Rashmi Metaliks Limited -...

Rashmi Metaliks Limited Proposed Feasibility Report for RML_ DIP Division _ Production Capacity Enhancement at village – Gokulpur, P.O – Shyamraipur P.S – Kharagpur (Local), District: Paschim Medinipur, W.B.

PRE-FEASIBILTY REPORTS

FOR

PRODUCTION CAPACITY ENHANCEMENT OF DUCTILE IRON PIPE PLANT

FROM 2, 00,000 TPA TO 5, 50,000 TPA

AT

VILLAGE- GOKULPUR, P.O – SHYAMRAIPUR, P.S – KHARAGPUR (L)

DISTRICT – WEST MEDINIPUR, WEST BENGAL

Project Execution By

RASHMI METALIKS LIMITED

PREMLATA BUILDING, 6thFLOOR

39, SHAKESPEARE SARANI, KOLKATA – 700 017

WEST BENGAL

Ph No.–033 – 22894255/56


CONTENTS

Page No.

Chapter -1 -Executive Summary

1.1- Introduction 01

1.2- Present Project 04

1.3- Market Demand 05

1.4- Process Concept & Technology 06

1.5- Capital Cost 07

1.6- Project Schedule 07

Chapter -2 - Introduction of the Project

2.1- Identification of Project & Project Proponent 08

2.2- Brief Description of nature of the Project 10

2.3- Need for Project & Its Importance 10

2.4- Demand Supply Gap 10

2.5- Import Vs Indigenous Product 16

2.6- Export Possibility 16

2.7- Domestic Export Market 17

2.8- Employment Generation 18

Chapter -3 – Project Description

3.1 Type of Project 19

3.2 Process Concept 19

3.3 Raw Material Requirement Detail 25

3.4 Availability of Power, Water & its Sources 26

3.5 Quality Assurance 28

Chapter -4 – Site Analysis

4.1 Connectivity 29

4.2 Land form, Land use and Land Ownership 29

4.3 Location of Map 30

4.4 Alternative Site Selection 32


Page No.

4.5 Topography (With Map) 33

4.6 Existing Land Use Pattern 34

4.7 Soil Classification 34

4.8 Climate Data from Secondary Sources 35

4.9 Social Infrastructure availability 36

Chapter -5– Planning Brief

5.1 Planning Concept 37

5.2 Population Projection 38

5.3 Land Use Planning 38

5.4 Assessment of Infrastructure Demand 38

5.5 Amenities/ Facilities 39

Chapter -6 – Proposed Infrastructure

6.1 Industrial Area 40

6.2 Residential Area 40

6.3 Green Belt 40

6.4 Social Infrastructure 41

6.5 Connectivity 42

6.6 Sewerage System 42

6.7 Industrial Waste Management 42

6.8 Solid Waste Management 43

6.9 Power Requirement & Supply/ Source 44

Chapter -7 – Environment Management Plan

7.1 EMP During Construction Phase 45

7.2 EMP During Operational Phase

7.2.1 Air Pollution Management Plan 46

7.2.2 Noise Pollution Management Plan 50

7.2.3 Water Pollution Management Plan 51

7.2.4 Pathway of Pollutant 52

7.2.5 Solid Waste Management Plan 52


Page No.

7.3 Occupational Health Management Plan 53

7.4 Green Belt Development Plan 55

7.5 Rain Water Harvesting 56

7.6 Road Connectivity 56

7.7 Monitoring Scheme 56

Chapter -8– Rehabilitation and Resettlement (R & R) Plan

8.1 Introduction 57

Chapter -9– Project Schedule & Cost Estimates

9.1 Detail 58

9.2 Estimate Project Cost 58

Chapter -10– Project Schedule & Cost Estimates

10.1 Financial and social benefits 60

Annexure-I- Plant Layout

Annexure-II- Green Belt Development

Annexure-III- Existing Rain Water Harvesting Facility

Annexure-IV- CSR Activities carried in past by RML

Annexure-V- Water Extraction Permission

Annexure-VI- Stack/ Ambient Analysis Report

Annexure-VII- Valid CFO, NOC & EC Detail

Rashmi Metaliks Limited

Proposed Feasibility Report for RML_ DIP Division _ Production Capacity Enhancement at village – Gokulpur, P.O – Shyamraipur P.S – Kharagpur (Local), District: Paschim Medinipur, W.B.

PFR for Production Capacity Enhancement of DIP Pipe Unit from 2, 00,000 TPA to 5, 50,000 TPA Page 1

1. Executive Summary

1.1 Introduction

M/s Rashmi Metaliks Limited has an Integrated Steel Plant & Ductile Iron Pipe

Plant and has already obtained EC on 12.06.2008 ; 01.06.2012 from MoEF, New

Delhi for integrated steel plant and on 09.10.2009 for Ductile Iron Pipe Plant of

2,00,000 TPA from SEIAA West Bengal and necessary NOC, CFO for running its unit.

Its registered office is at Premlata Building, 6th Floor, 39-Shakespeare Sarani, Kolkata

– 700 017 in West Bengal.

M/s Rashmi Metaliks Limited at present operating Sinter Unit (50,000 TPM), Mini

Blast Furnace (14,000 TPM), SMS (15,500 TPM), Rolling Mill (9600 TPM), Ductile Iron

Pipe (11833 TPM), Pellet Plant-I (75,000 TPM), Coal Gasifier (6000 Nm3/hr) at village -

Gokulpur, P.O. Shyamraipur, Kharagpur. District Paschim Mednipur in West Bengal.

It is important to note that by virtue of Hon‟ble Calcutta High Court order for

demerger, as on date the complete Sponge Iron Plant, Captive Power Plant, MBF ( 1 X

320 m2), Pellet Plant-II (0.6 MTPA), Pellet Plant-III (0.6 MTPA), Iron Ore Beneficiation

Plant and Producer Gas Plant got transferred to M/s Orissa Metaliks Private Limited

(OMPL). The name of plant units of RML is given in Table 1.1. The name of plant

units of OMPL is given in Table 1.2.

Table 1.1 Name of Units with Rashmi Metaliks Limited

Name of the Units Size of Units

under Operation

Production

Capacity

Name of Product

Mini Blast Furnace 1 x 215 m3 168000 TPA Molten Iron

Sinter Plant 2 x 25 m2 600000 TPA Sinter

Pig Casting Machine

- 120000 TPA Pigs

SMS - 378000 TPA Steel

Pellet Plant 0.9 MTPA 900000 TPA Pellets




Ductile Iron Pipe Plant 0.14 MTPA 140000 TPA Pipe

Rolling Mill TMT 8 - 32 mm

Wire Rod 5.5 mm

- 12 mm

120000 TPA TMT Bar

Table 1.2 Name of Units with Orissa Metaliks Private Limited (By Virtue of Hon’ble Calcutta High Court Order)

Name of the Units Size of Units

under Operation

Production

Capacity

Name of Product

DRI kilns 6 x 100 TPD +

1 x 350 TPD

321000 TPA Sponge Iron

Iron Ore Beneficiation

Plant

1.5 MTPA Iron ore concentrate

Pellet Plant 2 x 0.6 MTPA 120000 TPA Pellets

Producers Gas Plant 10 x 7500 Nm3/ h

- Producer gas for pellet

making

CPP-WHRB DRI based WHRB &

AFBC

28 MW Electricity

After transferred of units to M/s Orissa Metaliks Private Limited the status of

units in the company name as follows.

Units under the company Name Orissa

Metaliks Private limited

Units under the Company Name Rashmi

Metaliks Limited

Under EC No J-11011/227/2010-IA-II (I) dated 12th, June, 2008 of MoEF, New Delhi

DRI (10 X100 TPD; 3 X350 TPD) WITH

WHRB

SINTER PLANT : 70 sqM (0.84MTPA)

MBF : 320 sqM (0.3MTPA) STEEL MELTING SHOP : 0.5 MTPA

OXYGEN PLANT : 60 TPD

LIME CALCINATION : 1200 TPD

F. No. J – 11011/372/2014-IA II (I) dated 12.02.2015. of MoEF, New Delhi

PELLET PLANT-I -0.9 MTPA

Under EC. No. EN/256/T-II-I/047/2009 dated 09.10.2009. of SEIAA, West Bengal

DUCTILE IRON PIPE PLANT -2,00,000 TPA

Under EC No J-11011/604/2010-IA-II (I) dated 1st, June, 2012’ of MoEF, New Delhi

I/O BENEFICATION PLANT-1.5 MTPA

PELLET PLANT (0.6 MTPA x2) 1.2 MTPA

PRODUCER GAS PLANT ( 10 X 7500 NM3/hr)




As a strategic decision the company has decided to expand their business model by

enhancing the capacity of Ductile Iron Pipe Plant from 2,00,000 TPA to 5,50,000 TPA

in phase wise at Mouza – Nandarchak (J.L. No.-124), Sujatpur (J.L. No.-139) &

Khidipur(J.L. No.-140) Village – Gokulpur, P.O – Shyamraipur, P.S – Kharagpur (L),

Dist. Paschmi Mednipur in the state of West Bengal.

Rashmi Group founded in 1966 really got impetus from its real promoter. Rashmi

Group of companies is a fast growing Group in the field of manufacturing steel and

cement. The company has developed core competence in minerals, steel and cement

with 40 years of experience. The Group‟s turnover is around Rs.2100 Crores and net

worth is Rs.2139 Crores. Rashmi Group awarded „Ultra Mega Project‟ status by Govt.

of West Bengal. The Group is also engaged in import/export of Mineral & Mineral

based products. The growth of the group during last few years has been phenomenal

and fast catching the attention of bankers, professionals and industry as a whole.

The group has grown from merely a re-rolling mill to a fully fledged Cement Grinding

unit having capacity of 0.18 MTPA and group have already obtained EC from the

SEIAA, W.B. in favour of Rashmi Cement Limited (Cement Division) vide letter no.

1276/EN/T-II-1/044/2014 on 27.05.2015 for expansion from 0.18 MTPA to 0.96

MTPA which is under commissioning stage at Jhargram in West Bengal.

