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Draft Environmental Impact Assessment Report

M/s Shree Ram Electrocast Pvt Ltd.,

DRAFT ENVIRONMENTAL IMPACT

ASSESSMENT REPORT

for

Expansion of existing

1,20,000 TPA Pig Iron unit to 2,00,000 TPA, 1,20,000 TPA Ductile

Iron pipe Plant to 2,00,000 TPA,

And 3.2 MW Captive Power Plant to 32.5 MW and

Establishment of

Coke Oven Plant - 1,60,000 TPA,

Sinter Plant– 3,00,000 TPA AND

Cement Grinding Plant – 1,00,000 TPA

atHonnarahalli , Halkote Village, Post-Hatcholi, Taluk Siruguppa, Dist.-Bellary,

Karnataka – 583114

By

M/s Shree Ram Electrocast

Pvt. Ltd.

ENVIRONMENTAL HEALTH & SAFETY

CONSULTANTS PRIVATE LTD,

# 13/2, 1ST MAIN ROAD, NEAR FIRE STATION,

INDUSTRIAL AREA, RAJAJINAGAR,

BANGALORE-560 010,

Tele: 080-23012100, Fax: 080 23012111

Email:[email protected]/[email protected]

www.ehsc.in

PRAGATHI LABS AND

CONSULTANTS PVT. LTD.

PLOT NO.8, TARBUND X ROAD,

SECUNDERABAD-9



Table of ContentsCHAPTER I - INTRODUCTION ................................................................................................ 181.0 Company Profile ..................................................................................................................... 18

1.1 Project Details ......................................................................................................................... 191.2 Purpose of the Report.............................................................................................................. 19

1.3 Need of the project and its Importance in the Country........................................................... 201.4 Comparison of Existing and Proposed Plants ......................................................................... 211.5 Project location ....................................................................................................................... 22

1.6 Siting Criteria .......................................................................................................................... 251.7 List of Industries ..................................................................................................................... 27

1.8 Scope of the Work................................................................................................................... 271.9 Impact Assessment Methodologies......................................................................................... 28

1.9.1 Air Quality Modeling....................................................................................................... 28

1.10 Environment Management Plan............................................................................................ 281.10.1 Green Belt Development Plan ....................................................................................... 28

1.11 Disaster Management Plan and Occupational Safety........................................................... 291.12 Post Study Monitoring Plan.................................................................................................. 29CHAPTER II- PROJECT DESCRIPTION .................................................................................. 30

2.1 Introduction............................................................................................................................. 302.2 Location .................................................................................................................................. 30

2.3 Project Description with Process Details:............................................................................... 412.3.1 Modernisation of Pig Iron Plant....................................................................................... 412.3.2 Coke Oven Plant .............................................................................................................. 43

2.3.3 Power Plant ...................................................................................................................... 472.3.4 Ductile Iron Pipe Plant ..................................................................................................... 49

2.3.5 SINTER PLANT.............................................................................................................. 562.3.6 Cement Grinding Plant .................................................................................................... 60

2.4 WATER AND POWER REQUIREMENT............................................................................ 64

2.5 MANPOWER ......................................................................................................................... 68CHAPTER III- DESCRIPTION OF THE ENVIRONMENT...................................................... 69

3.0 Introduction............................................................................................................................. 693.1 Baseline Data .......................................................................................................................... 703.2 Soil Characteristics ................................................................................................................. 70

3.3 Air Environment ..................................................................................................................... 733.3.1 Micrometeorological Data ............................................................................................... 73

3.3.1.1 Historical Data .......................................................................................................... 733.3.1.2 Meteorology – Data generated at plant site .............................................................. 75

3.3.2 Selection of AAQ stations ............................................................................................... 77

3.3.3 Existing AAQ (Pre-project) status ................................................................................... 773.4 NOISE ENVIRONMENT ...................................................................................................... 86

3.4.1 Impact Assessment of Noise Environment ...................................................................... 863.4.2 Existing Noise Levels ...................................................................................................... 863.4.3 Methodology of Noise measurement ............................................................................... 88

3.5 WATER ENVIRONMENT.................................................................................................... 90



3.5.1 Water quality monitoring ................................................................................................. 90

3.6 Hydrology ............................................................................................................................... 983.6.1 Hydrometeorology ........................................................................................................... 983.6.2 Rainfall............................................................................................................................. 98

