PRE-FEASIBILITY REPORT FOR PROPOSED EXPANSION OF EXISTING ASBESTOS CEMENT SHEETS & ACCESSORIES PRODUCTION FROM 72000 TPA TO 175000 TPA OF Limited JASIDIH Dist.: Deoghar 814 142 (Jharkhand)
INDEX Contents Page Nos. 1. Executive Summary 01 2. Introduction of the Project / Background Information 01 3. Project Description 04 4. Site Analysis 10 5. Planning Brief 13 6. Proposed Infrastructure 16 7. Rehabilitation and Resettlement (R & R) Plan 17 8. Project Schedule & Cost Estimates 17 9. Analysis of Proposal 18
1. EXECUTIVE SUMMARY : HIL Limited (formerly Hyderabad Industries Limited) is one of India s most respected names in the building material solutions industry. HIL is a pioneer of green building materials, producing roofing solutions, panels, walling blocks, high-quality pipes and fittings, and industrial insulation. As per EIA Notification 2006 and amendments thereof, the proposed expansion project is A category project and listed in Schedule of EIA Notification 2006 at Sl. No. 4(c). The present proposal of HIL is for expansion of production capacity from existing 72000 TPA to 175000 TPA within existing premises. No additional land is being acquired for the proposed expansion project. The project site is well connected with road and railway, nearest city Deoghar is located at distance of 5 km and Mayurakshi River (seasonal) passing in east direction at distance of 3.5 km. There is no forest, national park, wild life sanctuary, eco sensitive areas in surrounding 10 km radius. Interstate border of Bihar-Jharkhand is 7 km. in North direction of the project zone. 2. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION : (i) Identification of Project & Project Proponent Project ; M/s. HIL Ltd. is situated in Industrial Area, Jasidih, Dist. Deoghar in Jharkhand State. M/s HIL is engaged in the manufacturing of Asbestos Cement Sheets & Accessories since 1980. The existing rate of production is 72000 MT/Annum and proposed to increase production by 103000 MT/Annum i.e. total 175000 MT/Annum. The manufacturing process involves unit operations and processes. The HIL has on site storage facilities for various raw materials such as White Chrysotile Asbestos, cement and fly ash. Manufacturing facilities areas are spread over about 87129 sq. meters of land in safe & hygienic environment. HIL is the largest manufacturer of Asbestos Cement Sheets & Accessories in Jharkhand. 1
Project Proponent ; Pitabas Behera General Manager HIL Ltd. Industrial Area Jasidih - 814142 Mob.: 9431137793 (ii) Brief description of nature of project : M/s HIL is engaged in the manufacturing of Asbestos Cement Sheets & Accessories since 1980 at the existing project location. The existing capacity 72000 MT/Annum and proposed increase capacity 103000 MT/Annum i.e. total 175000 MT/Annum. (iii) Need for the project and its importance to the country and or region The asbestos cement sheeting industry is growing at a healthy 7-8 percent a year. Even as the real estate sector has taken a hit due to the slowdown and subsequent reduction in demand, the asbestos cement (AC) sheet industry, which provides roofing material for about 50 per cent of the rural population, is relatively untouched. Driven by steady demand from the rural markets, the industry is growing at a steady. There are some 18 big players in the industry catering to the domestic market. The industry employs about 300,000 people and its annual turnover is around Rs 4,000 crore, about 12 percent of which goes to the states as direct and indirect tax. There is a huge housing deficit in rural India as many houses currently fall into the category of kaccha houses, thereby leaving tremendous opportunity of sustained growth of new age construction practices and products. The demand for asbestos cement sheets will not come down anytime soon. Few products can compete with asbestos cement roofing sheets due to its longevity and lower cost. Majority of rural population of our country is still living under asbestos roofed buildings due to economic conditions. M/s HIL Ltd. is in the business of Asbestos Cement Sheets since last 69 years with Head Quarters located at Hyderabad. The demand for asbestos cement sheets is increasing in the region & entire country. After proposed expansion M/s HIL will cater to the demand of various products locally. The Project will create direct & indirect employment opportunities in the nearby areas. HIL will employ local people from the nearby villages 2