In addition to this, the Group also has a Sponge Iron Plant in the name of Rashmi

Cement Limited (Steel & Power Division) for which EC (File No. J-11011/227/2007-

1A.II (I)) had obtained from MoEF, Delhi on 12.02.2009 for expansion of capacity from

3, 00,000 TPA TO 6, 00,000 TPA, Ferro alloy with capacity 72,000 TPA & Power Plant

25 MW and at present we are having operation capacity of 4, 00,000 TPA Sponge Iron,

Ferro alloy 24,000 TPA & Captive Power Plant WHRB based 28 MW at village -

Jitusole, P.O. Jhargram, District Paschim Mednipur in West Bengal.

Also , Rashmi Group is going to set up another 1.0 million TPA Steel Plant and 200

MW power plant at Jamuria, Dist.-Burdwan in West Bengal by the name of Rashmi




Cement Limited, for this MOEF, Delhi has already issued the Environmental

Clearance (File No. J -11011/112/2010-IA II (I)) dated 26th August 2014.

As a strategic decision, the management has decided to expand their business model

by enhancing the capacity of Ductile Iron Pipe Plant from 2,00,000 TPA to

5,50,000 TPA by the name of M/s Rashmi Metaliks Limited in phase wise, the

detail is given in Table-1.3 at Mouza – Nandarchak (J.L. No.-124), Sujatpur (J.L. No.-

139) & Khidipur(J.L. No.-140) Village – Gokulpur, P.O – Shyamraipur, P.S –

Kharagpur (L), Dist. Paschmi Mednipur in the state of West Bengal.

Table 1.3- Proposed Expansion Project Detail

Sr. No Plant Existing

(TPA)

Proposed (TPA) Total

(TPA) Phase-I Phase-II

1 Ductile Iron Pipe 2,00,000 1,50,000 2,00,000 5,50,000

1.2 Present Project

The proposed project, after obtaining the „EC‟ & „NOC‟ project works will be started at.

Management has decided to enhance the capacity of Ductile Iron Pipe Plant from

2,00,000 TPA to 5,50,000 TPA in phase wise at Mouza – Nandarchak (J.L. No.-124),

Sujatpur (J.L. No.-139) & Khidipur(J.L. No.-140) Village – Gokulpur, P.O –

Shyamraipur, P.S – Kharagpur (L), Dist. Paschmi Mednipur in the state of West

Bengal for following reason:

Raw Materials availabilities like Hot Metal which will be obtaining from RML

and adjacent unit i.e. OMPL

Close to high growth deficient markets

Economies of scale will result in lower operating cost

Offers freight advantage vis-à-vis competitors

Excellent export opportunities to South Asian countries




The markets in the East & North-East are potential territories for Ductile Cast Iron

Pipe & offer great opportunity to market this product, which is well accepted in other

parts of the country.

1.3 Market Demand

India is one of the fastest developing economies in the world. Infrastructure lacuna

has been an anathema to India's growth. Not surprisingly, India lags behind water

infrastructure and sewerage development with only 33% of the total population having

access to improved sanitation. In rural areas, where 72% of India's population lives,

only 22% has better coverage for sanitation.

The Indian pipes business has been growing rapidly since the past several years

mainly due to increasing demand for pipes in the irrigation sector, for crude oil, real

estate industry and growth in Gross domestic product (GDP) of the country. Among

the several varieties of pipes available in the market, the demand for plastic pipes

such as PVC, CPVC in particular, is on a rise due to its low cost, high quality and

high durability. Other types of pipes, like steel pipes and ductile iron pipes also have

major demand. Nationwide infrastructural development, urbanization, government‟s

focus on real estate, irrigation to drive agricultural growth have been identified as

major factors facilitating the growth of the pipes industry in the country.

The Government of India is launching new schemes in the irrigation and the real

estate sector for significant investments. It is evident here that the focus of Indian

government is on water supply for housing sector, which will only be fulfilled with

effective use of pipelines. Therefore, this end-user is a major demand driver of pipes.

Furthermore, strong demand for crude oil transportation is also adding to the demand

of pipes across the country.

The major grades demanded in the Indian markets is the K7 and K9 series, the

governmental authorities and waste water authorities majorly demand DN 80 mm to

DN 1000 mm diameter or sizes of specifications. The major feature of this market is

that it is 100 % organized as the commissioning of project is routed through EPC




contractors and vendor selection criteria by the government is completely based on

Quality of the DI pipes and robust quality standards with regards to ISO and British

Standards

The Ductile Iron pipes market in India is set to grow in the short term and medium

term (2 – 5 years) clocking consistent growth rates, with major players ramping up

their operations along with a sudden surge in demand in the Indian markets as well

as export markets like South Asia, Middle East and North Africa.

In the medium term and long term (7 to 10 years) we predict a demand supply gap in

terms of excess supply in the Indian markets over demand as a result of established

infrastructural waste water and water projects, and India would have prime focus to

export to developing & underdeveloped regions which lacks infrastructural

development in waste water & water infrastructure.

This proposed production enhancement project of Ductile Iron Pipe Plant from

2,00,000 TPA to 5,50,000 TPA by the name of M/s Rashmi Metaliks Limited in

phase wise at Mouza – Nandarchak (J.L. No.-124), Sujatpur (J.L. No.-139) &


Dist. Paschmi Mednipur in the state of West Bengal shall be partially fulfilling the

demand of the Ductile Iron Pipe in India & Global market.

1.4 PROCESS CONCEPT & TECHNOLOGY

The existing DI pipe plant is based on state of the art technology with respect to

energy efficiencies and environmental protection. In Blast Furnace Hot Metal carbon

percentage 4.2 to 4.3 but in DI pipe, carbon percentage is 3.6 %. Therefore steel scrap

with 0.3% carbon is to be added by about 12% to 15 % for chemistry correction. After

that hot metal is treated with Magnesium and taken for Centrifugal casting.

Successfully casting pipes are sent for heat treatment, Zn-coating, Hydraulic Pressure

Test, Cement Motor Lining and Bitumen Coating respectively. Bag Filters, Suction

Hoods are using for Induction as well as Annealing Furnaces to control of dust




emissions for main processing equipments. For Fugitive emissions control from

various transfer points/storage areas etc, by Bag filters, Suction Hoods, dust collector

systems and dust suppression systems

1.5 CAPITAL COST

The estimated capital cost, for the proposed production enhancement project works

out to about Rs. 165 crores including Machineries, Building construction, Road

construction, Green Belt Development etc.

1.6 PROJECT SCHEDULE

This project would be designed by Capex Projects Management division of RASHMI

GROUP and will be executed by M/s Rashmi Metaliks Limited project division, which

is located at Kolkata, West Bengal. The entire project will be completed within 60

months from the date of obtaining of Environment Clearance & Consent to establish.




2. Introduction of the Project

2.1 Identification of Project and Project Proponent

M/s Rashmi Metaliks Limited has an Integrated Steel Plant & Ductile Iron Pipe

Plant and has already obtained EC on 12.06.2008 ; 01.06.2012 from MoEF, New

Delhi for integrated steel plant and on 09.10.2009 for Ductile Iron Pipe Plant of

2,00,000 TPA from SEIAA West Bengal and necessary NOC, CFO for running its unit.

Detail Enclosed as Annexure- VII. Its registered office is at Premlata Building, 6th

Floor, 39-Shakespeare Sarani, Kolkata – 700 017 in West Bengal.

M/s Rashmi Metaliks Limited at present operating Sinter Unit (50,000 TPM), Mini

Blast Furnace (14,000 TPM), SMS (15,500 TPM), Rolling Mill (9600 TPM), Ductile Iron

Pipe (11833 TPM), Pellet Plant-I (75,000 TPM), Coal Gasifier (6000 Nm3/hr) at village -

Gokulpur, P.O. Shyamraipur, Kharagpur. District Paschim Mednipur in West Bengal.

It is important to note that by virtue of Hon‟ble Calcutta High Court order for

demerger, as on date the complete Sponge Iron Plant, Captive Power Plant, MBF ( 1 X

320 m2), Pellet Plant-II (0.6 MTPA), Pellet Plant-III (0.6 MTPA), Iron Ore Beneficiation

Plant and Producer Gas Plant got transferred to M/s Orissa Metaliks Private Limited

(OMPL).

As a strategic decision the company has decided to expand their business model by

enhancing the capacity of Ductile Iron Pipe Plant from 2,00,000 TPA to 5,50,000 TPA

in phase wise at Mouza – Nandarchak (J.L. No.-124), Sujatpur (J.L. No.-139) &



Rashmi Group founded in 1966 really got impetus from its real promoter. Rashmi

Group of companies is a fast growing Group in the field of manufacturing steel and

cement. The company has developed core competence in minerals, steel and cement

with 40 years of experience. The Group‟s turnover is around Rs.2100 Crores and net




worth is Rs.2139 Crores. Rashmi Group awarded „Ultra Mega Project‟ status by Govt.

of West Bengal. The Group is also engaged in import/export of Mineral & Mineral

based products. The growth of the group during last few years has been phenomenal

and fast catching the attention of bankers, professionals and industry as a whole.

The group has grown from merely a re-rolling mill to a fully fledged Cement Grinding

unit having capacity of 0.18 MTPA and group have already obtained EC from the

SEIAA, W.B. in favour of Rashmi Cement Limited (Cement Division) vide letter no.

1276/EN/T-II-1/044/2014 on 27.05.2015 for expansion from 0.18 MTPA to 0.96

MTPA which is under commissioning stage at Jhargram in West Bengal.

In addition to this, the Group also has a Sponge Iron Plant in the name of Rashmi

Cement Limited (Steel & Power Division) for which EC (File No. J-11011/227/2007-

1A.II (I)) had obtained from MoEF, Delhi on 12.02.2009 for expansion of capacity from

3, 00,000 TPA TO 6, 00,000 TPA, Ferro alloy with capacity 72,000 TPA & Power Plant

25 MW and at present we are having operation capacity of 4, 00,000 TPA Sponge Iron,

Ferro alloy 24,000 TPA & Captive Power Plant WHRB based 28 MW at village -

Jitusole, P.O. Jhargram, District Paschim Mednipur in West Bengal.

Also , Rashmi Group is going to set up another 1.0 million TPA Steel Plant and 200

MW power plant at Jamuria, Dist.-Burdwan in West Bengal by the name of Rashmi

Cement Limited, for this MOEF, Delhi has already issued the Environmental

Clearance (File No. J -11011/112/2010-IA II (I)) dated 26th August 2014.

