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INDEXNo. Description Page
No 1.0 Executive Summary 12.0 Introduction of the Project 8
i Identification of Project and Project Proponent 8ii Brief Description of the Project 15ii Need for the Project 15iv Demand‐Supply gap 16v Employment Generation (Direct and Indirect) 16
3.0 Project Description 174.0 Location of Proposed Project 17
i Alternative Site 19ii Resource Requirement 19iii Land requirement 20
5.0 Manufacturing Capacity & Process 236.0 Water Environment
i Water Consumption 26ii Wastewater Generation 26iii Method of Treatment 26
7.0 Air Environment 278.0 Solid/Hazardous waste 319.0 Noise Environment 3110.0 Auxiliary System
i Coal Handling System 3211.0 Occupational Health & Safety Management 3312.0 Site Analysis
i Connectivity 35ii Topography 36iii Existing Infrastructure 36iv Soil Classification 37v Climate Condition 37
13.0 Proposed Infrastructure 3814.0 Project Schedule & Cost Estimates 39 Conclusion 40
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INDEXNo. Description Page
No 15.0 Copy of valid CTE/CCA 4216.0 Copy of land documents 49
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List of Annexures
Annexure No. Description
Annexure‐1 Copy of CTE & CCA
Annexure‐2 Land document
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1. EXECUTIVE SUMMARY
Name of the Project : Jay Bharat Metcast Pvt. Limited Location : Survey No. 57/2, Village: Morai, Ta: Pardi, Pin Code: 396191 Dist. ‐ Valsad (Gujarat) Project: Jay Bharat Metcast Pvt. Limited (JBMPL) is located at Village: Morai, near GIDC Vapi, Ta: Pardi, Di: Valsad, Gujarat. The company falls under medium scale category of industries and has obtained Consent To Establish and Operate from Gujarat pollution Control Board. Copy of CTE & Valid CCA is enclosed herewith as Annexure – I. The company proposes to enhance the capacity of existing products under the category “Ferrous & non ferrous metal processing industries” Proposed expansion Project Cost: Rs. 962 lacs. Applicability of EIA notification – 2006 Category as per the amended EIA notification‐2006: the existing and proposed products (i.e. Ferrous & non ferrous metal processing industries”) are covered under the Category‐3(a). Hence, Environmental clearance is required. As per the EIA Notification the proposed expansion project is covered under category B but due to the applicability of General conditions the same is to be considered Category – A project & will be appraised at MoEF for obtaining EC under provision of EIA notification 14 September 2006 as amended. The proposed project site is located within 5 km from the boundary of Union Territory of Daman and Gujarat state. The unit is involved in manufacturing of Mild Steel and Alloy Steel Billets & its Re‐rolling:, having granted capacity of 2400 MT/month. The Unit holds Consolidated Consent vide Order no. AWH‐ 57878 dated 23/10/2013. The unit is now planning to increase its production capacity of existing products from 2400
MT/month to 13300 MT/month.
This pre‐feasibility report includes a brief introduction of the company, need and justification
of the project, manufacturing process description, required and available resources,
proposed Environment Management Systems, existing land‐use and proposed infrastructure,
project schedule and cost estimate, and proposed Terms of reference for conducting the EIA
studies.
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The industry has engaged Eco Chem Sales & Services as their Environment Consultant to
conduct the EIA studies for obtaining EC for the proposed expansion. Eco Chem Sales &
Services (ECSS) is NABET accredited (QCI approved) Environmental Consultant (Sr. no. 30 in
list “A” of MoEF).
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PROJECT BRIEF
No. Description Proposed Project Details
1 Name of project &
Address
Jay Bharat Metcast Pvt. LimitedVillage‐ Morai, Survey No.‐ 57/2 Taluka‐ Pardi District‐ Valsad, Gujarat State (India)
2 Project Category 3 (a) of EIA notification – 2006.
3 Project capital cost Existing: Rs. 4299 lacs
Proposed: Rs. 962 lacs
Total: Rs. 5261 lacs
4 Products Enhancement of production capacity
Product Existing Proposed Total
Mild Steel & Alloy Steels Billets
2400 10900 13300
Re‐ Rolling Mild steel and Alloy Steel – TMT Bars, Round and Bars, Square Bars and structural Steel
13300 0 13300
5 By‐products No By‐Product will be generated
6 Resource Requirement
Land 22450 m2 (No additional land will be required for the
proposed expansion)
Water Source: Bore well (7.5 HP x 2 nos.)Total: 195 KLD of water will be required after proposed expansion.
Electricity Source: DGVCL
Existing Power requirement: 4000 KVA
Proposed power requirement: 10000 KVA
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Total: 14000 KVA
500 KVA DG set for emergency is also proposed alongwith
the expansion.
Fuel Existing:
Imported Coal/steam coal:930 MT/Month
After Proposed expansion :
Imported Coal/steam coal:930 MT/month
HSD:75 LPH
Man power Construction phase – 25 nos.
Operation phase – 146 nos.
7 Source of Pollution
Waste Water
Generation
Existing:
Effluent : 2 KLD
Sewage : 8 KLD
Proposed:
Effluent : 2 KLD (Additional)
Sewage : 16 KLD (Additional)
Total after proposed expansion:
Effluent : 4 KLD
Sewage : 24 KLD
Air Emission PM10 , PM2.5, SOx & NOx
Solid Waste
Generation
Hazardous waste: Used Oil,
Non‐Hazardous Waste:
Slag from furnace, Coal ash
8 Mode of Treatment
Waste water 1) Effluent generated from only back wash of softening plant, will be utilized for sanitation and gardening.
2) Domestic effluent will be treated in septic tank/soak pit system.
Air Air pollution control devices shall be provided to achieve
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GPCB norms.
Solid Waste Solid/hazardous waste will be collected, stored and
disposed as per Hazardous Waste Management Rules.