depending upon the availability of skilled & un-skilled man-power surrounding the project site. In operation phase, the proposed project would require significant workforce of non-technical and technical persons. Migration of highly educated and skilled experience will result in increase of literacy in the surrounding villages. (iv) Demand Supply Gap: The demand supply gap of Asbestos Cement sheets etc. are increasing over the years. The consumption of asbestos products in 2012-13 was about 104100 tonnes and requirement is increasing year by year. At present the industry s total production capacity is about 4.5 million tonnes and a small part of the output is exported to other countries. The growing demand and supply gap in the region has compelled HIL to expand its existing production capacity. (v) Imports vs. Indigenous Production: The industry is thriving on the import of about 350,000 tonnes of Chrysotile Asbestos every year from Canada, Brazil, Russia, Zimbabwe and Kazakhstan for production of AC Sheets and Pipes. Asbestos is also mined in India, particularly Rajasthan, but the quantity and quality are of no relevance to AC Sheet production. HIL will import Chrysotile Asbestos from Canada, Brazil, Russia and other countries through seaport and then by roads through closed containers. (vi) Domestic/Export Market: The asbestos industries total production capacity is about 4.5 million tonnes and a small part of the output is exported. (vii) Employment Generation (Direct & Indirect) At present HIL has 95 nos. direct staff and 80 Nos. indirect manpower. No additional manpower is required after proposed expansion project. However, proposed expansion of HIL will generate employment opportunities in indirect mode. In indirect mode people will be appointed as company authorized dealers & sellers and approx. 50 nos. of indirect manpower will be required for cement feeding and loading. 3
3. Project Description: (i) Type of project including interlinked and inter dependent project: M/s HIL is engaged in the manufacturing of Asbestos Cement Sheets & Accessories since 1980 at the existing project location. The existing capacity is 72000 MT/Annum and proposed to increase capacity by 103000 MT/Annum i.e. total 175000 MT/Annum. There are no interlinked and inter dependent project with the proposed expansion project of HIL. (ii) Location: Village : Jasidih Block : Deoghar District : Deoghar State : Jharkhand Refer Project Location Map of HIL Ltd. on next page. (iii) Details of alternate sites Considered and the basis of selecting the proposed site, particularly the environment consideration gone into should be highlighted. No alternate sites have been considered for the proposed expansion project as all the expansion activities will be carried out within existing premises and no additional land will be required for the proposed expansion project. (iv) Size or magnitude of operation: HIL existing rate of production is 72000 MT/Annum and proposed to increase production by 103000 MT/Annum i.e total 175000 MT/Annum. All the expansion activities will be carried out within existing premises of 21.53 acres. No additional land is required for the proposed expansion. 4
HIL PROJECT LOCATION MAP Howrah Delhi Main Line Deogarh Town Project Location :- HIL LTD. INDUSTRIAL AREA JASIDIH DEOGHAR (JHARKHAND) LONGITUDE: 86 38'24.61"E LATITUDE : 24 30'57.47"N MSL : 264 M. Triveni Smelters Pvt. Ltd., Raipura, Fatuha, Patna, Bihar 5
(v) Project description with process details: (a schematic diagram/flowchart layout, components of the project) Refer Manufacturing Process Flow Chart on next page (vi) Raw Material required along with estimated Quantity, likely source, marketing area of final products, mode of Transport of raw material & finished product. Raw material Existing 72000 MT per Annum Proposed 175000 MT per Annum Cement 23976 58275 Fiber 3636 8838 Slag 5522 13423 Source Nearby Cement Plants Maiher, M.P Imported (Russia) Giridih & Ramgarh, Jharkhand Mode of Transport By Rail / Road By Ship up to the port then by Road (Closed containers) By Road (Trucks) DWR 821 1995 Plant Generation Internal MMF002 166 403 Patalganga, Maharashtra By Road (Trucks) Pulp 1037 2520 Chennai By Road (Trucks) Flyash 18490 44940 Nearby Power Plant Bikeswar Termal Power Station, W.B By Road (Trucks) FR2 864 2100 Rajasthan By Road (Trucks) (vii) Resources optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined. In the proposed expansion project no fuel will be used for heating purposes. Moreover, water is being conserved by recycling and reuse in process. 6
