary of Ludhiana, it will be appraised as Category A, project under schedule 3(a) in EIA
Notification, 2006. Details of project is given in Table-3.1
TABLE-3.1
Project Data Description
S.
No. PARTICULARS EXISTING PROPOSED TOTAL
A EXISTING & PROPOSED CAPACITY OF FURNACES & ROLLING MILLS
1 Induction Furnace 1X8TPH 1X15TPH
B PRODUCTS
1 Steel Ingot/Billets 29,750 54,250 84,000
(TPA)
C RAW MATERIAL
MS Scrap, Ferro-alloys 32, 550 58,400 91,000
1
(TPA)
D GENERALS
Project Cost (Crores) Rs. 7.30 Rs.4.20 Rs 11.50
1
Land 9112.36 m2 NIL 9112.36 m2
2
Power (KW) 3853 4000 7853

3
DG Set 125 kVA 320 kVA 320 kVA
4
125 kVA
Manpower (No’s) 50 10 60
5
Working days 24 hrs 350 working days in year
6
26
II. Location (map showing general location- Figure-3.1, Layout plan - Figure-3.2, and 500 mt
radius Google plan Figure-3.3).
LOCATION:
The proposed project site is located at Kanganwal road, V.P.O Jugiana, Ludhiana west, Distt.
Ludhiana (Punjab). The coordinate of project site is given in Table 3.2. The general location plan of
project is given Figure-3.1& on goggle 3.2. The layout plan of the project showing different activity
is given in Figure 3.3.
Table-3.2
Location Co-ordinates
LATITUDE 30°51'15.64"N
30°51'11.81"N
30°51'10.59"N
30°51'14.58"N
LONGITUDE 75°55'48.36"E
75°55'54.92"E
75°55'53.93"E
75°55'47.41"E
27
Figure-3.1
Location on Google Imagery
28
Figure-3.2
Location map General (500m radius)
29
Figure-3.3
Pillar Co-ordinates Map
30
Figure-3.4
Location on Topo-sheet (10km Radius)
31
Figure-3.5
Location of Project Site on Master Plan of Ludhiana
32
Figure-3.6
Layout Plan
33
III. Alternate sites considered and the basis of selecting the proposed site, particularlythe
environmental considerations gone into should be highlighted.
Addition will be done within existing premises. So, consideration of alternate site is not
applicable.
IV. Size or magnitude of operation.
Existing plant is having Induction furnace of 8TPHcapacity. Now,it is proposed to enhance

the capacity of unit by replacing existing induction furnace of 8TPH capacity with 1 no. of
Induction furnace of 15TPH capacity. After expansion the production details will be as under:
Product Name Existing (TPA) Proposed (TPA) Total (TPA)

Steel Ingots/Billets 29,750 54,250 84,000
V. Manufacturing Process details (a schematic diagram flow chart showing the project
layout, components of the project etc. should be given)
Firstly, Raw Material i.e. M.S. Scrap/Heavy Melting Scrap is tested in laboratory and if
reports are satisfactory then it is issued for the further processing. Testing Raw Material is put
in to the Furnace where 1200-18000C approximately. Temperature is provided to make the
raw material melting. Hot raw material is poured into Concast to make steel billet. Hot Steel
Billet is taken to seventeen stands (according to size) where it is passed through various sized
rolls depending upon size to be produced. After the product is passed through the finishing
stand further go in to the coiler to make the coil of steel Round. Steel Round is taken and
checked by the quality controller with the help of venire. This inspection is carried out by the
quality controller after every hour. Different Bundles are prepared of different sized products
and are well placed. Material balance chart & Layout of manufacturing process is given
Figure 3.5& 3.5a
34
FIGURE-3.5
MATERIAL BALANCE
RAW MATERIAL
RECOVERY OF
SCRAP+FERRO
IRON
ALLOYS
(260TPD)
BURNING LOSS
(9.55TPD)
SLAG GIVEN TO
MELTING &
SLAG CEMENT
REFINING
(10TPD) MANUFACTURING
PROCESS
PLANT FOR FINAL
(240TPD)
USE
SEND TO TSDF
APCD DUST SITE / MADHAV
(0.45TPD) ALLOYS FOR
FINAL DISPOSAL
BILLETS
35
FIGURE-3.5 (a)
FLOW CHART OF MANUFACTURING PROCESS
POWER RAW MATERIAL