2. INTRODUCTION OF THE PROJECT
(i) Introduction of the project and project proponent:
Name of the project Proponent: Jay Bharat Metcast Pvt. Limited. Jay Bharat Metcast Pvt. Ltd. is a metallurgical industry manufacturing mild steel & alloy steel products. The unit is located Survey No. 57/2, Village: Morai, Near GIDC Vapi, Ta: Pardi, Dist: Valsad, Gujarat having total plot area of 22450 m2. The total investment after the proposed expansion will be Rs. 5261.34 lacs. The proponent wishes to enhance the existing production capacity. The products i.e. mild steel & alloy steel products after re‐rolling are especially used in reinforcement in RCC Structures. Jay Bharat Roadlines (JBR) is the flagship company of the Group. It started its business as Transport Service Provider – having more than 25 owned trucks and made its brand name in transport business amongst industrialists and public in South Gujarat and Maharashtra.
After achieving success in transport service business, JBR diversified into infrastructure development business by the same name. It started the Construction activity of roads and it holds a Registration Certificate of Government of Gujarat in Class ‘AA’ in Special Category Road I, because the firm holds the merit of completing all Government projects in time. In addition to the above, it also undertook contracts for ‘Military Engineering Services’ (M.E.S.), Mumbai.
Later, JBR went into Mining/Quarrying activity of Kapchi and Reti which is Backward Integration for the firm as it was already undertaking construction projects. They have their own mines in Morai (Valsad), Daman and Chikhli (Navsari).
Having earned tremendous experience in construction and transport business, the promoters then expanded their horizons to add another value chain to their group. The group set up its steel mill project to produce billets. The project was set up in the name of Jay Bharat Metcast Private Limited. (JBMPL) JBMPL commenced commercial operations of producing Steel Billets from July 2013; but due to economic instability & inflation, the billet division of JBMPL did not take off as envisaged by the company.
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Hence, JBMPL decided to set up Rolling Mill project as a long term strategic plan. However, at the same time, company got a very profit able opportunity from Kamdhenu Ispat Ltd. and entered into Retail Licence Agreement on 21/04/2014 for sale of TMT/QST Bars.This agreement is a forward integration for Steel Billet. Company is nowsetting up 1,60,000 TPA Rolling Mill to produce Thermex TMT/QST Bars for reinforcement in RCC Structures.
About Kamdhenu Ispat Limited
Kamdhenu Ispat Limited (KIL) was established in the year 1995 entering into India’s steel sector with a reinforcement steel bars manufacturing business at Bhiwandi in Rajasthan.
KIL is involved in a diverse range of manufacturing products including Reinforcement Steel Bars (TMT/HSD), Structural Steels (Channels, Angles, Beams & flats) Binding Wire, Housing, PVC Pipes, Plywood, Paints and many more.
KIL, the largest manufacturer of international quality Steel Bars in India, is the first company to get the prestigious ISO 9001:2000 certifications. KIL uses the latest Belgium technology to manufacture its string of products in a flattering time of 18 seconds against 52 seconds of other manufacturers. They have decentralized their current production base by undertaking strategic alliances – tie‐ups/acquisitions of unorganized and small sized manufacturing units mushrooming all over the country and getting all of them along. The brand is now positioned the “Best Quality at Best Price.”
Business Model of Kamdhenu Ispat Limited
KIL has been pioneer in the concept of Franchisee Model having attained success in the middle tier steel segment on a regional front. This mode serves a dual purpose – the franchisee units benefit a lot by availing Kamdhenu’s brand premium and strong marketing network, while Kamdhenu Ispat Ltd. benefits from the royalty that it gets from these franchisee for using its brand name.
The model also gives a unique identity to the franchisee units and helps them in leveraging their level of operations and quality to sustain well amidst rising competition in the steel sector. And ultimately it also benefits the customer, who gains the most by getting quality products at the most effective prices.
JBMPL has entered into this similar franchise model with Kamdhenu to use its trademark for the purpose of manufacture and trade of products for a period of 3 years.
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Benefits to JBMPL
• This alliance provides JBMPL with Kamdhenu’s expertise and experience for an efficient business practices.
• Kamdhenu Ispat Ltd. brand leverage to JBMPL is immense.
• It also gives JBMPL access to the Kamdhenu Ispat Ltd. nationwide marketing network.
• JBMPL can avail Kamdhenu Ispat Ltd. quality assurance and technologies’ expertise.
• JBMPL can also get assistance of Kamdhenu Ispat Ltd. centralized promotion support.
Benefits to Kamdhenu Ispat Limited
• More franchisee units result in increasing of market share and improvement of brand equity without investment in manufacturing activity, for Kamdhenu Ispat Ltd.
• The franchisee units also ensure quick delivery of products to the consumers.
• Kamdhenu is also benefited by efficient handling of large volumes, which ultimately add to its’ bargaining power.
• Kamdhenu has a better brand presence due to easy availability of product in all parts of the country.
• Kamdhenu profitability increases as revenues enhance from royalty earned from franchisee units.
• Kamdhenu also enjoys more savings on transportation costs and faster product delivery due to decentralised manufacturing network.
Further, Kamdhenu Ispat Ltd. adopted ‘The Stockyard Model’, which helps in achieving decentralization in its daily activities. By initiating direct marketing policy of setting up stockyards at various strategic locations, Kamdhenu has led to easy availability of goods throughout the country. Kamdhenu’s strategically placed stockyards help its clients in improving their inventory control due to fast delivery to the client in minimum time. Controlled by their centralized marketing mechanism, Kamdhenu’s stockyards have proved beneficial to its long list of corporate clients.
Business Strength
Kamdhenu Ispat Ltd. has highly efficient marketing team with innovative and out of the box ideas. The company has its centralized marketing office at Gurgaon backed with committed chain of over 2500 dealers and distributors spread across the country. The company has
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been consistently creating better brand awareness of its products. Kamdhenu’s focused marketing strategies have catapulted it to enjoy a price premium for ‘Kamdhenu’ brand products over non‐branded products in the market.
Salient Features of the Contract of JBMPL and Kamdhenu
Period:
• JBMPL will use Trade Mark of Kamdhenu Ispat Ltd. for manufacture and trade of TMT Bars for a period of three years.