3.7 Geology and Structures ........................................................................................................... 993.7.1 Regional Geology ............................................................................................................ 99

3.8 Hydrogeology.......................................................................................................................... 993.9 ECOLOGICAL STATUS (TERRESTRIAL AND AQUATIC).......................................... 1053.10 Demographic data ............................................................................................................... 108

CHAPTER-IV ANTICIPATED IMPACTS ............................................................................... 1094.0 Introduction........................................................................................................................... 109

4.1 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES ..... 1104.2 Impact on Environment during Construction Phase ............................................................. 120

4.2.1 Impact on Land use ........................................................................................................ 120

4.2.2 Impact on Soil ................................................................................................................ 1204.2.3 Impact on Air Quality .................................................................................................... 121

4.2.4 Impact on Water Quality................................................................................................ 1214.2.5 Impact on Noise Levels .................................................................................................. 1214.2.6 Impact on Terrestrial Ecology........................................................................................ 123

4.2.7 Impact on Aquatic Ecology............................................................................................ 1234.2.8 Demography and Socio-economics ............................................................................... 123

4.2.9 Public Expectation ......................................................................................................... 1244.3 Identification of Potential Impacts during Operational Phase .............................................. 124

4.3.1 Impact on Soil ................................................................................................................ 125

4.3.2 Topography and Climate................................................................................................ 1254.3.2.1 Impact on Topography............................................................................................ 125

4.3.2.2 Impact on Climate ................................................................................................... 1254.3.3 Impact on Air Quality .................................................................................................... 125

4.3.3.1 Air Pollution Impact Identification by use of Air Modeling .................................. 126

4.3.3.2 Pollutants/Model Options Considered For Computations ...................................... 1264.3.3.3 Model Input Data .................................................................................................... 127

4.3.3.4 Fugitive Emissions .................................................................................................. 1274.3.4 Impact on Traffic ........................................................................................................... 1304.3.5 Impact on Water Resources ........................................................................................... 134

4.3.6 Impact on Water Quality................................................................................................ 1344.3.7 Impact of solid waste ..................................................................................................... 134

4.3.8 Impact on Noise Levels .................................................................................................. 1354.3.9 Impact on Ecology ......................................................................................................... 1354.3.10 Socio-Economics ......................................................................................................... 136

CHAPTER V-ENVIRONMENTAL MONITORING PROGRAMME..................................... 1375.1 Environmental Monitoring.................................................................................................... 137

5.2 Environmental Monitoring Plan ........................................................................................... 138CHAPTER-VI............................................................................................................................. 140OCCUPATIONAL HEALTH AND SAFETY AND DISASTER MANAGEMENT PLAN.... 140

6.0 Introduction........................................................................................................................... 1406.1 Quality, Environment and Occupational Health and Safety Policy...................................... 140

6.2 HAZARD CHART ............................................................................................................... 142



6.3 Occupational Health.............................................................................................................. 148

6.4 Safety Plan ............................................................................................................................ 1496.4.1 General........................................................................................................................... 1496.4.2 House – keeping............................................................................................................. 150

6.4.3 Wearing apparel............................................................................................................. 1506.4.4 Protective equipment ...................................................................................................... 150

6.4.5 Stacking of materials...................................................................................................... 1506.4.6 Loading of material........................................................................................................ 1506.4.7 Eye protection................................................................................................................ 150

6.4.8 Safety belts ..................................................................................................................... 1516.4.9 Transport ........................................................................................................................ 151

6.4.10 Short cuts...................................................................................................................... 1516.4.11 Defective tools ............................................................................................................. 1516.4.12 Power rails or transmission line ................................................................................... 151

6.4.13 Guards .......................................................................................................................... 1516.4.14 Refueling ...................................................................................................................... 151

6.4.15 Permit to work.............................................................................................................. 1526.4.16 Starting and repairing machinery................................................................................. 1526.4.17 Lifting or carrying weights .......................................................................................... 152

6.4.18 Overhead crane ............................................................................................................ 1536.4.19 Electricity..................................................................................................................... 154

6.4.20 Ladders and scaffolds................................................................................................... 1546.4.21 Working overhead........................................................................................................ 1556.4.23 Welding and gas cutting............................................................................................... 155