7853KW
MELTING & REFINING SIDE

COOLING TOWER FUGITIVE
PROCESS SUCTION
(ARC/INDUCTION FURNACE) EMISSIONS
HOOD
MAKE UP APCD
WATER SLAG CONCAST (BAGFILTERS)
MACHINE
APCD CLEAN
BILLET
DUST AIR
METAL
RECOVERY PLANT
SENT TO
TSDF SITE
ROLLING
WASTE SENT
TO CEMENT
PLANT
FINISHING
FINAL PRODUCT
36
VI. Raw material required along with estimated quantity, likelysource, marketing area
of final products, Mode of transport of raw Material and Finished Product.
The details of product quantity and source of raw material required are given in the Table 3.3.
TABLE-3.3
Production and Raw material Details
PRODUCTS EXISTING ADDITION TOTAL
1 Steel Ingot/Billets 29,750 49,000 78,750
(TPA)
RAW MATERIAL
MS Scrap&Ferro-
1 32, 550 58,400 91,000
alloys (TPA)
Source & Transport Local & International Markets & transport

2
through covered Trucks.
VII. Resourceoptimization/recycling and reuse envisaged in the project, if any, should

be briefly outlined.
Water:
As this project is based on Zero Discharge. Domestic waste water @ 2.4KLD will be
generated which will be treated in septic tank and treated wastewater will be reused for
plantation/cooling purposes.
Solid/ Hazardous waste:

Used DG Set oil will be 0.1KL/ annum after expansion and it will be used as lubricant for
machines.The existing quantity of slag is2TPD andafter expansion quantity of slag will be
10TPD. Slag is being/will be sent to cement manufacturing plant for final disposal. The
37
existing quantity of hazardous waste (APCD Dust) is 52.5TPA and after expansion it will be
157.5TPA. The dust generated from APCD is being/will be stored in impervious pit and sent
to TSDF site/ Madhav alloys for final disposal. The details of waste generation are given in
table 3.3a.
Table 3.3a
Quantity of Solid/Hazardous waste
S. Type of Source of Waste Quantity Category Disposal
No. waste Existing After of waste
expansion
Sent to
Non-
1 Slag Induction Furnace 2 TPD 10 TPD cement plant
Hazardous
for reuse
IF Send to TSDF
APCD
2 (Primary/secondary 52.5TPA 157.5TPA Hazardous site/
DUST
Fumes extraction)
VIII. Availability of water its source, Energy/power requirement and source should be
given.
Water requirement met through tube well. The detail of water requirement is given below: -
DESCRIPTION EXISTING PROPOSED TOTAL

REQUIREMENT REQUIREMENT REQUIREMENT
Domestic 2.50 KLD 0.50 KLD 3 KLD
Cooling (makeup 12 KLD 22KLD
10 KLD
water)
Total 12.5 KLD 12.50 KLD 25 KLD
Power requirement of proposed project along with source is given below:-
DESCRIPTION EXISTING REQUIREMENT AFTER EXPANSION

Power Requirement 3853KW 7853KW
Source Punjab State Power Corporation Limited, Punjab
38
IX. Quantity of wastes to be generated (liquid and solid) and scheme for their
Management/ disposal.
Liquid effluents- Proposed project is based on ZERO discharge. There will be no generation
trade effluents from process. The waste water generated from domestic & cooling towerwill
be treated through septic tank and will re-use for cooling purposes.
Solid Waste -
Slag generated from the process is being/will beused in road making/ sent to cement
manufacturing plant for reuse. Used oil from DG sets will be used as lubricants & dust
from APCD is being/will be sent to TSDF site for final disposal.
Flue Gas Management

There are no combustion related polluted gaseous emissions as no fuel will be used in the
process. The air pollution will be the result of the heating and melting process in the induction
furnace. The gaseous emissions coming out of the mouth of the furnace crucible need
treatment before discharging it into the atmosphere.
The gaseous emissions will comprise of vapours/fumes, suspended particles, and some gases.
The vapours are, primarily, of metals (iron) and metal oxides (in very low quantities). Dust
and metal particles also contribute to the suspended particulates. Gaseous pollutants are,
mainly, carbon di-oxide, carbon mono-oxide, and nitrogen oxides, though in very low
amounts. The suspended particulate matter (SPM) concentration will be about 1500-2000
mg/NM3. Most of the particulates (about 75%) are expected to have size in the range of 1-5
microns. The emissions (after dilution) will have temperature of <150°C.
As per the applicable statutory norms, the SPM level in the gas emission, at discharge point,
shall not exceed 50 mg/NM3. Additionally, the stack height requirement for discharge of
process emissions is also to be complied with. Also, ambient air quality within the premises
should not have particulate matter concentration exceeding 100μg/m3 on 24 hour basis, and
39
60μg/m3 averaged on annual basis. The details of up gradation in existing APCS are given
below:
DETAILS OF APCD
EXISTING APCD:
S. FURNACE VOLUME OF TOTAL NO. CAPACITY STACK HEIGHT