Quality Control and Logo of Product:
• JBMPL shall manufacture and trade in the product under the license Trade Mark KAMDHENU only. And JBMPL shall get a BIS Certificate for production and should ensure complete quality consistency and control as per BIS specifications.
Manufacturing:
• During the subsistence of Agreement, JBMPL will manufacture all TMT Bars for Kamdhenu Ispat Ltd. only.
Selling Arrangement:
• JBMPL shall sell the products under the Trade Mark KAMDHENU only through the authorised network of dealers and distributors as communicated by Kamdhenu Ispat Ltd. from time to time.
Business Strength Management The Directors are well versed and experienced in Construction business and have very good reputation in the market. They are experienced in managing Infrastructure Projects, besides other construction related business & real estate. Additionally the company has appointed technical and managerial personnel to carry out day‐to‐day affairs of the company very efficiently. Prospective Customers The Company has entered into contract with Kamdhenu Ispat Ltd., according to which the entire production of TMT Bars being manufactured by JBMPL will be sold through the authorized network of dealers and distributors as communicated by Kamdhenu Ispat Ltd. under the trademark of KAMDHENU. This agreement has reduced the sales risk and marketing strategies. Company will be now more focused on quality production of TMT Bars and timely supply.
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The unit is operated by technocrats having experience in manufacturing and marketing of various Mild steel & alloy steel billets and re‐rolling of MS steel, Alloy steel, TMT Bars, Square bars & structural steel worldwide. The company has a well equipped production plant which is being managed by dedicated, qualified & skilled persons. The proposed expansion envisages to expand the capacity of Mild Steel & alloy Steel Billets with total capacity of 13300 MT per month and process capabilities to manufacture all types of Mild steel & alloy steel billets and re‐rolling of MS steel, Alloy steel, TMT Bars, Square bars & structural steel. The proposed expansion project site lies at approx. geographical co‐ordinates 20025’39.14” N Latitude & 72054’21.36” E Longitude. The unit is located at Survey. No. 57/2, Village: Morai, Near GIDC Vapi, Ta: Pardi, Di: Valsad in Gujarat state. The project site is located near National Highway No. 8 connecting Mumbai and Ahmedabad and is surrounded by Union territories of Daman on the western side and GIDC Vapi on the southern side. The western Railway Main Line passes through the area (Double & Electrified). Vapi is the biggest railway station in the study area; where, almost all the important mail & express trains stop. Entire study area is well connected with other major cities of the state and the country. Besides, the rail connectivity, the site is also well connected by road transport. There is a good network of roads in the area and contributes for the development and economic growth of the area. The National Highway No. 8 (Surat – Mumbai) is now a six laned, double tracked, more elevated and Jam free highway, developed by L&T Company. This highway has given a further boost to the economic growth of this area. About Project Site Village Morai: There are about 15 various paper mills, textiles & rolling mills industries in the nearby vicinity of the project site. About Vapi town: Vapi township has emerged as an Industrial hub on the Gujarat – Maharashtra border. Administratively, it is a part of Valsad district. After the establishment of GIDC estate, Vapi has gained a special status on the industrial map of the country mainly for chemical industrial units. Over the years, it has emerged as a major cosmopolitan industrial township equipped with hospitals. school, colleges, community centers, temples, churches, mosques, cinema house, fire stations, blood banks, water filtration plants, police stations, post offices, banks, telephone exchanges hotels, guesthouses etc. The town has got a major face‐lift after the completion of national highway and other links roads. Mumbai, the economic capital of the country is 180 km from Vapi; whereas, the state capital “Gandhinagar” is 370 kms. The district Head Quarter – Valsad is 30 km from Vapi town.
VAPI INDUSTRIAL ESTATE: Vapi Industrial estate came into existence during 1967‐1968. The entire estate, which was developed in phases, is now spread over 1140 hectares and houses more than 1400 industries, most of which are small‐scale industrial units although some
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have grown bigger units at later stages. The industrial township is basically a declared “Chemical Estate” where about 705 of the industrial units are either Chemical or Chemical related, such as, Dyes and Dyes intermediates, pigments pesticides, fine chemicals, pharmaceuticals, etc. The remaining 30% comprises of paper mills, packing, plastics, engineering, textiles, paints, food processing, printing, etc. One of the country’s largest common effluent treatment plants has been setup in Vapi industrial estate. Being a major industrial & commercial centre, it caters to other peripheral industrial estates like Daman, Silvassa, Sarigam, Umbergaon & Dadra and Nagar Haveli, etc.
eIntroduction of the project proponent
The Company is managed by the promoters and whole time Directors, Shri Mukesh Thakur, Chairman and Managing Director and Shri Rakesh Thakur, Executive Director.
BACKGROUND OF PROMOTERS
Name Designation Qualification ExperienceMr. Mukesh Thakur Chairman B. Sc. (Chemistry) 26 years Mr. Rakesh Thakur Director B. E. (Civil) 16 Years Mrs. Nisha Thakur Director B. A. 8 Years Mr. Rushabh Shah Director B. Tech. 2 Year Mr. Kamlesh Thakur Director B. Com 11 Years Mr. Nitesh Thakur Director MBA 1 Year Mr. Pritesh Shah Director B. B. A 5 Years
1. Mr. Mukesh Rajendraprasad Thakur (Chair Person)
Mr. Mukesh R.Thakur is Bachelor of Science in Chemistry. He is the Chairman of Jay Bharat Metcast Pvt. Ltd. & is a very diligent businessman. For the past 20 years, he has been managing the group by his dynamic leadership. His dedication and strategic guidance has led the group to its present stature. Due to his excellent management skills and wide experience, he has gained name and fame in social field around Vapi and South Gujarat. He has been an active member of many associations and has headed organization like Valsad District Quarry Owner’s Association, Western Railway Welfare Passenger Association, Uttar Bharitya Sangh, etc.
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His current responsibilities in the company includes overseeing the affairs of the Company subject to superintendence, control and business development.