6.4.24 Hot metal and slag........................................................................................................ 1556.4.25 Fire in coal yard ........................................................................................................... 156

6.4.26 Open manholes............................................................................................................. 1566.4.27 Excavations .................................................................................................................. 1566.4.28 Vehicles........................................................................................................................ 157

6.4.29 First aid boxes .............................................................................................................. 1576.4.30 Fire fighting equipment ................................................................................................ 157

6.4.31 Unfamiliar equipment .................................................................................................. 1586.4.32 Horseplay..................................................................................................................... 1586.4.33 Work permits................................................................................................................ 158

6.5 Administrative Controls ........................................................................................................ 1586.6 Personal Protective Equipment (PPE) .................................................................................. 159

6.7 Emergency Organization....................................................................................................... 1606.8 ROLES AND RESPONSIBILITIES OF EMERGENCY ORGANISATION..................... 161

6.8.1 Site Controller................................................................................................................ 161

6.8.2 Incident Controller ......................................................................................................... 1626.8.3 Emergency Coordinator (Services & communication) .................................................. 162

6.8.4 Emergency Coordinator (First Aid & Medical Management)....................................... 1636.8.5 Emergency Coordinate (Security & Supply) ................................................................. 1636.8.6 Emergency Coordinator (Production Unit).................................................................... 164

6.8.7 Emergency Coordinator (Utility & Maintenance) ......................................................... 1646.8.8 Assistant – Communication........................................................................................... 164

6.8.9 Safety squad ................................................................................................................... 165



6.8.10 Drive – Ambulance ...................................................................................................... 165

6.8.11 In Charge – Occupational Health Center ..................................................................... 1656.8.12 Department heads / shift / in charge / supervisors ....................................................... 1666.8.13 Duties of Receptionist / Telephone Operator............................................................... 166

6.9 Emergency Response Plan.................................................................................................... 1676.10 Health register will be maintained as follows:.................................................................... 167

6.11 Emergency Action Plans ..................................................................................................... 1686.11.1 Emergency Action Plan for Cylinder Fire: .................................................................. 1686.11.2 Emergency Action Plan for Electric Fire:.................................................................... 169

6.11.3 Emergency Action Plan for Office Fire:...................................................................... 1696.11.4 Emergency Action Plan for Oil Fire:........................................................................... 169

6.11.5 Emergency Action Plan for Medical Aid: ................................................................... 1706.12 Natural Hazards................................................................................................................... 171

6.12.1 Emergency Action Plan for Tornado/High Winds: ..................................................... 171

6.12.2 Emergency Action Plan for Earthquakes..................................................................... 1726.12.3 Emergency Action Plan for Bomb Threat ................................................................... 172

6.13 GUIDELINES FOR SHUTDOWN OF PRODUCTION BLOCKS .................................. 1736.14 EMERGENCY PLANNING .............................................................................................. 174

6.14.1 TRAINING AND REHEARSAL ................................................................................ 174

6.14.2 ACTION PLAN / TRANING...................................................................................... 1756.14.3 GENERAL SAFETY................................................................................................... 175

6.14.5 SAFETY WHILE HANDLING EQUIPMENT .......................................................... 1766.14.5 ELECTRICAL SAFETY ............................................................................................. 1776.14.6 FIRE SAFETY............................................................................................................. 178

6.14.6.1 FIRE...................................................................................................................... 1786.14.6.2 FIRE FIGHTING, RESCUE AND FIRST AID TEAM....................................... 179

6.15 DECLARATION OF EMERGENCY ................................................................................ 1806.16 EMERGENCY SIREN ....................................................................................................... 1806.17 EVACUATION OF PERSONNEL .................................................................................... 181

6.18 SAFE ASSEMBLY POINTS ............................................................................................. 1816.19 ACCOUNTING OF PERSONNEL.................................................................................... 181

6.20 ARRANGEMENT FOR MEDICAL TREATMENT......................................................... 1816.21 INFORMATION TO RELATIVES OF INJURED............................................................ 1826.22 INFORMATION TO LOCAL AUTHORITIES ................................................................ 182

6.23 INFORMATION TO DISTRICT AUTHORITIES ............................................................ 1826.24 LAW & ORDER................................................................................................................. 183