MANUFACTURING PROCESS FLOW CHART Dust Free Air Water Raw Asbestos Cement & Fly Ash Binders Dust collector with automatic Bag Shaking Device Bag Opening Device Cone Tanks Edge Runner Mill Clarifier Fibre Silo Weigh Hopper Slurry Mixer Collected Materials Storage Mixer Dilution Water Back Water 6 VAT Sheet Machine Water from Cone Tank Green Asbestos Cement Sheets on Conveyor Green Sheets Trimming Waste Dissolver Corrugation Stripping Heating Chamber Atmospheric Curing Finished Products for Dispatch 7
(viii) Availability of Water its source, Energy/Power requirement and source should be given At present & after expansion in future also, water requirement is fulfilled through bore wells & open wells inside premises. Water requirement will be approx. 189 KLD (Kilo Liters per Day) after proposed expansion. Water requirement details are as under; Requirement Existing Proposed Make up water for process 77 KLD 186 KLD Domestic & other Gardening purpose 3 KLD 3 KLD Total 80 KLD 189 KLD (ix) Quantity of waste to be generated (Liquid and solid) and scheme for their management. WASTE WATER GENERATION & TREATMENT ; The HIL project will not generate any industrial effluent and will achieve Zero Discharge Concept. Entire water will be reused back in to the process. Only 1.8 m 3 /day of domestic waste water will be generated. This waste water will be diverted into a septic tank followed by soak pit inside the existing premises. Air Pollution: Fiber Bag Opening and Milling The fiber bags shall be slit open in closed automatic Bag Opening Device (BOD). The empty bags shall be lifted by a hooking device attached within the bag opening device and carried to the attached bag shredder unit and the fiber after passing through the lump breaker shall be collected in the attached blender where some water shall be added to maintain the process in wet condition. When all the bags in one batch are emptied in to the blender, the fiber in wet form shall be taken to the Edge Runner Mill (ERM) with a screw conveyor and elevator which is also joined by the shredded bag pieces from the shredder unit. Here at ERM some more water is further added to the fibre for milling operation. The bag opening device & the edge runner mill shall be kept under negative pressure by means of a Bag Filter Type Dust Collector with reverse pulse jet cleaning which is connected to a blower. The delivery point of the blower is connected to a stack of 7.5Mtr. height. 8
Cement and Fly ash Feeding o The cement feeding point will be connected to a bag filter type dust collector with reverse pulse jet cleaning and with a blower driven by an electric motor. Stack height would be maintained upto 30Mtr. o The Fly ash feeding point shall be connected to the same above bag filter type dust collector with reverse pulse jet cleaning and with a blower driven by an electric motor. The outlet is connected to the stack of 5Mtr. height. Details of Existing & Proposed Air Pollution Control Devices ; ID NO. NAME OF PCE ATTACHED TO DE 1 Strategic Dust collector BOD DE 2 Strategic Dust collector DRY WASTE DE 3 Strategic Dust collector CEMENT FEEDING DE 4 SILO TOP FLYASH SILO No.1 DE 5 SILO TOP FLYASH SILO No.2 DE 6 SILO TOP FLYASH SILO No.3 DE 7 SILO TOP CEMENT SILO DE 8 WEIGH HOPPER CEMENT WEIGH HOPPER DE 9 SILO TOP FR2 SILO DE 10 Strategic Dust collector FR2 FEEDING DE 11 SILO TOP SLAG DE 12 Strategic Dust collector CEMENT & SLAG MIXING TANK Solid Waste Management: All solid waste generated during the process are recyclable in nature. The details are as under ; Nature of Solid Waste Quantity Management Broken Sheets Sediments from Cone Tank 1750 TPA 17.5 TPA These sheets will be pulverized and recycled in the close circuit manufacturing process These waste will be processed through ball mill and recycled in the close circuit manufacturing process The HDPE Fibre bags are shredded in the Shredder unit attached to the Bag Opening Device and sent along with the fibre into the fibre mill through the screw conveyor. 9