2. Mr. Rakesh Rajendraprasad Thakur A Civil Engineer by profession, Mr. Rakesh R. Thakur is hardworking and target oriented businessman. As a partner, he has provided his management skills to Jay Bharat Roadlines, Jay International and in stone crushing unit named Vishal Metal. He is also the proprietor of Pritish Construction. Due to his social skills, he has been the Public Relation Director of Rotary Club of Vapi West. He has alliance with many Associations like Industrial Association, Builder Association and Contractor association at Vapi. He is responsible for financial and accounting aspects of the company.
3. Mrs. Nisha R. Thakur A graduate in Arts, Mrs. Nisha R. Thakur is one of the directors in Jaybharat Met cast Pvt. Ltd and also a proprietor of Jay Infrastructure and Karishma Infrastructure. She is actively involved in day to day activities of the Company as well as the Human Resource Department of the company.
4. Mr. Rushabh Vipul Shah Mr. Rushabh, Bachelor in Technology is one of the directors in Jay Bharat Metcast Pvt. Ltd. He handles production and technical aspects in the company. He is the partner in Rushabh Wire Industries and Paper Trading Business.
5. Mr. Kamlesh Avdeshbhai Thakur
Mr. Kamlesh A. Thakur is one of the directors in Jay Bharat Met cast Pvt. Ltd. A dynamic and hard working businessman, he has been a partner in M/s Vishal Metal and proprietor of M/s Aayush Construction. He will be responsible for day to day operations and financial aspects of the company.
6. Mr. Nitesh Thakur Mr. Nitesh Thakur, a young enterpreneur has done his graduation in Bachelor of Commerce from Mithibhai College, Mumbai and MBA from University of Lincoln, U.K. He is looking after the sales and day to day affairs of the company. He is, also, a partner in Jay Industries.
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Thakur family is one of the reputed business families in Vapi, engaged in business for the last 30 years. Mr. Nitesh Thakur is the second generation of Thakur family with business mindset. He is young & dynamic and intends to lead the company to greater heights with his global exposure of education. He aims to provide the company with managerial effectiveness and develop key strategies for achieving sales targets.
7. Mr. Pritesh Mahendra Shah
Mr. Pritesh Shah, BBA in International Business & Finance is one of the directors in Jay Bharat Metcast Pvt. Ltd. He is partner in G.S. Industries, Amar Packaging, Amar Industries, Shreenath Paper Agency, Falcon Infra and Nandini Insurance & Investment Company. He will be looking after administration, production planning and raw material procurement.
(ii) Brief description of the project
Jay Bharat Metcast Pvt. Limited proposes the expansion of their production capacity at Survey. No. 57/2, Village: Morai, Near GIDC Vapi, Ta: Pardi, Di: Valsad in Gujarat state. The proposed expansion project involves the production of “Mild Steel & Alloy Steel Billets” As per the amended EIA notification‐ 2006, the proposed products are covered under Category 3 (a) ‐ A and hence require Prior Environmental Clearance.
For the proposed expansion project, the company intends to procure the latest technology for manufacturing the products.
(iii) Need of Proposed Project
The proposed project provides a potential growth opportunity for the already running business of the company. The company is engaged in the business of manufacturing of “Mild Steel & Alloy Steel Billets”. The Industry is passing through a phase of optimism and considerable growth in the steel sector globally. This is mainly caused by a steady rise in steel demand due to the boom in construction business across the entire Asian region. According to research studies, this global demand for steel will continue to rise in the coming decade with Asian countries and especially China leading the way.
The emerging economies around the world are supposed to contribute a major chunk of more than 70 % of the total global steel demand by the year 2020.
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While this trend is reversing in developed countries, which have reached a stage of saturation. Hence their share in the global steel demand is expected to be around 40%.
India along with China are seen as the major contributing factors in the growth of construction business and consequently resulting in the rise of steel consumption and demand in the world.
(iv)Demand Supply Gap
The products have very high specific demand as they are especially used in reinforcement in RCC structure. Indian steel industry is passing through a period of boom since 2002 because of steady rise in steel prices caused by boom in construction business across the entire Asian region.
India has also made a marked progress in increasing it’s share in world steel production of Improving its ranking among global steel producers. (v) Imports vs. Indigenous production :
Existing products manufactured in the country will be very much economical compared to imports of the same and also the export of the same will earn extra revenue generation for our county.
(vi) Export Possibility :
Existing products have high export potential. Also these products have very good potential in the local market. Additional capacities of product range required over & above the unit’s existing capacities, as the company expects strong growth of exports to the extent of 60‐70%. Local market also shows strong growth potential.
(vii) Domestic / export Markets :
The company’s products are used in reinforcement in RCC structure. These are having very good demand in domestic as well as international markets.
(viii) Employment Generation (Direct and Indirect) due to the project :
There will be very good opportunity of employment generation directly and indirectly due to proposed expansion project. Due to the proposed project there will be requirement of manager, supervisor, operator and semi‐skilled workers. For this, the company will employ about additional 20 people to fulfill its need to handle the plant. Thus after expansion total 146 people will be directly employed.
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3. PROJECT DESCRIPTION
PROPOSED PROJECT & APPLICABILITY OF EIA:
The unit is located at Survey No. 57/2, Village Morai, Ta: Pardi, Dist. Valsad, Gujarat. The
proposed project site is located at a distance of 5 km from the boundary of UT of Daman and
Gujarat state.
It is now planning to increase its production capacity of Mild Steel & Alloy Steel Billets from
2400 MT/M to 13300 MT/M.
Existing production capacity of Mild Steel & Alloy Steel Billets is less than 30,000 MTA which
does not fall under the provision of the EIA notification, but after expansion the total
production capacity will be more than 30,000 MTA, which falls under the item no. 3(a) i.e.
Metallurgical industries (ferrous & non ferrous) and under Category B. But due to the
applicability of general conditions – presence of state boundary of UT of Daman within 5 km
radial periphery of the existing project site, the project is to be considered at the Central
level. Thus, it falls under Category – A and requires EIA study as per TORs awarded by
MoEFCC, Delhi.