As a strategic decision, the management has decided to expand their business model

by enhancing the capacity of Ductile Iron Pipe Plant from 2,00,000 TPA to

5,50,000 TPA by the name of M/s Rashmi Metaliks Limited in phase wise, the

detail is given in Table-2.1 at Mouza – Nandarchak (J.L. No.-124), Sujatpur (J.L. No.-

139) & Khidipur(J.L. No.-140) Village – Gokulpur, P.O – Shyamraipur, P.S –

Kharagpur (L), Dist. Paschmi Mednipur in the state of West Bengal.






(TPA)




2.2 Brief Description of Nature of The Project

The proposed project, after obtaining the „EC‟ & „NOC‟ project works will be started at.

Management has decided to enhance the capacity of Ductile Iron Pipe Plant from

2,00,000 TPA to 5,50,000 TPA in phase wise at Mouza – Nandarchak (J.L. No.-124),

Sujatpur (J.L. No.-139) & Khidipur(J.L. No.-140) Village – Gokulpur, P.O –

Shyamraipur, P.S – Kharagpur (L), Dist. Paschmi Mednipur in the state of West

Bengal.

2.3 Need For the Project and Its Importance to the Country and/or Region

&

2.4 Demand- Supply Gap

Economic Growth

Indian economy is likely to grow in the range of 5.4 to 5.9 per cent in 2014-15 and the

outlook is very positive. The average consumer spending has increased significantly

which has fuelled demand for quality infrastructure services like roads, electric power,

transportation, water supply, sanitation, communication, etc.

Demand for Water

Water is a precious resource in India because the country accounts for 16% of the

world population as against just 4% of global water resources. The water use

efficiency is low in the country compared to international standards. As in the

previous years, agriculture will continue to be the major demand segment for water in

India. However, the demand from industries is expected to grow faster than the




demand from agriculture and domestic sectors. It is understood that the use of water

in Indian industries is high due to a combination of factors such as obsolete process

technology, poor recycling and reuse practices, and poor wastewater treatment. Use of

water in industries is closely linked to the economy of a country. The major water

guzzling industries are pulp and paper units, thermal power plants, fertilizer units,

iron and steel plants, sugar plants, and textile units. Estimates vary with respect to

the requirement of water for industries. According to the Ministry of Water Resource

(MoWR), the requirement will increase from 30 billion cubic metre in 2000 to 120

billion cubic metre by 2025. According to the World Bank, the water demand for

industrial uses and energy production will touch 228 billion cubic meters by 2025. As

per the Tenth Plan, the stipulated norms are 40 liters per capita per day (lpcd) of safe

drinking water within a walking distance of 1.6 km and at least 1 hand pump for

every 250 persons. The norm will be relaxed to 55 lpcd in states where the 40-lpcd

norm has been achieved already. The above-mentioned norms are quite reasonable

because it is reported that in many large cities, water withdrawal amounts to 300 to

600 lpcd. In contrast, the consumption in the developed countries of Europe and

North America had already touched 500-1000 lpcd by the turn of the last century.

Water demand projection varies from agency to agency. Consumption of water by

2020 in different sectors as projected by Water Resources Division, Planning

Commission is given below.

According to a WHO-UNICEF Sponsored Study (India Assessment 2002-Water Supply

& Sanitation), the total water requirement by 2050 will be 1,422 billion cubic meter.

Tata Energy Research Institute (TERI) has estimated that the overall water demand

will virtually double from 564 billion cubic meters in 1997 to 1,048 billion cubic meter




in 2047. MoWR has assessed the water requirement at 694 cubic km in 2010, 784

cubic km in 2025, and 973 cubic km in 2050. As against the projected demand, the

availability of water in 2050 is estimated at 996 cubic km.

At the national level, it will be a difficult to increase the availability to the projected

levels as most of the water resources are concentrated in a few river basins.

Transporting huge quantity of water from like rivers, lakes, wells, and treatment

plants to millions of homes would require a reliable pipeline system that will serve for

years without leaks and contamination. The increase in demand for water will call for

enormous efforts to capture, preserve, and distribute available water equitably.

Urbanization

It is estimated that by the end of the 12th Plan in 2017, approximately 40% of the

country‟s population will live in cities and towns. This fast pace of urbanization will

increase the demand for piped water supply. Thus, the increase in population

accompanied by the fast pace of urbanization will together contribute for the growth

in demand for pipes.

Improvement in Water and Sanitation Coverage of Government to provide drinking

water & sanitation to100% of the population:

Thrust of government to provide drinking water & sanitation to100% of the population

Government‟s focus to improve the urban infrastructure has increased significantly

during the last 10 years. The investment allocation to water supply & sanitation

during five year plan is INR 423 Bn.

• The year wise fund allocation growth rate in this five year plan is 21% which is

higher than the year wise growth rate of 15% during last five year plan.

• The JNNURM scheme commenced during the five year plan is the main driver for

urban infrastructure development. JNNURM scheme is focused towards strengthen

the infrastructure in 63 cities, the other schemes UIDSSMT & AUWSP focuses on

other cities/towns.




• Water PPP‟s have emerged during the last 10 years & are fairly successful in India;

the central Government has planned to increase the number of PPP projects in order

to support state water authorities in improving the system efficiency

• The depletion of fresh water sources is driving the need of desalination projects &

these projects are expected to drive the growth of urban water infrastructure in the

coming years. The desalination projects are being planned & ongoing in certain

coastal cities

Source: JNNURM Website & Frost & Sullivan Primary Research & Analysis

Demand Analysis for DI Pipes

The demand drivers for pipes in general and DI pipes in particular are:

Economic growth

Demand for water

Urbanization

Improvement in water supply and sanitation coverage

Awareness on safety and hygiene

Investment by the Central and State Governments in Water and Sanitation

schemes

Assistance from external agencies

Inter-linking of rivers

Export potential

Investment in Water Projects and Role of Government Bodies

The central government had given thrust to improve the urban infrastructure during

the last 10 years and have been implementing various programs & schemes in the

WSS sector. Apart from the state governments also funds & undertake various

schemes. The funds for certain WSS projects are pooled from international banks &

financial institutions (World Bank, JICA, ADB etc. Key WSS Programs in India

JNNURM (Jawaharlal Nehru National Urban Renewal Mission) UIDSSMT (Urban




Infrastructure Development Scheme for Small and Medium Towns) AUWSP

(Accelerated Urban Water Supply Programme) Program Description

Flagship program for improving urban infrastructure

Focuses on 63 mission cities

Program covers the cities & towns which are not covered under JNNURM

Focuses on improvement on urban infrastructure facilities & PPP projects

Aimed at extending WSS services in smaller cities & towns

Partly funded by central government & partly by state government/municipal

bodies

Government/municipal bodies: It is estimated that at the current rate of growth, in

about two decades, water demand in India and China together will be thrice the

world‟s current consumption. Budgetary outlay for Indian government‟s 12th 5-yr

plan 2012-17 for water supply and sanitation is more than Rs. 255,310 crores which

is significantly higher than previous plan.

Increasing investment of government in water and sanitation projects, the main driver

for DI pipe demand is evident from the figure below.

External Aid

Water resources projects in India are supported by multilateral or bilateral aid,

grants, loans, and commodity aid from foreign countries as well as donor agencies

such as the International Bank of Reconstruction and Development (IBRD) commonly

known as the World Bank. During 2013, the Sian Development Bank has sanctioned

projects worth Rs 8800 crores for projects to improve drinking water and sanitation in

major cities like Delhi and Kolkata along with projects in Rajasthan. The National

Ganga River Basin Authority (NGBRA) has received one Billion USD financing from

the World Bank.

The Ministry of Water Resources, Government of India assists the state governments

in tying up external assistance from different funding agencies to fill up the resource

gaps.




Water resources projects have also been funded through bilateral support of France,

Australia, Canada, Germany, and the Netherlands

Industry Analysis

While the purchase of pipes in general has increased, the share of DI pipes in the total

purchase of pipes has increased significantly from 33% to 52%. The share of other

pipes has been either declining or stagnant. The plastic pipes used are predominantly

PVC pipes and recent increase in use of HDPE pipes in competition for PVC pipes. The

other pipes include GRP, BWSCC pipes, Hume pipes, stoneware pipes, etc. GRP pipes,

RCC pipes, and stoneware pipes are used predominantly in sewerage applications.

The increasing share of DI pipes obviously indicates its rising acceptance by

customers and its growing popularity. The increasing share of DI pipes indicates that

DI pipes are gradually replacing all other pipes, especially steel pipes. The government

bodies have virtually stopped purchase of CI pipes for potable water supply and the

existing CI pipelines are increasingly being replaced by DI pipes. Plastic pipes and

cement pipes (AC/RCC/PSC) are also being replaced in urban and semi-urban areas;

however, in rural water supply schemes they still exist due to the low initial

investment.

Preference of Pipe Materials

The choice of the pipe material, on technical grounds, is governed by two major

factors: the pipe diameter and the area of application, i.e., transmission or

distribution. The general preference of pipe materials for water supply projects are

available in three different diameter ranges and used in urban, semi-urban, and rural

areas. DI pipes are widely preferred in urban and semi-urban areas. In urban and

semi-urban areas, uncovered water is considered unsafe and it is mandatory to

provide piped water supply to prevent pollution and contamination of drinking water.

Moreover, in the urban and semi-urban areas, DI pipes are preferred because they are

the best suited in places where heavy traffic loads, digging for cable laying and




bridges/flyover, etc. are quite common. In diameter sizes above 600 mm, MS pipes are

preferred because the initial investment is less as compared to that of DI pipes. DI

pipes are preferred in the lower diameter sizes, for both high-pressure transmission

and low-pressure distribution system. However, the users are increasingly considering

the life cycle cost (LCC) rather than just the initial investment because this factor is

being focused in tender evaluation as well. The government departments and

organizations are well aware of the long-term economic benefits of using DI pipes in

water supply and sanitation projects.

Inter Linking of Rivers (ILR) Project

Inter Linking of Rivers (ILR) project is Government of India‟s proposal to link 37 rivers

through 30 links, dozens of large dams and thousands of miles of canals, making it

the largest water project in the world. Once this project is set in motion, there will be

an unprecedented demand for not only DI pipes and fittings, but also services for

design, implementation, project management, and maintenance.

The project offers an excellent opportunity for M/s Rashmi Metaliks Limited (RML)

enhance its production capacity from 2, 00,000 TPA to 5, 50,000 TPA in same

premises.