NO. CAPACITY FLUE GASES OF BAGS OF ID FAN
3
1. IF 30, 000m /hr 260 Nos. 100HP 20mt (GL)
1x8Ton
PROPOSED APCD:
3
1. IF 1,00,000m /hr 864 Nos. 200HP 25mt (GL)
1x10 Ton
40
4.0 SITE ANALYSIS
I. Connectivity:
 NH-44New Delhi to Ludhiana is well connected with the project. (700m North side)
 Ludhiana Railway Station (3 Km west side)
The regional road network comprises of New Delhi-Ludhiana G.T. Road (NH-44) and
forms the major spine. In fact, the entire road network gravitates along this major spine.
The project exists in the Industrial land as per master plan of Ludhiana.
II. Land Form, Land use and Land ownership:

The land in Ludhiana is typically level having an average elevation of 250 m above sea level.
The land use is primarily industrial and residential and there exists several clusters of notified
industrial areas. The project site falls in an industrial ZONE as per master plan of Ludhiana.
III. 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 sanctuary, eco from the HFL industrial area, be given.
The area in which the project is located is an industrial zone as per master plan of
Ludhiana.There is no sanctuary, river present within 10 km radius of the project.
IV. Existing Infrastructure:

The infrastructure amenities available in the area denote the economic wellbeing of theregion.
The project area is connected with local road and NH-44New Delhi-Ludhiana. Educational
facilities likeSenior Secondary School, College, Hospital & Banking facilities are available at
Ludhiana City about 3 km away from the project site. The existing building comprise of,
Induction Furnace, Workshop shed & Competitive administrative block along with office
quarters.
41
V. Soil classification:Soil is generally sandy loam almost all over the District and soil
depth is generally shallow except in areas having good vegetative cover. It is generally dry,
shallow and deficient in organic matters. The study area comprises mostly of alluvial
deposits of Quaternary age. The geological formations in the area comprise of sandstone
largely micaceous and form major features. The top zone of this stage consists of maroon
clays and buff clays alternating one by one.
VI. SocialInfrastructure available.

Social infrastructure constitutes various facilities pertaining to education, health,
recreational, cultural and other public amenities/ facilities available in urban areas at
various levels whose availability and accessibility determines the quality of life of an
urban centre.
42
5.0 PLANNING BRIEF
I. Planning Concept (type of industries, facilities, transportation etc.) Town and Country
Planning/Development authority classification.
The proposed project is being set up at the existing land of Waryam Steel Castings Pvt. Ltd.,
Kanganwal road, V.P.O.-Jugiana, Tehsil- Ludhiana west, Distt. Ludhiana (Punjab). There are
many types of industries like Steel, Textile, Paper and Rubber industries.The regional road
network comprises ofNew Delhi-Ludhiana G.T. Road (NH-44) and forms the major spine. In
fact, the entire road network gravitates along this major spine.
II. Population projection

The industry is in Industrial Focal point of Ludhiana. The industrial area is surrounded by
residential colonies. The labour will be locally employed. So, there will be no enhancement of
population around the area due to proposed project.
III Land use planning (Breakup along with green belt etc.)
As the proposed project is located in IndustrialFocal point, Ludhiana, 40% of total area of the
industry will be developed as Green belt.
IV Assessment of Infrastructure demand (Physical & Social)

The site is approachable from NH-44. (New Delhi- Ludhiana). Further, the site is located in
industrial Zone as per master plan of Ludhiana. Nearest railway station is in Ludhiana. The
site is fully developed. The product and raw material transportation can be easily managed.
V Amenities/Facilities
As the proposed project is come into being in the existing industry, there will be no more
amenities/facilities are required.
43
6.0 PROPOSED INFRASTRUCTURE
I. Industrial Area (Processing Area): -
This is an expansion project and no new land will be acquired for the purpose of expansion.
The proposed project is a brown field project for substantial expansion of the existing Steel
Melt Shop, modernization of existing Mills, setting up a new Induction Furnace based Steel
Line and setting up of a new Bright Bar Shop. Thus, the proposed project is a metallurgical
project for steel melting, refining, casting, rolling and bright bar making.
II. Residential Area (Non-Processing Area): -

Focal Point Industrial Area is surrounded by residential colonies. Therefore, no residential
area is provided in the plant.
III. Green Belt.

The main objective of the green belt is to provide a barrier between the plant and surroundings
areas. Green belt will be developed according to CPCB guidelines.
IV. Social Infrastructure.