4. PROJECT DESCRIPTION
(i) Project Location The unit is located at Survey No. 57/2, Village Morai, Ta: Pardi, Dist. Valsad, Gujarat. The
proposed expansion project site is located within 5 km radius from the boundary of UT of
Daman and Gujarat state .The Google map showing site of the project and the site plan of the
project are as under;
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Site Plan
The project site falls in Taluka Killa Pardi of the Valsad district of Gujarat and is located at
20025’39.14” N Latitude & 72054’21.36” E longitude. Vapi surrounds Pardi taluka on the
Southern side. Nearest railway station from project site is Udwada which is approximately 3.8
km, whereas Vapi railway station is approximately 7 km away from the project site.
The site is connected by road with NH‐8 which is around 0.9 km from the project site. Union
Territory of Daman is about 1 Km away from the project site. The nearest town from project
site is Vapi, which is located about 7 km away. Vapi is the largest industrial estate in Pardi
taluka. Around 2000 small scale & medium scale industries are in Pardi Taluka.
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(ii) Alternative Studies No alternative site is required as proposed expansion project is capacity enhancement of
existing activities at the existing plot.
(iii) Resource Requirement
To carry out the proposed expansion various resources like raw materials, power, fuel, water,
manpower, etc will be utilized.
Raw Material
Estimated requirements of various raw materials for the proposed expansion is given in
following table.
Product Name of RM RM consumption in MT
Per ton of
product
Per month
Existing Total After
Proposed
Expansion
For Mild Steel & Alloy
Steels Billets
M S Scrap 0.958 2300 12742
Sponge iron 0.125 300 1662
Ferro silica 0.002 4.8 26.6
Silico
Manganese 0.012 29.0
160.66
Total 1.0982 2633.8 14591.26
For Re‐ Rolling Mild steel
and Alloy Steel – TMT
Bars, Round and Bars,
Square Bars and
structural Steel
M S Ingots or
M S Billets
1.00 13300 13300
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No Name of Raw Material
Suppliers Mode of transport
1 M S Scrap Local & Overseas By Road & Ship
2 Sponge iron Local & Overseas By Road & Ship
3 Ferro silica Local By Road
4 Silico Manganese Local By Road
Land Requirement
As mentioned above, the proposed expansion should be developed within existing premises
by using existing infrastructure. No additional land will be purchased/procured for proposed
expansion. Plant layout is attached as Annexure‐3.
• Total Plot Area – 22450 m2
Sr. No.
Description Existing Area m2
Proposed Aream2
Total Aream2
1. Production plant 2280 4960 72402. Raw material storage
area 1366 0 1366
3. Utility 372 82 4544. Road 4763 0 47635. Green belt 800 2000 28006. Canteen 50 0 50 7. Administrative
building/R &D 372 0 372
8. Security cabin/weigh bridge
18 0 18
9. Coal storage area 72 0 72 10. Parking 600 0 60011. Loading/unloading
area 2246 00 2246
12. Open space 9511 ‐7042 2469Total 22450 0 22450
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Man Power
Approx 25 nos. of people will get direct employment during the construction phase.
Based on the unit’s organizational pattern, after proposed expansion total 146 nos. of staff
will be required to operate plants.
Electricity
Existing sources: 1) Power requirement: 4000 KVA
2) Fuel: Imported Coal/Steam coal:930 TPM,
Proposed: 1) Power requirement: 14000 KVA
2) Fuel: Imported coal/steam coal: 930 TPM, HSD: 75 liters/Hr
Water Requirement:
No Activity Existing , M3/Day Proposed, M3/Day Total after expansion, M3/Day
Operation Phase1.0 Domestic 20 10 302.0 Industrial 110 57 167
a Cooling Tower for (induction furnace, casting machine & quenching system)
make up
108 55 163
b Softening plant back wash
2 2 4
Total (1+2) 130 67 197
Note: Source of water is own bore well
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(iv) Product detail:
Sr. No. Product Capacity, TPM
Existing Proposed Total after expansion
1 Mild Steel & Alloy Steels Billets
2400 10900 13300
2 Re‐ Rolling Mild steel and Alloy Steel – TMT Bars, Round and Bars,
Square Bars and structural Steel
13300 0 13300
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5. MANUFACTURING PROCESS:
MILD STEEL & ALLOY STEEL BILLETS : In the induction furnace scrap is melted and continuous charging is done until the full capacity of the furnace is reached. Slag off is done and additions of Ferro Alloys is done as required. After that, the melting sample is taken to check the chemical analysis. On the basis of this analysis, further additions and refining is done to achieve the desired composition. On melting and achieving required temperature, the molten metal is poured into the ladle, which is preheated.
To improve the cleanliness of liquid steel Argon/Nitrogen stirring in the ladle has recently been introduction. This aids in the floatation of non‐metallic components.
After purging, the ladle is lifted with the help of suitable E.O.T Crane and put on the ladle turret. From the ladle turret, the metal is transferred to tundish of concast machine. The 6/11 M Concast machine consists of Tundish, Bottom Slide Gates, Oscillating Copper Moulds, withdrawal Pinch Rolls and Rack Type billet Cooling Bed. High pressure water jacket is used to cool down oscillating copper mould. High pressure jet is also used to cool down the guide rolls & withdrawal pinch rolls etc.
The Tundish regulates the flow of metal to the copper mould tube which is water‐cooled. The Tundish also distributes the metal to different strands.
Application of Electro‐Magnetic Stirring in the mould and strand improves the surface and internal quality of the billet respectively. In addition to the quality improvement, more homogeneous internal structure permits the casting of thinner sections.
The billet, which leaves the mould with a well‐formed shell, is cooled by spraying water. The cooling water volume and intensity of spraying can be adjusted to suit the steel grade, billet size and casting speed. The billet reaches the withdrawal‐cum‐straightening unit through the spray apron. The billet is cut to desired length by gas cutting or hydraulic shear and is transported through roller table to the cooling skid. After cooling, the billets are stacked. These billets are raw materials for Rolling Mill Division.