2.5 Imports vs. Indigenous Production:

India is self sufficient to meet the demands of the market with the GDP projected at

10 % in the coming decades and in view of the infrastructure. Facilities going across

the region the growth rate of demand will increase to meet the expansion of new

proposal are muted.

2.6 Export Possibility

Total global DI pipe production is about 5.4 million TPA, out of which dependence on

import by various countries is about 500,000 TPA. Export ratio is 10 – 40%. Middle

East and Asia is everybody‟s target. Low domestic capacity and production has been




the major constraint that inhibited exports of DI pipes from India. India has the

competitive advantage of being strategically located to cater to Asian, South Asian,

and Middle East countries. The Middle East is a very prospective region for DI pipes

because being water scarce, as the countries in the Middle East give special focus on

water supply and sanitation. During the last four years, India exported DI pipes to as

many as 37 countries of which the regular destinations have been Algeria, Brunei,

Hong Kong, Qatar, Singapore, Spain, Sri Lanka, Sultanate of Oman, and UK. Thus, DI

pipes will continue to be in good demand in these countries in the forthcoming years

as well.

Kharagpur being nearer to both Orissa and Jharkhand states, the select plant

location is ideal for growing markets especially East & North East states. Further,

proximity to the Haldia port is ideal for export of DI pipe to neighbouring country and

Middle East. Also company has own private Railway siding for raw materials inwards

and finished goods outwards.

2.7 Domestic / Export Markets

There are number of units engaged in the manufacture of DI pipes in India and the

total installed capacity (as on June 2015) is around 2.42 MnT & the production

during 2015– 16 is estimated to be 1.51 Million MT.

The average capacity utilization is around 57%, which may go up to 70% during 2016-

17 and the production is likely to go up to 1.70 MnT during 2016-17.

The investment allocation to water supply & sanitation during the 12th five year plan

is INR 255319 crores. Based on prior experience, it is estimated that 13% of this

expenditure to be on DI pipes.

Considering domestic demand and the requirement from the export market, Pipes

demand is expected to reach 1.99 MnT by 2016 – 17. The detail about the demand

supply gap is given in Table-2.2.




Table-2.2- Demand Supply Gap

With the demand growing and the supply scenario showing incremental growth, the

demand supply gap is set to increase to 0.29 MnT.

The investment in water supply and sanitation sector by the Central and State

governments registered a compound annual growth rate of 18.5% from the end of the

8th Five Year Plan to the end of the 11th Five Year Plan.

Supply constraints in the past have inhibited market expansion and the industry is

yet to pick up momentum. DI pipes being at the beginning of its product life cycle, it is

expected that the growth trajectory will be very buoyant at least in the next decade or

so after which it may mature to a stable level.

2.8 Employment Generation (Direct & Indirect) due to the project:

The project will create the direct employment of 300 Peoples during the construction

phase and around 600 Peoples will be involve during operational period. Skilled and

unskilled people on daily average will be employed. RML will give preference to the

local peoples during construction and operation phase of the project depending upon

the skill, job requirement and capability. Several others around 200 indirect

employment opportunities will be created in the surrounding areas by transport,

business, vehicle drivers and attendants, workshops, grocery and retails, medical, etc.




3. PROJECT DESCRIPTION

3.1 Types of Project

M/s Rashmi Metaliks Limited, is going to enhance the production capacity of

Ductile Iron Pipe Plant from 2,00,000 TPA to 5,50,000 TPA phase wise (the detail

is given in Table-3.1) at Mouza – Nandarchak (J.L. No.-124), Sujatpur (J.L. No.-139)

& Khidipur(J.L. No.-140) Village – Gokulpur, P.O – Shyamraipur, P.S – Kharagpur (L),

Dist. Paschmi Mednipur in the state of West Bengal within the same premises near to

the existing DIP Unit.



(TPA)




3.2 Process Concept and Technology

a) Process Concept and Technology

Ductile Irons Pipe‟s Manufacturing Process consists of various processes; they are

1. Molten Hot Metal preparation and Chemistry correction

2. Magnesium treatment

3. Centrifugal Casting

4. Core Making

5. Mold Maintenance

6. Heat Treatment by Annealing Furnace

7. Zinc Coating

8. Hydraulic Pressure Testing

9. Cement Motor Lining

10. Bitumen Coating

11. Finishing




A ductile iron pipe is produced with centrifugal casting method. The molten ductile

iron is poured into a rapidly spinning water-cooled mould and centrifugal force results

in an even spread of iron around the circumference.

A schematic process flow diagram is given in Figure-3.1.

Each process will explained in below

1. Molten Hot Metal Preparation: In Blast Furnace Hot Metal, Carbon percentage

(%) is usually 4.2 % to 4.3 %. But in DIP, Carbon percentage is 3.6 %. Therefore

Steel Scrap with 0.3 % Carbon is to be added by about 12 % to 15 % of BF Hot

Metal.

2. Magnesium Treatment: During this process, molten Hot metal treated with

Ferro Alloys, like Silico-Manganese, Magnesium, carbon etc. and melted with

14600-15200 C of temperature. The sphere-iodization process has been carried

out in the crucibles at about 1500 °C by tundish treatment and it was

performed by means of 2,1 % of Fe-Si-Mg. Next, molten iron will be poured to

the cast process.

3. Centrifugal Casting: Centrifugal casting requires water cooling metallic and

centrifugal casting machine that works automatically. Types of the machine are

divided as the pipe dimension (DN). Here For example, there are machine for

DN80-300mm, machine for DN400-700mm or machine for DN700-1000mm.

During the process, the molten iron will be poured to the volumetric ladle.

When the molten iron entered the mould spinning, it needs water high speed

spin through the long through for the water cooling system. During this

process, the solidification process will be started. Finally, the extractor will

extract the pipe after it solidified completely.

4. Core Making: Core making equipment consists of manual machine and

automatic machine known as core-making jets. Silicon sand, solidifying agent

and resin will be mixed and rolled. Then it‟s moved to the hopper of the core-




making jets machine with a conveyor. Core making process will be started by

jetting that material into core box. When it‟s solidified completely core will be

made and tested. Next, core will be conveyed to casting process.

5. Mould Maintenance: To remove the rust in the internal surface of a mould, it

will be grounded with sand wheel before it‟s dotted with penning head to

increase its crack resistance. If cracks found on the mould surface, it will be

removed by turning the mould and welding the turning area. Next grinding and

penning will accomplish the maintenance.

6. Annealing/ Heat Treatment : The process consists of heating section, heat

holding section, slow cooling section and fast cooling section. Ductile iron pipe

will be entered to this 52 meters long machine and rolled on it. Certainly its

temperature will be controlled.

7. Zinc Coating: Adhesive molten zinc will be extracted to external surface of pipe.

EN 545/598 mandates a minimum zinc content of 130 g/m2 (with local minima

of 110 g/m2 at 99.99% purity), and a minimum average finishing layer

thickness of 20 µm .

8. Finishing and Hydrostatic Testing: Pipe dimension will be checked here and

it‟s important to remove the fins on the external and internal surface. A

Hydrostatic checking will be done in 10 seconds with proper pressure refers to

the dimension.

Hydraulic pressure for hydrostatic testing

Nominal Diameter (mm) Hydraulic Pressure (Mpa):

80≤DN≤300, 200≤DN≤600, 700≤DN≤1000, 1100≤DN≤2000

9. Cement Lining: Pipe will be rolled with low speed and it will be sprayed with

material. This material includes cement, sand, and water. Pipe will be rolled




with high speed to move excessive water and deposit cement. Nature cure will

be given to cement lining. Grinder will smooth its surface

10. Bitumen Coating: As zinc coating, bitumen will be sprayed to pipe. But it will

be done to internal and external surface. Bitumen will reduce the corrosive on

the internal surface.

11. Finishing: This process includes marking (trade mark), painting if it‟s required

and packing. It will pack with thick wood and bundled with steel belt.

Ductile Iron Metallurgy: Ductile Iron is an iron with elementary alloy such as

carbon, Si, Mn and Mg. Commonly, the carbon content on its structure is 3 % or

more. Ductile iron is one of the most important engineering materials, in view of its

excellent cast-ability, significantly better mechanical properties and low cost. Simply,

it‟s similarly to steel in strength, toughness, ductility and hardness.

Figure-3.1 Process Flow Sheet for Ductile Iron Pipe Manufacturing




Production Capacity/Batch Time Calculation:

Double Track Induction Furnace 2 Nos = 2 x 15 T with 6 crucibles (4 in operation and 2 stand by)

Induction Furnace Batch time -45 minutes

Operational Time-15 hours in a day

Maximum production- 60 Ton/Batch

No of working days in a year-300 days

Total Batch in a day-(15*60)/45 = 20 (Max.)

Therefore, annual Production =Batch per day x Maximum Production x No. of working

days in a year

= 20*60*300

= 3, 60,000 TPA

Considering breakdown /time lapse the annual production will be 3, 50,000 TPA

b) List of Machineries for the proposed Activities: -

The capacity enhancement of proposed plant will have a capacity to produce 5, 50,000

TPA of DI pipes in Phase Wise having a size range of DN 80 to DN 600.The detail is

given below:


(TPA)



1 Ductile Iron Pipe 2,00,000 1,50,000

Size of Pipe

(SDP I)

DN(80- 300

mm ) x 5.5 m

2,00,000

Size of Pipe

(SDP II)

DN(200- 600

mm ) x 5.5 m

5,50,000




The plant will comprise of the main plant & machinery indicated in following Table

3.2.

Table-3.2 List of the machineries required to be added to enhance production

Sr. No Machinery Quantity

(No.)

1 15 T Induction Furnace with 3 crucible ( 2 in operation & 1 stand by)

02

2 Annealing Furnace of 30 TPH for making SDP of Dimension

(DN-80-300 mm) x 5.55 m ; (DN 200-600) x 5.5 m

02

3 Magnesium Converter of 18 TPH 02

4 Zinc Coating Machine of 10 TPH 01

5 Centrifugal Casting machine of 5 TPH 10

6 Hydraulic Pressure Testing Machine 02

7 Cement Mortar Lining/ Curing System of 15 TPH 03

8 Bitumen Coating Machine with preheating & post heating

furnace

02

9 Pipe Socket Grinding/ Mould Grinding 02

10 Sand Drying & Conveying System 01

11 Finishing Line 02

Table-3.3 List of the machineries existing and proposed for achieving 5, 50,000 TPA productions

Sr. No Main Plant & Machinery Quantity (No.)