The wet waste accumulated during the scheduled cleanings are continuously recycled though the Wet Ball Mill in slurry form. Periodically recycled after the containers placed beneath the rotary valve of the respective Dust Collectors are adequately filled in. The settling solids in slurry form from the recuperating tank are collected in a clarifier (where it is kept under suspension) and reused in the process. 4. Site Analysis: (i) Connectivity: HIL is situated in Industrial Area, Jasidih, Dist. Deoghar in the state of Jharkhand. Jasidih is situated on Howrah Delhi Main Line of ECR. NH 333 is approx. 1km. away from the project site which connects district headquarters and rest of country from project site. Project site can be assessed by road and rail from all over the India. Nearest Airport is located at Ranchi. Jasidih Junction is approx 0.5 Km. from the project site. ii) Land Form, Land use & Land ownership: Land Form :- Land Use :- Land use of the project area and surrounding is industrial in nature. Project site is located within industrial area. Proposed expansion will be carried out within existing premises of HIL. No additional land is being acquired for the proposed expansion project. Land Ownership :- HIL project land of 21.5 Acres was allotted by Industrial Area Development Authority, Patna, Govt. of Bihar on leasehold basis in the year 1979 for establishment of asbestos cement roofing sheets project. iii) Topography (along with map): The region contains several clusters of rocky hills covered with forest, but series of long ridges with intervening depressions. Most of the rolling uplands are cultivated by highland crops. The average elevation of the district is 247Mtr. above MSL, However hill ranges like Phuljari (750Mtr.), Teror (670Mtr.) and Degaria (575Mtr.) break the monotony of the landscape. The general slope of the district is from north west to south 10
east. Geologically the district is mainly covered by chhotanagpur granite gneiss of Archean age with paches of alluvium, sandstone and shale of Gondawana formations. Important rivers flowing in the district are the Ajay, the Paltro etc. These rivers gather a large number of tributaries which form the land scape full of Tanrs and Dons. 5 KM. RADIUS LOCATION MAP iv) Existing land use pattern (Agriculture, non agriculture, forest, water bodies including CRZ), shortest distance from the periphery of the project forest, national park, wild life sanctuary, eco- sensitivity area, water bodies Distance from HFL line, CRZ notification for notified industrial area. There is no reserved forest, national park, wild life sanctuary, eco sensitive zones in surrounding 10 Km of the plant boundary. CRZ is not applicable to the project. 11
v) Existing Infrastructure ; All the required infrastructures are available within existing premises of HIL at Jasidih, Deoghar, Jharkhand. In addition to existing infrastructure, for proposed expansion, new infrastructure will be developed or existing will be upgraded. vi) Soil Classification: The district is characterized by a wide variety of soils, which can be classified as clayey, loamy, sandy loam and lateritic. Sandy loams to loamy sands are common in uplands whereas loam to sandy loam is common in lowlands. The soils occurring in different landforms have been characterised during soil resource mapping of the state on 1:250,000 scale (Haldar et al. 1996) and three soil orders namely Entisols, Inceptisols and Alfisols were observed in Deoghar district (Fig.1 and table 1). Alfisols were the dominant soils covering 50.0 percent of TGA followed by Inceptisols (42.0 %) and Entisols (6.3 %). vii) Climatic Data ; The temperature variations in different three seasons are given in table below: Period Min m. Temperature Max m. Temperature Mar. June 12 0 C 22 0 C 35 0 C 44 0 C Jul. Oct. 14 0 C 20 0 C 31 0 C 38 0 C Nov.- Feb. 8 0 C 11 0 C 15 0 C 30 0 C Rainfall in Study Area : Period Rainfall in mm. (Source : IMD Report) 2010 641.2 2011 711.8 2012 661.2 2013 1141.1 12
viii) Social Infrastructure available ; All the social infrastructure, as mentioned below, are available within 1-5 Km. of HIL Project Site. Schools (Primary as well as secondary) Colleges (Science, commerce, Arts, engineering, medical, pharmacy, education) Health centers, dispensaries, hospitals Electricity Drinking water supply Banks (Cooperative as well as nationalized) and credit societies 5. Planning Brief: i) Planning concept (type of Industries, facilities, transportation etc) Town and country planning/development authority classification. Type of Industry : HIL Limited (formerly Hyderabad Industries Limited) is one of India s most respected names in the building material solutions industry. HIL is a pioneer of green building materials, producing roofing solutions, panels, walling blocks, high-quality pipes and fittings, and industrial insulation. As per EIA Notification 2006 and amendments thereof, the proposed expansion project is A category project and listed in Schedule of EIA Notification 2006 at Sl. No. 4(c). The present proposal of HIL is for expansion of production capacity from existing 72000 TPA by 103000 TPA i.e. total 175000 TPA within existing premises. No additional land is being acquired for the proposed expansion project. ii) Population Projection: No major population influx is anticipated due to the proposed expansion project. iii) Land Use Planning Site Layout Plan showing existing & proposed facilities along with green belt area is shown herewith on next page. 13