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RE‐ROLLING MILD STEEL AND ALLOY STEEL‐ TMT BARS, ROUND AND BARS, SQUARE BARS AND STRUCTURAL STEEL :
The manufacturing process of all the products is very much similar and conventional; it can be described as below:
Heating of Billets/Ingots (Size 100 X 100 Sq. mm) into Billets/Ingots Heating Chamber at 1100 0C to 1200 0C temperature.
The heated billets / ingots are ejected & cut of the heating chamber in to a roll table by the side of the heating chamber one by one and are pushed on to the main roller table by a turning device.
The discharged heated billets will be fed in to the first stand of roughing mills. The number of passes are given depending on the section to be produced. After this, the rolled bar is fed in to successive stands to repeaters situated in lines.
The front end of the rolled bar is then cut to facilitate entry in to intermediate stand.
The rolling will be done in a continuous mill.
Snap shears are used between each group of stands for taking samples to control the mill looping and final section rolled.
The hot rolled bar (called the ribbed bar) is automatically cut into required length by shearing machine and transferred to a cooling bed.
After cooling of the ribbed bar, it is again cut by a separate shearing machine in to marketable lengths of generally 12 meter.
Finally the TMT Steel is bundled and dispatched.
For making TMT, the hot rod is passed through a tube where water is counter flowing under very high pressure. From cooling platform the TMT bars are taken to shearing machine and cut individually to the required length and bundled for dispatch.
During the manufacturing of products, there is no any metal surface treatment which can generate polluted waste water and there is no any process gas emission during the manufacturing of products.
Water will be used for cooling purpose only and water will be consumed to compensate the evaporation loss in the cooling system.
The paper from the dryer section is now ready and has to be reeled. This is done on the reel
where large rolls are wound. From here the roll goes to the winder where cut sizes are
possible. Suitable drive with couplings, motor and gear boxes are required.
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Manufacturing Flow Chart for Mild steel & Alloy billets
Manufacturing Flow Chart for Re‐rolling
MS Scrap: 12742 MT
Sponge Iron: 1662 MT
Ferro Alloys: 26.6 MT
Silico Manganese: 160.66 MT
INDUCTION FURNACE1700 0C
Flue gas Dust particles: 129 MT
Slag: 1164 MT
Sell to brick manufacture or utilize for road making
Spark Arrester
Bag Filter ID Fan Chimney
Flue gas dust: 67 MT, recycle in furnace
CASTING MACHINE
BILLETS: 13300 MT
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6.0 Water Environment:
(i) Water Consumption
No Activity Existing , M3/Day
Proposed, M3/Day
Total after expansion, M3/Day
Operation Phase1.0 Domestic 20 10 302.0 Industrial 110 57 167a. Cooling Tower for (induction
furnace, casting machine & quenching system) make up
108 55 163
b. Softening plant back wash 2 2 4Total 130 67 197
(ii) Wastewater Generation:
No Activity Existing , M3/Day
Proposed, M3/Day
Total, M3/Day
1.0 Domestic Use 16 8 242.0 Industrial (Process) 2 2 4
a. Softening plant back wash
2 2 4
Total 18 10 28
(iii) Method of Treatment
Sewage:
Sewage will be expected to be generated due to domestic activities of workmen and staff
personnel during construction phase as well as operation phase. Existing sewage quantity is
16 KLD during the operation phase and additional 8 KLD of sewage will be generated during
the operation phase. Sewage generated during construction & operation phase will be
treated in existing septic tank /soak pit facility.
Effluent:
Wastewater originated from back wash will be 4 KLD softening plant & will be collected to be
utilized for sanitation or gardening.
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7.0 AIR ENVIRONMENT
Details of proposed flue gases, stack, nature of emitted pollutants and system provided for air
pollution control are mentioned in the following table,
Sr. No.
Particulars DetailsExisting Proposed After Proposed
Expansion 1.0 Capacity of
Induction furnace 12 MT 12 MT 12 MT x 2 = 24 MT
1.1 Fuel Used Electricity Electricity Electricity1.2 Fuel Consumption 60000 KWH/day 115000
KWH/day 175000 KWH/day
1.3 APC provided Spark arrester, bag house, ID fan
& 33 meters height of
common chimney
Additional spark arrester, bag
house, ID fan & 33 meters height of existing common chimney
Spark arrester, bag house, ID fan & 33 meters height of common chimney
1.4 Pollutants PM: < 100 mg/Nm3
SOx: < 50 ppm NOx: < 50 ppm
2.0 Stack attached to Re‐heating furnace
0 Re‐heating furnace
2.1 Fuel used Coal 0 Coal 2.2 Fuel Consumption 930 TPM 0 930 TPM2.3 APC bag house, ID fan
& 33 meters height of
common chimney
0 bag house, ID fan & 33 meters height of common chimney
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Details of Air pollution Control equipments attached to Induction Furnace for Existing & the
same specification of the Proposed APC
Sr. No. Particulars Details
1.0 Spark Arrester
1.1 Capacity 49500 m3/hr
1.2 Pressure drop 40 MMWG
1.3 Height 2.8 meter
1.4 Width 1.7meter
1.5 MOC MS
2.0 Bag House
2.1 Size of bags 4.1m height x 165 mm dia
2.3 MOC Polyester with PTFE treated
2.3 Weight of bags 550 gms/m2
2.4 Thickness 2mm
2.5 Resistance temperature 130 to 140˚C
2.6 Melting point 300 to 325˚C
2.7 Nos of bags 308 bags
2.8 Height of bag house 8000 mm
2.9 Width of bag house 3550 mm
2.10 Total number of bag house 1 Nos
3.0 Height of common chimney 33 meters
3.1 Dia of chimney 1 Meter
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• DETAILS OF BAG HOUSE ATTACHED TO RE‐HEATING FURNACE (EXISTING)
Sr. No. Particulars Details
1.0 Bag House
1.1 Size of bags 4.1m height x 165 mm dia
1.3 MOC Polyester with PTFE treated
1.3 Weight of bags 550 gms/m2
1.4 Thickness 2mm
1.5 Resistance temperature 130 to 140˚C
1.6 Melting point 300 to 325˚C
1.7 Nos of bags 308 bags
1.8 Height of bag house 8000 mm
1.9 Width of bag house 3550 mm
110 Total number of bag house 1 Nos
2.0 Height of common chimney 33 meters
2.1 Dia of chimney 1 Meter
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8.0 Solid/Hazardous Waste
Detail of solid/hazardous waste to be generated from proposed plant activities are
mentioned in following table,
Sr. No.