Existing Proposed Total

1 8 T Induction Furnace with 3 crucible ( 2 in operation & 1

stand by)

2 NIL 02

2 15 T Induction Furnace with 3

crucible ( 2 in operation & 1 stand by)

NIL 02 02

3 Annealing Furnace of 30 TPH 02 02 04

4 Magnesium Converter of 18 TPH 02 02 04

5 Zinc Coating Machine of 10 TPH 05 01 06

6 Centrifugal Casting machine of 5

TPH

10 10 20

7 Hydraulic Pressure Testing

Machine

05 02 07

8 Cement Mortar Lining/ Curing

System of 15 TPH

05 03 08




9 Bitumen Coating Machine with preheating & post heating furnace

05 02 07

10 Pipe Socket Grinding/ Mould Grinding

03 02 05

11 Sand Drying & Conveying System 02 01 03

12 Finishing Line 08 02 10

13 Core Shooter Machine 04 NIL 04

3.3 Raw Material required along with estimated quantity, likely source,

marketing area of final products/s, mode of transport of raw material and

finished product.

Raw Material Requirement

The major raw materials for DI Pipe manufacture is liquid pig iron, also known as hot

metal. 1.07 t of hot metal is required per tonne of DI pipe. The charge-mix will be 90%

hot metal and 10 % solids comprising of purchased steel scrap and reject pipes. Raw

materials to be sourced must fulfill the quality requirements demanded by process,

equipment and technological parameters. The annual requirement of raw materials

including other materials for the 5, 50,000 TPA capacity DI Pipe Plant is presented in

Table 3.3.

Table 3.3-Raw Materials** Requirement Detail

Sr.No.

Name of the Raw

Materials

Source (TPA) Mode of

Transportation

Estimated

Quantity

(TPA)

1 Pig Iron/ Hot Metal Rashmi Metaliks Ltd,

Kharagpur; Orissa

Metaliks Pvt. Ltd. ,

Kharagpur Plant

Through Crane/

conveying

System

3,75,000

2 Mold Powder Local Market Road 949

3 Refractory (WH-A+K) Local Market Road 2065

4 Ferro Silico Rashmi Cement

Limited, Jhargram

Rail/ Road 1050

5 Inoculants Local Market Road 336

6 Magnesium Local Market Road 595




7 Slag Coagulant Local Market Road 485

8 Zinc Local Market Rail/ Road 662

9 Runner Coat Local Market Road 1789

10 Bitumen/ Epoxy Paint WRAS Approved

Vendor

Rail/ Road 1472 KL

** The above quantities are likely to vary in narrow range as the quality of inputs to

have variations.

Table 3.5-Materials Balanced For the Proposed Project

Name of the Input Materials

Quantity input in (TPA)

Name of the output Materials Quantity output in (TPA)

Hot Metal from B.F 3,75,000 D I Pipes 3,50,000

Mold Powder 949 Slag 10500

Refractory (WH-A+K) 2065 Dust & Sludge 8403

Ferro Silicon 1050 LOI, etc 15500

Inoculants 336

Magnesium 595

Runner Coat 1789

Slag Coagulant 485

Zinc 662

Bituminous Solution 1472 KL/ Year

Total 384403 384403

3.4 Availability of Water, Energy /Power Requirement & Its Sources

POWER:

The power required for the proposed production enhancement project will be 10 MW

sourced from WBSEDCL.

Table 3.6-The Power Requirement for the production enhancement project is as:

SR NO PRODUCT GROSS CAPACITY SPECIFIC

POWER CONSUPMTION

TOTAL CONSUMED

POWER

LOAD FACTOR

CONNECTED LOAD

TPA TPD TPH IN KWH IN KWH IN KWH

1 DIP 350000 1166 49 158.8 7781.2 0.80 9726.5

2 OFICE , STREET LIGHT

4

POWER REQUIRED IN KWH 7781.2 0.80 9730.5 IN MWH 7.78 9.73




TABLE 3.7-The Total Power Requirement

Sr. No Utility Existing

Requirement

Additional

Requirement

Total Source

1 Power 5.5 MW 9.73 15.23 West Bengal State

Electricity Distribution

Company Limited

WATER:

The existing plant water is 20 m3/hr (480 KLD) and additional water requirement for

the proposed expansion project is about 34.5 m3/hr (830 KLD). The break-up of water

required for existing and proposed is given in Table-3.8.

This requirement will be met from the River “Kasai‟ & ground water sources by bore

wells and Rain Water Harvesting pond. Rashmi Metaliks Limited has already obtained

permission for withdrawal of 1 MGT water from „Kasai‟ river & 0.6 MGT from bore well

and has already made another application for obtaining permission for additional 1

MGT withdrawal from‟ Kasai‟ River to SWID for industrial uses and it is in final stage

of approval. The water withdrawal permission is enclosed as Annexure-V. So, it is

clear that required water will be managed by River „Kasai‟, Bore Well and Rain Water

Harvesting pond.

Table 3.8-The Total water Requirement for the complete project (existing &

proposed) is as:


Requirement

(KLD)

Additional

Requirement

(KLD)

Total after

Expansion

(KLD)

1 Induction furnace 126 230 356

2 Centrifugal Casting 233 380 613

3 Annealing Furnace 64 64 128

4 Zinc Coating Machine 3 18 21

5 Hydraulic Pressure Testing Machine

35 62 97




6 Cement Mortar Lining Machine

10 45 55

7 Bitumen/ Epoxy Coating 4 22 26

8 Green Belt Development/ Dust Suppression

2 5 7

9 Domestic Use 3 4 7

Total 480 830 1310

3.5 Quality Assurance

DI pipes need to conform to stringent quality standards as they are used to transmit

drinking water. Pipes are produced according to the stipulations of applicable quality

standards as below:

Indian standard - IS 8329: 2000, and

International standards – ISO:2531

International standards - BS EN 545: 2002

In order to attain stipulated specifications, stringent quality assurance measures will

be enforced at every stage of production which will include chemical analysis, visual

inspection, pressure testing, pipe thickness measurement, cement lining thickness

measurement, bitumen coating thickness measurement, physical testing, etc.




4. SITE ANALYSIS

4.1 Connectivity

The project site is well connected to Howrah (110 Kms), Kharagpur and to Tata Nagar

(120 Kms) via Ghatsila. It is nearest city Kharagpur is at a distance of 4.5 Kms and

Jhargram Town 30 kms. The nearest Railway station Gokulpur railway station at a

distance of about 1.0 kms is the railway station on broad gauge line of South Eastern

Railway connecting Howrah and Jamshedpur. This distance chart of major cities and

towns in WB from the project Site is as below.







4.2 Land form, Land use and Land Ownership

The proposed capacity enhancement project will be carried out within the existing

plant area and around 10 acres of land will be required. The required 10 acres land is

already in possession by Rashmi Group in the name of M/s Rashmi Metaliks Ltd.

To Distance in kms (Approx.)

Jhargram 30

Kharagpur 4.5

Howrah 110

Tata Nagar 120

Durgapur 125

Medinipur 6.5

Haldia (Port) 92




As per existing land used pattern, land is generally flat and no major earth filling is

required for the proposed capacity enhancement project within the same premises

near to the existing DIP Unit.

4.3 Location of the Project







Total land requirement is 10 acres which is already in possession by Rashmi Group in

the name of M/s Rashmi Metaliks Ltd.

The proposed plant will be located at longitude 87017‟46.89”E and latitude

22021‟40.44”N and elevation 112 feet from mean sea level at village-Gokulpur, Dist.

Paschim Medinipur, West Bengal.

The nearest airport is Netaji Subhash Chandra Bose International Airport at distance

of about 123 KM from the proposed project site.

The proposed plant site is at distance of around 4.5 Km from Kharagpur Junction

Railway Station on Howrah- Mumbai broad gauge railway line of South-Eastern

Railway and Gokulpur Railway line is only 1.5 KM away from the project site.

Nearest port is Haldia Port which is around 135 KM away from the proposed project

site. Private Railway siding of RML is around 2 KM from the proposed project site and

generated power will be consumed the existing unit operation.

This site is favourable for proposed capacity enhancement project for following

reasons

1. Availability of adequate Land




2. Availability of Railway Siding which is only 1 KM from the proposed project site.

3. Availability of Raw Materials like hot metal which will be obtained from Rashmi

Metaliks Limited and from adjacent unit i.e. OMPL.

Pic.4.1: LOCATION OF THE PROPOSED PROJECT SITE

District wise State Map of West Bengal Kharagapur Block – I

Pic.4.2-Satellite Google Imaginary for the proposed project site




Pic.4.3-Toposheet of Project site

4.4 ALLTERNATIVE SITE SELECTION

In this case, have no option to select the alternative site because this project is an

expansion project within the existing plant premises. Hence, no alternative site where

examined.




4.5 Topography (along with map)

Based on the contour map, the Digital Elevation Model has been prepared. The

nearest neighbour method has been used to interpolate the elevation data to develop

the elevation model. This map gives clear picture that the South-Western part of the

area having higher elevation ranges from 50-79 m. Eastern part of the area has lowest

range of elevation from 22-50m. Remaining area shows the medium elevation from

35-55m.

The Digital Elevation Model for the area in 10 km radius from the proposed site is

shown below.

Pic 4.4-Satelite Immage in 10 km radius

Site Location: Village Gokulpur, Mouja-Nandarchak, Sujatpur, Khidirpur Tehsil-

Kharagpur (Block), District Paschim Medinipur, West Bengal

Site Co-ordinate:

Latitude 22˚21′40.44″N & Longitude 87˚17′46.89″E, MSL- 112 ft.




4.6 Existing Land used Pattern

Proposed plant site does not falls under the CRZ area or notified industrial area. Its

graphical coordinates longitude 87˚17′46.89″E and latitude 22˚21′40.44″N and

elevation 112 feet from mean sea level (MSL). River Kangsabati are passing approx. 4

km distance in the northern side w.r.t the project site. The project site is generally

flat, infertile, non-irrigated land. Land Use Pattern of 10KM area shown below:

Land Use Pattern Of T Area

4.7 Soil Classification

Predominantly the texture of the soil is clay. Sand, slit and clay percentage ranges

form 22-27%, 32-35% and 40-43% respectively.