There is sufficient number of educational facilities but health facilities are not up to the mark.
The sports and recreational facilities are also not adequate as there is no national or state level
sports complex; however, an indoor / outdoor stadium of lower hierarchy is available within
the town. One cinema and two clubs also exist in town.
V. Connectivity (Traffic and Rail/Metro/Water ways etc)

The regional road network comprises ofNew Delhi-Ludhiana (NH-44) and forms the major
spine. In fact the entire road network gravitates along this major spine.
44
7.0REHABILITATION AND RESETTLEMENT (R&R) PLAN: -
This is an expansion project and the existing plant is in a notified industrial area and there
exist no habitation in the area. Hence this expansion and modernization project does not
involve the displacement of any human settlement.
No public buildings, places, monuments etc. exist within the project area or in its vicinity.
The project will not disturb/ relocate any village hence no resettlement would be required.
Thus, no adverse impact is anticipated.
8.0 PROJECT SCHEDULE & COST ESTIMATES: -
I. Likely date of start of construction and likely date of completion (Time schedule for
the project to be given): -
Within one year after receipt of NOC & Environmental Clearance
II. Estimated project cost along with analysis in terms of economic viability of the
project: -
Total proposed project cost is estimated to be around Rs. 11.5Cr
III. Cost toward Environment Protection: - .Rs. 100 Lacs.
45
9.0ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
I. Financial and social benefits with special emphasis on the benefit to the local people
including tribal population, if any, in the area.
The proposed expansion of this project would have multifaceted benefits. It would create
additional employment options for the local unskilled labourers thereby lead to their
economic up-liftment. This economic development would help in improving the quality of
life for all these workers. To cater to the needs of the additional workforce several ancillary
support infrastructures would crop up mainly in the form of transportation facilities and food
catering services. Thus the overall economic impact of the project is far reaching and would
involve a huge stratum of the society.
This project will lead to overall development of the region in particular and the state in
general. This project will also generate indirect employment to a considerable number of
families, who will render their services to the employees of the project. Thus, in view of the
considerable benefits from the project without major adverse environmental impact, the
proposed up-gradation of project is most advantageous to the region as well as to the nation.
10.0 CER ACTIVITIES

Proposed plant will result in growth of the surrounding areas by increased direct and indirect
employment opportunities in the region including ancillary development and supporting
infrastructure. Special emphasis on Financial and Social benefits will be given to the local
people. Development of social amenities will be in the form of medical facilities, education to
underprivileged and creation of self-help groups.
As per OM F.No.-22-65/2017-IA-III dated on 01st May, 2018, the organization will spend
Rs.1.6 Crores for Corporate Environment Responsibility. Detail will be given in final EIA
report.
No adverse effect on environment is envisaged as proper mitigation measures will be taken
up for the same.
46

Waryam Steel - Feasibility Report For Casting and Projections. PrefeasibilityReport

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CPTL-PFR-WSCPL-129/3

EXPANSION OF STEEL MANUFACTURING UNIT BY

M/S WARYAM STEEL CASTINGS PVT. LTD.

CHANDIGARH POLLUTION TesTING LABORATORY

3.0 PROJECT DESCRIPTION 26-36

Location of Project Site on District Map

S. No. Particulars Details

3. Project Area Existing Land = 9112.36m2

C. Production Capacity Existing:

10. Seismic Zone Seismic Zone – IV

S.No. Description Nos.

2. ENVIRONMENTAL MONITORING SCHDULE:

IMPACT & MITIGATION PLAN:

Monitoring Ambient air quality and stack emission is being/will be regularly

 There will be no danger of noise pollution from plant. The

Power (KW) 3853 4000 7853

IV. Size or magnitude of operation.

Existing plant is having Induction furnace of 8TPHcapacity. Now,it is proposed to enhance

Product Name Existing (TPA) Proposed (TPA) Total (TPA)

POWER RAW MATERIAL

MELTING & REFINING SIDE

Source & Transport Local & International Markets & transport

VII. Resourceoptimization/recycling and reuse envisaged in the project, if any, should

Solid/ Hazardous waste:

DESCRIPTION EXISTING PROPOSED TOTAL

Power requirement of proposed project along with source is given below:-

DESCRIPTION EXISTING REQUIREMENT AFTER EXPANSION

Flue Gas Management

S. FURNACE VOLUME OF TOTAL NO. CAPACITY STACK HEIGHT

 Ludhiana Railway Station (3 Km west side)

II. Land Form, Land use and Land ownership:

IV. Existing Infrastructure:

VI. SocialInfrastructure available.

II. Population projection

IV Assessment of Infrastructure demand (Physical & Social)

II. Residential Area (Non-Processing Area): -

III. Green Belt.

IV. Social Infrastructure.

V. Connectivity (Traffic and Rail/Metro/Water ways etc)

8.0 PROJECT SCHEDULE & COST ESTIMATES: -

III. Cost toward Environment Protection: - .Rs. 100 Lacs.

10.0 CER ACTIVITIES

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