Name of Waste
Waste category
Existing Total after Proposed expansion
Solid waste Disposal / Management
Hazardous waste 1 Used Oil 5.1 0.1
KL/Year
0.2
KL/Year
Collection, Storage,
Transportation & Disposal by
selling to registered refiners
Non‐Hazardous waste 1 Coal Ash ‐‐‐ 781
MT/Year
781
MT/Year
Collection, Storage,
Transportation & Disposal by
selling to brick manufacturing &
modular brick construction
2 Slag from
furnace
‐ 2522
MT/Year
13978
MT/Year
Collection, Storage, crushing in
own unit.
Slag Utilization:
The slag is proposed to be collected, crushed in magnet crusher in the unit’s own crusher
plant. Metal particles are separated and used in the induction furnace, balance materials are
utilized for road making. We have provided adequate storage & transport facilities for the
slag generated from the induction furnace.
9.0 Noise Environment
The noise generation inside plant ranges from 75‐85 dB(A) due to heavy machinery
operations. Noise pollution arises from, compressor, generator room, etc. Higher noise level
will be felt only near the active working areas. However at distance away from the source, the
level gets considerably reduced. The plant and equipment have been/will be specified and
designed with a view to minimize noise pollution.
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Use of PPE like ear plugs and ear muffs are/will be made compulsory near the high noise
generating machines. Moreover, the personnel are/will be provided breaks in their working
hours, with the continuous exposure not increasing three (3) hours.
Noise generation is also high during operation of soot blowers, safety blow off valves,
pressure release valves etc. To reduce such noise, pipe lines will be liberally sized for low
velocities. Safety blow off valves, discharge pipes, relief valves, etc. will be equipped with
silencers. Hearing Conservation program will be imparted to the employees working in areas
where noise level exceeds 90dB(A).
10.0 Auxiliary System (i) Coal Handling System:
A standard Coal handling system with screening, coal crushing and conveying system is
already installed for the existing plant. There is one compact coal crusher plant of 5 TPH. This
plant is provided with four roll crusher, screen, conveyor & elevator and rejects of the screen
is recycled with two roll crusher and elevator. The plant is suitable to handle imported coal,
Indian coal and lignite coal
EMP is already in place for proper handling of coal and same shall be followed after the
proposed expansion. Measures shall be as under:
• Water sprinklers are used to control the fugitive dusts.
• Greenbelt is provided in and around the premises area, around the coal stack yard and
along the roads to minimize the generation of fugitive coal dust.
• All necessary equipments/machineries are in good condition for proper operation.
• For transportation, loading & unloading of goods, closed conveyor belt system is
provided.
• To control the fugitive dusts from coal and/ or Lignite handling, adequate moisture
content is provided.
• Enclosure for transport vehicles /storage vessel, spraying of water on road & ground
can be effectively implemented to control the coal dust problem. During the operation
phase, proper EMP shall be in place for handling of Coal and/ or Lignite.
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• Water bound Macdam (WBM) Road Net work shall be done in the whole area for truck
movement to prevent dust emission.
• Water spraying system is provided for coal wetting before unloading from truck to
reduce the dust levels significantly.
• The trucks used for transporting the goods are being covered by the tarpaulin and
overloading in truck is not be allowed, to prevent the dusting and spillage of goods
from the truck.
• Employees are provided with sufficient environmental management & safety
materials. They are given proper training as well as display of the summarized
Environmental Management & Safety Procedures are being made available at site
through signboard.
• Regular Air monitoring and inspection of the environmental management practices is
being carried out and the necessary documents & records shall be maintained.
• A fire hydrant system line is also provided for immediate response to the unlikely
spontaneous combustion in the stored fuel.
11.0 Occupational Health and safety Management:
The company is very much concerned in terms of health, safety and environment protection.
Jay Bharat is commitment towards safety of the environment as well as employees.
No major accident has taken Place in the factory so far in the existing project. From their
previous performance, same dedication is to be continued for the proposed expansion. To
maintain high standards in Health, Safety and Environment, various activities are undertaken
at the site. Similar practice will be followed after the proposed expansion.
The following key safety measures are implemented in the existing plant and the same shall
be a part of proposed expansion project:
1. Safety Training is provided to the employees.
2. Safety Sirens with Alarm System in case of emergency are provided.
3. Emergency Control Room is established.
4. Assembly point is provided.
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5. Sprinkler Systems will be provided as needed
6. Fire Hydrant System is installed.
7. Fire Extinguishers are provided.
8. First Aid Facility and training are provided.
9. Personal protective gears and equipments are provided to employees.
10. Health Check up of employees is regularly carried out.
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12.0 SITE ANALYSIS
(i) CONNECTIVITY
The project location is well connected with road, rail and air route to transport raw materials,
machineries etc. and hence, it exhibits good potential for industrial growth. The salient
features mentioned below, indicate favorable conditions for industrial development at the
project location.