Sl.

No Class

Area

(km2)

Area

(%)

1 Forest 29.90 9.51

2 Village Orchard

70.33 22.38

3 Farmland:

Fallow

119.4

2 38.00

4 Farmland:

Cropped 13.71 4.36

5

Culturable

Waste

(mainly

grass)

35.43 11.27

6

Wasteland

(mainly

laterite)

7.63 2.43

7 Urban Area

/ Paved 23.76 7.56

8 Sand 8.83 2.81

9 Water 5.28 1.68

Total of all

classes 314.29 100.00




4.8 Climate Data from Secondary Sources

A meteorological station was also established earlier at Plant site to generate site-

specific meteorological data on hourly wind speed, wind direction, ambient

temperature and relative humidity. Measurement techniques, instruments,

specification of measurements and accuracy of instruments for meteorological

parameters from the Indian Standard: 8829-1978 "Guidelines for Micrometeorological

Techniques in Air Pollution Studies" were followed for data generation. The site-

specific wind-rose generated during summer season.

Temperature – December and January constitutes winter months with daily mean

minimum temperature around 12.8oC and daily mean maximum temperature around

26.4oC. May is the hottest month with daily mean maximum temperature at 38.4oC

and daily mean minimum temperature at 25.9oC. During the study period the daily

mean minimum temperature was found to be 24.3oC and daily mean maximum

temperature around 38.7oC.

Relative Humidity – The air is generally dry in the region except during monsoon.

April and May are driest with relative humidity between 43-66%. The maximum

humidity during rainy season is 84% and minimum was 70%. High humidity is found

during daytime and low humidity values during night time in all the months. During

the study period the humidity levels were found to be 40 –71 %.

Rainfall – The annual total rainfall is 1478 mm. Over 80% of the total annual rainfall

is received during the monsoon period between July to September.

Wind Speed– The wind speed was mostly between 3.1 – 9.0 km/hour for all the

months.

WIND - The wind speed during summer season was mostly between 6.8 – 9.0 km/hr,

during rainy season it was between 5.0 – 6.8 km/hr and in winter months wind speed

ranges between 3.1 – 3.3 km/hr.




Wind Direction – The predominant wind direction is from South and South West for

all months except winter season. During winter the wind flows from north and North

West direction. The wind direction (dominant) during the study period was from south

west direction.

4.9 Social Infrastructure availability:

All infrastructure facilities such as Education, Health facilities and other Social

facilities are adequate at Kharagpur town which is around 4.5 KM and district head

quarter Medinipur is 6 KM from the proposed project site. Entire area is enjoying the

modern facilities. RASHMI Group always tries to socio-economic up liftmen of entire

area since 2006.




5.0 Planning Brief

5.1 Planning Concept (types of industries, facilities, transportation etc) Town

and Country planning/Development authority Classification

During planning phase of the proposed project the following steps will be carried out:

1. Feasibility studies

2. Technical appraisal and due diligence

3. Project development planning, permitting and consenting

4. Environmental audits and impact assessments

5. Financial and thermal modelling, business planning

6. Tariff studies, power purchase agreement

7. Conceptual and pre-engineering design

8. Implementation planning and cost estimating

9. Special studies and risk assessment

The proposed project is for enhancing the capacity of Ductile Iron Pipe Plant from

2,00,000 TPA to 5,50,000 TPA by the name of M/s Rashmi Metaliks Limited in

phase wise, at Mouza – Nandarchak (J.L. No.-124), Sujatpur (J.L. No.-139) &



The rail and road will be developed/strengthened around the plant for

transportation of raw materials. This will also enhance the transportation facilities

of the area.

As the project is envisaged to employ 200 indirect employees during construction and

operation phase and 300 direct employees so the basic infrastructure facilities like

medical facilities, schools, playground, drinking facilities, bank, post offices etc. will

be developed and the same can also be used by nearby villages.




5.2 Population Projection

The increasing in production capacity of Ductile Iron Pipe Unit from 2, 00,000 TPA to

5, 50,000 TPA in phase wise would aid in the overall social and economic development

of the region. The plant will give direct employment to about 300 people; in addition

there will be indirect employment to many more people in the form of out sourcing

jobs, business opportunities, service facilities etc. This will enhance the economic

status of the local region. Apart from the jobs, the company will provide medical and

educational facilities to the employees which can also be availed by the people around

the plant.

The Demographic and Socio economic characteristics with regards to demography,

literacy and occupational status will be describe in EIA report.

5.3 Land use Planning

Sr. No. Particulars Existing

(Acres)

Proposed

(Acres)

Total Area

(Acres)

1 Ductile Iron Pipe Unit 4 6.7 11.7

2 Raw Material Yard 2 -- 2

3 Storage Yard 2 1 2

4

Administrative Building/

Canteen 0.5 -- 0.5

5 Reservoir 1.0 -- 1.0

6 Road 0.5 -- 0.5

7 33% Green Belt 5 3.3 8.3

TOTAL AREA 15 10 25

5.4 Assessment of Infrastructure Demand

Adequate physical and social facilities are available in this area for the proposed

production Capacity enhancement project of Ductile Iron Pipe Plant from 2, 00,000

TPA to 5, 50,000 TPA in phase wise




5.5 Amenities / Facilities

All infrastructure facilities such as education, health facilities and other social

facilities are adequate at district headquarter which site makes the region adequate in

amenities.

RML will take the initiative to develop the roads of the villages to provide better

connectivity to the nearest State and National highways. Apart from this the following

amenities will be developed:

A. Street Light and Avenue Trees

B. Well Maintained park with Children‟s Play area

C. Educational Institutions

D. Primary Health Centres / Hospital

E. Healthy camps and free medical check-up should be encouraged for local

population.




6 Proposed Infrastructure

6.1 Industrial Area

Layout of the proposed capacity enhancement project has been optimized considering

the space requirements of the all the equipment and systems, buildings and

structures, green belt etc.

All facilities of the plant area will be laid out in close proximity to each other to the

extent practicable so as to minimize the extent of land required. The layout is also

facilitating the movement of men and materials between the various units both during

construction and subsequent operation and maintenance to entire project.

The general layout plan of the plant is attached in Annexure – I.

6.2 Residential Area

Residential colony does not required for the proposed production enhancement project

of Ductile Iron Pipe Plant from 2,00,000 TPA to 5,50,000 TPA in phase wise at Mouza

– Nandarchak (J.L. No.-124), Sujatpur (J.L. No.-139) & Khidipur(J.L. No.-140) Village

– Gokulpur, P.O – Shyamraipur, P.S – Kharagpur (L), Dist. Paschmi Mednipur in the

state of West Bengal because the local unskilled worker will be engaged, they will

work at plant from their own residence and the company has existing Guest house

there qualified expert will get the accommodation.

6.3 Green Belt

Extensive afforestation has been taken in the past by Rashmi Metaliks Limited (copy

of the same is enclosed as Annexure-II) at plant and will be undertaken for this

proposed capacity enhancement project which would not only act as long space in the

area but would also improve aesthetics. Local, fast growing species will be used for




Green Belt Development keeping in view the guidelines and directions of MOEF, Govt.

of India and W.B.P.C.B as well C.P.C.B.

6.4 Social Infrastructure

M/s Rashmi Metaliks Limited has well-defined ESR policy under which will Carry out

social development and welfare measures in the surrounding villages. The detail of the

ESR activities carried in the past by management of Rashmi Metaliks is briefed in

Annexure-IV. Under ESR activity RML to create partnership with its local

communities, RML under its Enterprise Social Responsibility (ESR) will take up

initiatives on three-focus areas

Education

Health & Sanitation

Sustainable Livelihood

The purpose of the ESR is to bring qualitative improvements in the lives of the

community residing in the vicinity of its activity of the activities. In addition to this,

RML focuses on sports and youth development programme, environment protection

drives and executes infrastructure development projects.

Keeping in mind the infrastructure needs of the area RML would focuses on the

following areas

Improving medical facilities in the village around the project area

Improving awareness and providing sufficient training in hygiene , sanitation

and proper diet

Encouraging people to send children to school and also educate themselves

through adult literacy programs

Improving education infrastructure by providing better teaching aid and

training for teaching faculty

Building skills among villagers as per skills requirements of the project during

constructing as well as during the operation time




Encourage entrepreneurial spirit among people and supporting such initiative

by conducting training programmes to acquire and enhance skill

Creating awareness about long term financial planning

2.5 % of the proposed project cost (Rs 4.125 Crore) will be earmarked for ESR

and will be spend in 10 year after proper planning.

6.5 Connectivity

The plant site is well connected by Road, Rail, Air and Water way. Plant is connected

to NH - 6 by a well maintained road which is passing at a distance of 15 KM from the

project site in East direction. Access road and internal roads are constructed within

the plant premises and maintained regularly.

Road Connectivity: The Plant site is well connected with NH-6 which is passing very

closed from the proposed project site.

Rail Connectivity: Nearest Railway Station is at Gokulpur, about 1.5 KM in north-

east and Kharagpur junction Railway station is around 5.0 KM from the plant site in

south-East direction.

Airport: Nearest Air Kolkata Netaji Subhash Chandra Bose International Airport

which is about 130 KM from the project site in North-East direction.

Port: Nearest port is at Haldia about 135 KM from project site in South-East

direction.

6.6 Sewerage System

Sewage from the various building in the plant as well as nearby locality will be routed

through sewage treatment aeration tanks; domestic waste water discharge will be

treated separately and used for green belt development within the premises.

6.7 Industrial Waste Management

The water treatment system of the project comprises of Water Pre-treatment Plant,

Water Dematerializing Plant, Chlorination Plant, Cooling Water Treatment Plant.




6.8 Solid Waste Management

The present practice being used for solid waste management by RML is:

From Induction Furnace solid waste is generated in the form of slag which is

utilized in Road Filling and Land Reclamation.

From Magnesium converter slag is generated which is utilized for Road Filling and

Land Reclamation.

The Runner Scrap is re melted.

Magnesium dust is used in our existing Sinter Plant.

Core sand in Casting Area as well as the same from the Annealing Furnace is used

in Land Filling and reclamation now, and will be recycled in the future.

Zinc Dust is sold to PCB certified Paint manufacturer.

Cement slurry is taken to the Effluent Treatment Plant from which the water is

recycled and the solid is either be used to manufacture brick/cement tiles or is

sold to a manufacturer of the same.