HIL SITE LAYOUT PLAN 14
iv) Assessment of Infrastructure demand (physical & social) : The basic infrastructure such as roads, electricity, transportation, drinking water supply, health centers and hospitals, school, colleges, sanitation facilities are available in the vicinity. The proposed project is not going to exert any unbearable load on any of these resources. v) Amenities/Facilities: Canteen, Laboratory, rest room, medical facilities, drinking water, etc. are available within existing project premises. 6. Proposed Infrastructure: No new infrastructure is planned for the proposed expansion project. i) Residential Area (Non-Processing Area): No residential area is envisaged in the proposed project. ii) Green Belt Area : 7.15 Acres of area is being utilized as green belt are and will be developed more precisely and maintained after proposed expansion. iii) Social Infrastructure: All infrastructure facilities are existing in the vicinity of the HIL. iv) Connectivity HIL is situated in Industrial Area, Jasidih, Dist. Deoghar in the state of Jharkhand. Jasidih is situated on Howrah Delhi Main Line of ECR. NH 333 is approx. 1km. away from the project site which connects district headquarters and rest of country from project site. Project site can be assessed by road and rail from all over the India. Nearest Airport is located at Ranchi. Jasidih Junction is approx 0.5 Km. from the project site. v) Drinking Water Management : After proposed expansion existing borewell & open wells will be used as drinking water source. 15
vi) Sewerage System: No industrial waste water will be generated from the proposed project. All the domestic waste water will be disposed off through septic tank followed by soak pit inside premises. vii) Industrial Waste Management: Waste Water Generation & Treatment ; No industrial waste water will be generated from the proposed expansion project. Only domestic waste water will be generated which will be disposed off through septic tank followed by soak pits inside the premises. Air Pollution: For proposed expansion project air pollution control system (pulse jet bag filters) will be installed at all strategic locations. viii) Solid Waste Management: After proposed expansion all the generated solid waste will be managed as per existing prevailing practices inside the premises as explained above. ix) Power Requirement & Supply/Source: 1070 KVA of power is being utilized at present for the HIL Project. After proposed expansion no additional power will be required for project operations. Existing 1 No. 1010 KVA & 1 No. 625 KVA DG Set will be utilized for power back-up after proposed expansion. 7) Rehabilitation & Resettlement (R & R) Plan: As there is no requirement of additional land for the proposed expansion project & HIL is already a running project which is under operation for last 35 years, so there is no need of any new Rehabilitation and Resettlement (R&R) Plan. 8) Project Schedule & Cost Estimates: i) Likely date of start of construction & likely date of completion. 16
Expansion activities will be started immediately after obtaining Environmental Clearance from MoEF & CC, Govt. of India. Expansion activities will be completed within 4-6 months time after start. ii) Estimated Project cost along with analysis in terms of economic validity: Total Estimated Cost of proposed expansion project is Rs. 17.00 Crores. Detail break-up is as under ; Particulars Cost (Rs. Lakh) Land (Existing on Lease) Existing Building & Civil Works 500.00 Plant & machinery 580.00 Pollution Control Equipment Existing Green Belt Maintenance Existing TOTAL COST OF EXPANSION PROJECT 1700.00 RECURRING COST FOR ENVIRONMENTAL MANAGEMENT Existing 9) Analysis of Proposal (Final Recommendation): (Financial & Social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area.) After proposed expansion of HIL approx. 50 nos. of indirect manpower will be required for cement feeding and loading operation which will be preferably hired from local villages surrounding the project area. As the project area is located in Santhal Pargana province of Jharkhand state where majority of population are schedule tribes and local tribal people will be benefitted in direct and indirect way. Moreover, State Govt. will get more revenue from HIL after proposed expansion.. * * * * * 17