Particulars Details Approx. Geographical Co‐ordinates Approx. Center 20025’39.14” N Latitude &
72054’21.36” E Village Morai (~ 0.3km‐SW)Nearest Town Vapi (~6km – S)River/Streams River Kolak (~0.15 km‐N)Nearest Highway NH‐ 08 (~ 1.13 km_E)Nearest Railway Station Vapi Railway Station (~ 7KM – SE) Nearest Airport Surat Airpot (~77 km –NNE) Tourist places Daman (~ 1 km –WWS) & Silvassa (~30 km‐
SE) Protected areas (National parks/ sanctuaries)
None within 10 km radial periphery
Nearest state boundary State boundary of Gujarat & UT Daman (~ 1. 0 km ‐ WWS)
Defense installations No defense Installation. Coast guard of Daman @ 6.26 kms (W)
Sites of Historical/ Archaeological Importance
Daman fort constructed during Portugueserule, Somnath temple in Dabhel, Parsi’s Zoroastrian Atash Behram in Udvada.
Densely Populated or built – up Area
Vapi town@~6 kms (S)
Major Industries in Area • Welspun Tarry Towels ltd • Alok Industries Ltd. • Devang Paper Mill • RJ Paper Mill • Shree Ajit Paper Mill ltd • Ruby Macons ltd
Note: All the above – mentioned distance are the aerial distances from project site.
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(ii) TOPOGRAPHY
The location is at 20o25’39.14” North Latitude and 72054’21.36” East Longitude having
elevation of 25 meters above sea level. The overall project site is located on plain barren land
devoid of any permanent and economically useful vegetation. The topography of the
proposed site for project is plain terrain.
No other forests, national park or wild life sanctuary is located within 10 km periphery of the
proposed project site. No change in land use/Topography will be observed as the proposed
project is expansion project.
(iii) EXISTING INFRASTRUCTURE:
Key infrastructures available around the:
Sr. No.
Description Available within 10 km around the project
1 Railway station Yes (Udwada ‐3.5 km)
2 Bus Station Yes
3 National Highways National highway No‐8 (1.13 km away)
4 School/College Vapi town has primary, secondary, higher and
CBSC schools as well as Arts, Commerce &
Science colleges.
5 Hospital In the study area, villages have either primary
health centers or sub centers. Some villages
have medical facilities within distance of 3‐5
Km. Civil Hospital and private experts of every
medicine are available in the area.
6 Religious place Yes
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(ii) SOIL CLASSIFICATION:
The soil quality of the area is not considered fertile for agricultural activities. No evidence of
any influence of contaminant has been noticed. In overall area the agricultural productivity is
very less due to absence of fertilization practices & poor fertility of soil.
(iii) CLIMATE DATA FROM THE SECONDARY SOURCE:
Climate Semi‐Arid
Seismic Zone II
Maximum temperature, 0C 42 °C
Minimum temperature, °C 8.5°C
Relative Humidity Max.:‐ 89%; Min.:‐ 56%
Max Rain Period June to October
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13.0 PROPOSED INFRASTRUCTURE
Sr. No.
Infrastructure Description
1 Industrial area (processing
area)
Total 22450 Sq. meter land is available
and same will be used for proposed
expansion
2 Green belt Necessary green belt will be developed in &
around the proposed plot
3 Connectivity As mentioned in 12. (i)
4 Drinking water management Source: Own borewell
5 Sewerage system Adequate Septic tank/Soak Pit will be
provided
6 Industrial waste management Adequate system provided
7 Air pollution & its
management
Adequate APC system shall be provided
7 Solid waste management Proper EMP shall be in place.
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14.0 PROJECT SCHEDULE & COST ESTIMATES:
(i) Project Schedule
Proposed expansion project activities will be started after getting statutory clearance from related authorities.
(ii) Project Cost Estimation
S.NO. PARTICULARS COST IN Rs.(Lacs) Existing Proposed Total 1.0 Land 213.85 0 213.852.0 Building 2596.0 300.0 2896.03.0 Plant & Machinery 0 0 03.1 Equipment & Machineries 1303.6 500.00 1803.63.2 Pipes & fittings 72.0 72.00 144.03.3 Utilities 50.0 50.0 100.03.4 Environmental Management
System 63.8 40.0 103.7
Total Project Cost 4299.2 962.0 5261.14.0 Cooling Tower, M3/Hr 160 x 3,
120, 400160 160 x 4,
120, 4005.0 D.G. Set (Standby), KVA 0 500 500 7.0 Power from DGVCL, KVA 4000 10000 14000 8.0 Fuel
8.1 Steam coal/imported coal, MT/Month
930 0 930
8.2 HSD, Kgs/hr 0 75 75
8.3 Electricity for Induction furnace, KWh/day
60000 115000 175000
9.0 Fresh Water from GIDC, Vapi, M3/day
130 67 197
10.0 Waste water ,M3/day 2 2 4
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Project Viability
Sr .No.
PARTICULARS AMOUNT (INR LACS)
1st YEAR 2nd YEAR
3rd YEAR
1 Proposed Sale 7600.00 19000.0 22800.00
2 Raw Material Cost 6570.00 16425.0 19710.00
3 Power & Fuel 330.00 825.0 990.00
4 Labour Cost 32.00 80.0 96.00
5 Maintenance Cost 4.68 5.15 5.67
6 Selling, Packing & Office Expenses
67.40 168.50 202.50
7 Proposed Profit 595.92 1496.35 1795.83
(iii) Financial & Social Benefits
• The proposed expansion activities will be carried out in the existing unit itself. Hence, no
additional land is to be purchased.
• The company has allocated some budget for CSR activities, which can lead to improved
social infrastructure, if planned properly.
• There will be approx. 146 no. of people who will be benefitted through direct
employment after proposed expansion.
Conclusion:
As summarized in the above sections, it has been noticed that the proposed expansion
project for expansion in capacity of Mild steel & Alloy steel Billets will not have any major
impacts, which can lead to serious issues of environmental pollution or any other hazards.
Considering the probability of impacts, Jay Bharat Metcast has planned adequate mitigation
measures and EMP. Further, it has also been planned by JBMPL to organize CSR programs,
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rainwater harvesting, energy conservation, which will have considerable beneficial impacts.
Looking to the employment potentials and other allied development potentials, it has been
noticed that the proposed project will significantly help in improving social status of the
region.
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COPY OF CTE & CCA
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COPY OF LAND DOCUMENTS
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