Waste oil, used oil and other hazardous wastes will be safely stored in

drums/tanks/covered shed and sold to authorized recyclers.

Organic waste will be used as organic manure in the green areas. The municipal

waste will be given to authorized agencies for suitable disposal. The detail of solid

waste management is given in Table-6.1.

Table-6.1-Solid Waste Management


(TPA)

Proposed

(TPA) Disposal Scheme

1 Core Sand & Slag

5429 9500 Used for land filling

2 Cement Slurry 572 1000 Sold, Brick Manufacturing

3 From APC Devices –Mg & Zn Dust

4800 8403 Used in Sinter Plant,

4 Scrap Variable -- Used in Process




The waste generated due the capacity enhancement will be handled as per the existing

practices. Sewage will be treated in existing sewage treatment plant.

6.9 Power Requirement & Supply / Source

POWER:

The power required for the proposed production enhancement project will be 10 MW

sourced from WBSEDCL.

Table 6.2-The Power Requirement for the production enhancement project is as:

SR NO PRODUCT GROSS CAPACITY SPECIFIC

POWER CONSUPMTION

TOTAL CONSUMED

POWER

LOAD FACTOR

CONNECTED LOAD

TPA TPD TPH IN KWH IN KWH IN KWH

1 DIP 350000 1166 49 158.8 7781.2 0.80 9726.5

2 OFICE , STREET LIGHT

4

POWER REQUIRED IN KWH 7781.2 0.80 9730.5 IN MWH 7.78 9.73

TABLE 6.3-The Total Power Requirement


Requirement

Additional

Requirement

Total Source

1 Power 5.5 MW 9.73 15.23 West Bengal State

Electricity Distribution

Company Limited




7 Environment Management Plan

Environmental Management Plan is the key to ensure a safe and clean environment.

Our plant may have taken proper pollution control measures but without a

management plan to assure its proper function, the desired results may not be

obtained.

7.1 EMP during Construction Phase

The impacts of the proposed construction phase on the environment would be

basically of transient nature and are expected to wear out gradually on completion of

the construction program. However, once the construction of the units will be

completed and its operations started, these operation stage impacts would overlap the

impacts due to the construction activities.

In order to mitigate such impacts and restrict them within tolerable levels, the

Authorities would adopt the following measures:

i) Designation and demarcation of sites for construction camps and ensuring due

provision of necessary infrastructural services as water supply, sewerage and

drainage facilities and electrification.

ii) Implementation of necessary drainage facilities, inclusive of catch pits or

sedimentation basins for the drainage of construction wastewater, prior to discharge.

iii) Regular sprinkling of water around vulnerable areas of the construction sites from

trucks or through installation of water sprinklers or any other suitable methods, to

control fugitive dust as and when required.

7.2 EMP during Operation Phase

The present practice being used by RML management in order to keep the pollution

load within the permissible limit is:




7.2.1 Air Pollution Management Plan

Fugitive Emission control :

All pollution control systems are connected to energy meters and the records

are maintained for run hours, failure time and efficiency.

Clean technologies/measures are implemented in the following way.

Flue gases are used for drying the Green pellet.

De-dusting is provided for product handling area.

Fugitive emissions are suppressed by using dust suppression system

Every possible effort is made to conserve the raw materials, energy and water

consumption to match with the international standards.

Good housekeeping practices are maintained

Raw Materials Handling Plant :

All vibrating screens are already covered to preventing the leakages of Dust

Dust suppression system (Pulse jet Bag Filter with Silicon coating bags) is

adopted to control the fugitive dust emanated during extra quantity of raw

materials unloading operations.

Raw Materials Storage system :

All discharge and feed points wherever the possibility of dust generation is there,

are provided with dust suppression system.

All material transfer points are connected with dust suppression water nozzles to

avoid the pollution

Control of Point Emission :

Clean gases having less than 150 mg/Nm3 of dust content are exhausted

through a stack of height 35 m height.

The Detail of Existing APC devices are mentioned in Table 7.1 and their

characteristics in Table-7.2.




Sr. No. Details Installation capacity as

per EC, & NOC Awarded

Existing Machineries

Air Pollution Control System

Stack Detail

1 Induction Furnaces

2 X 8 MT with 6 Crucibles

2 X 8 MT with 4 Crucibles

Swivelling Hood, Spark Arrestor, Bag Filter & ID Fan.

Bag filter- Capacity

60,000 m3/hr

Existing Common Stack Height:- 35 meter from GL

2 Centrifugal

Casting machine

10 X 5 TPH 10 x 5 TPH Not Required Not Required

3 Magnesium Converter

2 X 18 TPH 2 X 18 TPH Common Bag Filter With one in Stand By Mode.


4 Annealing Furnaces

2 X 30 TPH 2 X 30 TPH Not Required Existing Common Stack Height:- 35 meter from GL

5 Zinc Coating Machines

5 X 10 TPH 3 X 10 TPH Common Bag Filter

Bag filter- Capacity 25,000 m3/hr


6 Cement Motor Lining & Cement Curing system

5 X 15 TPH 4 X 15 TPH Not Required Existing Common Stack Height:- 30 meter from GL

7 Bitumen Coating Machine with per-heating & Post-heating Furnaces

5 X 15 TPH 4 X 15 TPH Not Required Existing Common Stack

Height:- 35 meter from GL




Characteristic of Pollutant Emission Source: Table-7.2

Source Pollutants Control measures

A. Air pollution

B. Domestic wastewater

C. Solid Waste

Dust and Fumes

Waste water

Dust

Bag / cascade filters would be provided

in various sections of material handling and processing units for controlling air

pollution. The waste gases would be discharged through tall stacks to ensure adequate dispersion and

dilution of pollutants.

To be used for green belt.

Collected dust from the control devices

will be recycled in the process.

8 Sand Drying & conveying system

02 Nos. 02 Nos. Existing Common Stack Height:- 15 meter from GL

9 D.G. Set 01 x 725 KVA 01 x 725 KVA

All DG Sets are acoustically enclosed and as per CPCB norms

Existing Common Stack Height:- 10.5

meter from GL

10 Core Making

Machine

03 Nos. 02 Nos. Not Required Not Required

11 Hydraulic

Pressure Testing

Machine

05 Nos. 04 Nos. Not Required Not Required

12 Mould Grinding

and Arc Welding

machines

03 Nos. 02 Not Required Not Required

13 Core shooter

Machine

04 Nos. 02 Not Required Not Required

14 Finishing Unit 08 Nos. 05 Not Required Not Required




The detail of proposed APC devices for the capacity enhancement project is mentioned

in Table-7.3

Table – 7.3-Proposed APC Devices for Expansion project

Sr. No. Particulars Quantity/ capacity

Name of the APC Devices

Proposed Stack Height

1 15 t Induction furnace

02 Nos. with 6 crucibles (4 in operation & 2 stand by)

Pulse Jet Bag Filter of sufficient capacity, Swivelling Hood, Spark Arrestor, ID Fan for individual Induction Furnace

35 Meter Individual

2 Annealing Furnace

02 x 30 TPH Not Required 35 Meter Individual

3 Magnesium Converter

02 x 18 TPH Bag Filter 35 Meter Individual

4 Zinc Coating Machine

01 x 10 TPH

Bag Filter 35 Meter

5 Centrifugal Casting Machine

10 x 5 TPH

Not Required 35 Meter

6 Hydraulic Pressure Testing Machine

02 Nos.

Not Required -----

7 Cement Mortar Lining/ Curing Machine

03 x 15 TPH Not Required 35 Meter

8 Bitumen Coating Machine

02 x 15 TPH Not Required

35 Meter

9 Mould Grinding/ Pipe socket Grinding

02 Nos. Not Required -----

10 Sand Drying & Conveying System

01 No. Not Required 15 m

11 Finishing Line 02 Nos. Not Required -----

Existing APC DEVICE pictures are shown as Figure7.1




7.2.2 Noise Pollution Management Plan

Noise will be minimized through regular maintenance of equipment / machines. Low

noise generating equipment is being used for the plant. Proper vibration dampening

arrangement is being provided to minimize the noise generation. It is ensured that the

noise level at plant boundary compiles with the standards of 75 dB (A) during day

time and 70 dB (A) during night time. The layout of the plant and greenbelt is

designed appropriately to achieve the standard. In other case enclosure or sheds is

constructed. Ear plugs / ear muffs are provided to personal working near high noise

areas to ensure that no plant personnel are over exposed. Sound absorbing material is

provided in rooms where both the noise source and plant personal is present so that

the reflecting sound is absorbed.




7.2.3 Water Pollution Management Plan

Waste water disposal method of septic tank is being followed as per the standard

regulations of PHED W.B. Neutralized water is let into the factory‟s general drainage

network. Outlet of the general drainage network is sent to the Effluent Treatment

Plant for further neutralization and recirculation. We also have a storm water

drainage network in place separately where the water is taken for Rain water

Harvesting.

Effluent Treatment Plant:

At present solid waste of around 106 kg/day coming out of the cement lining

process. This slurry is pumped into sedimentation chambers of the E.T.P. The

sediments thus deposited into the sedimentation chambers. These sediments are

periodically removed with the help of a Mechanical shovel or Excavator. The solid

waste thus collected is removed to a drying bed and dried. After that it is

converted to brick or tiles or is sold to a manufacturer of the same. The turbid water

is taken for further neutralization since the ph value is around 12 and adequate

acid dozing is done to bring the ph nearer to 7. The said neutralized water is re-

circulated into the process. The detail of existing ETP plant is shown in Figure 7.2.




7.2.4 Pathway of Pollutants (Seepage into Groundwater)

Raw materials stock pile, open dump yard is made inside the plant premises, which

have the potential to contaminate the groundwater level through seepage. Following

mitigation measures are recommended to avoid any groundwater contamination:

1. Stockpiles of all raw materials and coal is made on pucca platform (preferably

concrete / clay compacted) and provided with garland drains and sedimentation

pit.

2. Stockpiles preferably being covered using tarpaulin, etc.

3. Wind breakers in the form of tin sheds are installed around open stock yard.

7.2.5 Solid Waste Management Plan

The present practice being used for solid waste management by RML is:

From Induction Furnace solid waste is generated in the form of slag which is

utilized in Road Filling and Land Reclamation.

From Magnesium converter slag is generated which is utilized for Road Filling and

Land Reclamation.

The Runner Scrap is re melted.

Magnesium dust is used in our existing Sinter Plant.

Core sand in Casting Area as well as the same from the Annealing Furnace is used

in Land Filling and reclamation now, and will be recycled in the future.

Zinc Dust is sold to PCB certified Paint manufacturer.

Cement slurry is taken to the Effluent Treatment Plant from which the water is

recycled and the solid is either be used to manufacture brick/cement tiles or is

sold to a manufacturer of the same.

Waste oil, used oil and other hazardous wastes will be safely stored in

drums/tanks/covered shed and sold to authorized recyclers.

Organic waste will be used as organic manure in the green areas. The municipal

waste will be given to authorized agencies for suitable disposal. The detail of solid

waste management is given in Table-7.1.




Table-7.1-Solid Waste Management


(TPA)

Proposed

(TPA) Disposal Scheme

1 Core Sand & Slag

5429 9500 Used for land filling

2 Cement Slurry 572 1000 Sold, Brick Manufacturing

3 From APC Devices –Mg & Zn Dust

4800 8403 Used in Sinter Plant,

4 Scrap Variable -- Used in Sinter Plant,

7.3 Occupational Health Management Plan

Exposure problems to noise, dust, heat and gases are the main occupational hazards

identified in this project. Silicosis, Bronchitis and Noise induced hearing loss are the

occupational health hazards identified from the plant. Workers involved in raw

material handling activity, dust and ash handling are exposed to high dust levels.

Over a long period of time such exposure is likely to result in respiratory problems

and occupational health problems.

Engineering measures is implemented to reduce the dust generation at the originating

point by installing appropriate control devices and / or regular water sprinkling.

Regular monitoring of work environment for humidity, heat, illumination, metal

fumes, gases, dust, etc is carried out and shall be done in near future also. Plant

personnel working in dust prone areas are encouraged to wear personnel protective

equipment like air filters over their nose.

Job rotation schemes are practiced for over-exposed persons, including heat stress.

Proper illuminations are maintained at each and every nook and corner of the work

places.




Regular advice is/ will be given to the workers through special campaigns and

illustrations related to safe work practices so that they do not develop any muscular

strain or fatigue during their work schedules. It is/ will be ensured that workers are

not exposed above the threshold noise levels through suitable administrative controls.

PPE like earplugs and muffs are provided and administrative pressure applied for

using them. Auditory examination by qualified doctors upon the first employment and

thereafter periodic examination are conducted which include determination of

auditory threshold for pure tones.

Medical check-up of all the employees will be done during pre-employment. The

healths of workers are regularly monitored under an occupational surveillance

programme. Under this programme, all the employees are subject to detailed medical

examination at the time of employment. The medical examination covers the following

tests.

General Physical Examination and Blood Pressure

X-Ray Chest and ECG

Sputum Examination

Routine Blood and Urine Examination

Lung Function Test

Eye Test

Audiometric Test

The medical histories of all the employees will be maintained in a standard format.

Thereafter the employees are subjected to medical examinations on annual basis. The

following tests results will upgrade the data base of medical history of the employees.

The recommended medical examinations are shown in following Table.

Recommended Medical Examination for Employees

Sr. No. Disease Tests to be conducted

1. Heart Disease ECG, blood for lipid profile, stress test, 2D-Echo and other tests are required




2. Lung Diseases Total Count (WBC Count), Differential Count, Sputum examination, X-ray Chest, Alveolar macrophage

3. Respiratory Disorders Differential Count, ESR, X-ray chest, Lung Function Tests (Spirometry) and Sputum examination

4. Diabetes Random blood sugar, urine sugar, if positive, BSL-Fasting / pp, Diabetic profile

5. Hypertension Blood Pressure reading, if required Renal profile, ECG and stress test

6. Abdomen Pain Routine Urine for Albumin, Sugar bile salts, Liver function test

7. Ear, Nose, Throat Routine Eye Test, Fungus examination, retinopathy test, color blindness, nose infections, auditory threshold for pure tones.

Plant personnel working in dust prone areas will be encouraged to wear personnel

protective equipment like air filters over their nose. Job rotation schemes will be

practiced for over-exposed persons. It will be ensured that workers are not exposed

above the threshold limits prescribed above through suitable administrative controls.

PPE like earplugs and muffs will be provided and administrative pressure applied to

the workers to using them despite uncomforted. Workers exposed to mechanical

accident-prone areas will be given personal protective equipment (PPE). The non-

respiratory PPE includes tight rubber goggles, safety helmets, welders hand shields

and welding helmets, plastic face shields, ear plugs, ear muffs, rubber aprons, rubber

gloves, shoes with non-skid soles, gum boots, safety shoe with toe protection. All

safety and health codes prescribed by the Bureau of Indian Standards are

implemented. Safety data sheets of the hazardous chemicals are displayed at specific

locations. The data is in English, Hindi and Bengali language / script.

7.4 Greenbelt Development Plan

RML has developed 20-25 % AS GREEN BELT copy of the same is enclosed as

Annexure -II. While selecting trees species following things will/ are be considered:

The tree species to be selected for the plantation will be pollutant tolerant, fast

growing, and wind firm, deep rooted. A three tier plantation is proposed comprising of

an outer most belt of taller trees which will act as barrier, middle core acting as air

cleaner and the innermost core which may be termed as absorptive layer consisting of

trees which are known to be particularly tolerant to pollutants.




7.5 Rain Water Harvesting Plan

RML has 02 nos. rain water harvesting pond having 95,000 cubic meter water storage

capacity. Copy of the same is enclosed as Annexure-III. Surface runoff from the plant

area is collected in the water reservoir located inside the plant. This stored water is

used inside the plant. The groundwater depth at the site is minimum 5 m during

post-monsoon season. Due to presence of Kasai River and their nalas the natural

recharge rate is high by nature.

Further it is proposed that the rain water harvesting and ground water recharge

structure may also be constructed outside the plant premises after the consultation /

permission with local gram Panchayat and village head to augment ground water level

of the area.

7.6 Road Connectivity

A proper road is available for daily use, transportation of raw materials and finished

product The Plant site is well connected with NH-6 which is passing very closed from

the proposed project site.

7.7 Monitoring Scheme

Monitoring of the stacks of existing stacks of Dip Units is done frequently by WBPCB

on quarterly or half yearly basis. Third party monitoring for ambient, fugitive, noise &

water will be carried out once in a year by WBPCB approved laboratory/

NABEL/MoEF approved lab. Copy of the same is enclosed as Annexure-VI.




8. Rehabilitation and Resettlement (R & R) Plan

8.1 Introduction

Total land requirement is 10 acres which is already in possession by Rashmi Group in

the name of M/s Rashmi Metaliks Ltd.

There was no residential habitat, so Rehabilitation and Resettlements (R&R) plant is

not required.




9. Project Schedule & Cost Estimates

9.1 Likely date of start of construction and likely date of completion (time

schedule for the project to be given)

Successful execution of the project largely depends on the coordinated approach of

the project implementing agencies. Proper co-ordination between the various project

execution agencies, monitoring of project schedules, appropriate mobilization of

manpower and other resources can achieve cost control and timely completion of the

project.

The proposed enhancement project of Ductile Iron Pipe Plant from 2, 00,000 TPA to 5,

50,000 TPA in phase wise at Mouza – Nandarchak (J.L. No.-124), Sujatpur (J.L. No.-

139) & Khidipur (J.L. No.-140) Village – Gokulpur, P.O – Shyamraipur, P.S –

Kharagpur (L), Dist. Paschmi Mednipur in the state of West Bengal is expected to be

commissioned within 60 months from the date of Environment Clearance issued by

WBPCB.

Civil work including building and equipment foundations are to be completed before

the equipment arrives at site.

All auxiliary system, plant water system needed for commissioning the plant should

be completed so as to match the schedule for initial trial of the main equipment.

9.2 Estimated project cost along with analysis in terms of economic viability

of the project

The Capital costs have been worked out on the basis of prices prevailing today and do

not include any provision for future escalation in costs during implementation period.

The various assumptions are made while estimating the capital cost estimation. The




cost estimate is based on the data available from similar type of steel projects. The

Estimated cost break up is given below:

Sr. No. Particulars of facilities Capacity Estimated Cost (Rs. Cores)

1. Ductile Iron Pipe Unit- PHASE-I

1,50,000 TPA 75

2. Ductile Iron Pipe Unit- PHASE-II

2,00,000 TPA 90

Total 165




10. ANALYSIS OF PROPOSAL

10.1 Financial and social benefits with special emphasis on the benefit to

the local people including tribal population, if any in the area.

Based on the growing demand in the state of West Bengal over the next 10 years, the

proximity of the project location is an advantage with respect sustainable growth of

the Rashmi Group. The financial viability also shows a good Rate of return from the

project for Rashmi Group. The project is environmental friendly as it is using the

Green Field Clean Technology. Considering the above, RML is planning to go-ahead

with the project, once it gets all the statutory approvals.

Employment: Preference will be given for locals for employment based on

qualifications &requirement

Medical facilities: Medical facilities will be provided for employees as well

as people of nearby villages

Educational facilities: Basic educational and vocational facilities will be provided

for the children of employees as well as nearby villagers

Infrastructure facilities: Approach roads will be developed at par with plant roads

Additional Facilities: The establishment of project will facilitate additional

auxiliary facilities like banking, post office & recreation facilities etc.

Other Tangible Benefits:

The overall quality of life of the people will improve due to better means of

transportation and communication. As a result, mobility will increase, which will

substantially increase job opportunities. The social exposure of the villagers will be

enhanced and will be able to related better to the outside world.

*********************************************




ANNEXURE NO. – I

PLANT LAYOUT




ANNEXURE NO. – II

Green Belt Development




ANNEXURE NO. – III

Existing Rain Water Harvesting

Facility




ANNEXURE NO. – IV

ESR Activities Carried in Past By

RML




ANNEXURE NO. – V

Water Extraction Permission




Certificates




ANNEXURE NO. – VI

Stack & Ambient Analysis Report




STACK GAS ANAYSIS REPORT




.




AMBIENT AIR ANALYSIS REPORT




ANNEXURE NO. – VII

Valid CFO, NOC & EC Detail




Valid CFO




NOC




NOC Amendment




EC Detail




EC Amendment




EC COPY

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