6.25 ALL CLEAR SIGNAL ....................................................................................................... 1836.26 Occupational Health Surveillance Programme ................................................................... 184CHAPTER-VII............................................................................................................................ 188

PROJECT BENEFITS ................................................................................................................ 1887.1. PHYSICAL INFRASTRUCTURE...................................................................................... 188

7.2. SOCIAL INFRASTRUCTURE........................................................................................... 1887.3. EMPLOYMENT POTENTIAL........................................................................................... 188

7.3.1. SKILLED...................................................................................................................... 188

7.3.2. SEMI- SKILLED .......................................................................................................... 1887.3.3. UNSKILLED ................................................................................................................ 188

7.4. OTHER BENEFITS............................................................................................................. 188



7.5 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES ................................................. 189

CHAPTER-VIII .......................................................................................................................... 192ENVIRONMENTAL MANAGEMENT PLAN......................................................................... 1928.1 Introduction........................................................................................................................... 192

8.2 Environmental Management during Construction Stage ...................................................... 1928.2.1 Water Resources and Quality......................................................................................... 194

8.2.2 Air Quality ..................................................................................................................... 1958.2.3 Noise Level .................................................................................................................... 1958.2.4 Solid /Hazardous Waste Management ........................................................................... 196

8.2.5 Site Security................................................................................................................... 1968.2.6 Traffic Pattern................................................................................................................ 196

8.2.7 Solid Waste Generation ................................................................................................. 1978.2.8 Ecological Aspects ......................................................................................................... 1978.2.9 Aesthetics....................................................................................................................... 197

8.2.10 Socio-Economic........................................................................................................ 1978.3 Operation stage ..................................................................................................................... 198

8.3.1 Air Environment ............................................................................................................ 1988.3.1.1 Air Pollution Control Equipment ............................................................................ 1998.3.1.2 For Fugitive Dust control........................................................................................ 202

8.3.2 Water Pollution.............................................................................................................. 2048.3.2.1 Water Environment ................................................................................................. 204

8.3.2.2 Water Pollution Control and Conservation............................................................. 2048.3.2.3 Water pollution control........................................................................................... 204

8.3.3 Noise Pollution............................................................................................................... 205

8.3.3.1 Noise Environment: ................................................................................................ 2058.3.4 Solid Waste .................................................................................................................... 206

8.3.5 Greenbelt Development ................................................................................................. 2068.3.5.1 Action plan for development of Greenbelt in 35% area ......................................... 207

8.3.6 Storm Water Management ............................................................................................. 208

8.3.7 Ecological Aspects ......................................................................................................... 2108.3.8 Aesthetics Aspects ......................................................................................................... 210

8.3.9 Socio Economic Aspects................................................................................................ 2108.3.10 Land Management ........................................................................................................ 2118.3.11 Traffic Management Plan............................................................................................. 211

8.4 Existing Environmental Management plan........................................................................... 2138.4.1 Wastewater..................................................................................................................... 213

8.4.2 Air Environment ............................................................................................................ 2138.4.3 Stack Emissions ............................................................................................................. 2138.4.4 Fugitive Emission .......................................................................................................... 214

8.4.5 Noise Environment ........................................................................................................ 2148.4.6 Land Management .......................................................................................................... 215

8.4.7 Green Belt Development ................................................................................................ 2158.5 Conservation of Air, Water and Energy recovery................................................................. 2188.6 Budgetary allocation for Environmental Protection Measures (in Rs. Lakhs) ..................... 219

8.7 CREP GUIDELINES ............................................................................................................ 220CHAPTER-IX SUMMARY AND CONCLUSION................................................................... 223

CHAPTER-1 INTRODUCTION............................................................................................ 223



CHAPTER-2 PROJECT DESCRIPTION .............................................................................. 226

CHAPTER-3.0 BASELINE ENVIRONMENTAL SCENARIO ........................................... 227CHAPTER-4.0 ANTICIPATED IMPACT AND MITIGATION MEASURES ................... 229CHAPTER-5.0 ENVIRONMENTAL MONITORING PLAN .............................................. 237

CHAPTER-6.0 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN ............ 238CHAPTER-7.0 PROJECT BENEFITS .................................................................................. 242

CHAPTER-8.0 ENVIRONMENTAL MANAGEMENT PLAN ........................................... 244CHAPTER-X .............................................................................................................................. 250DISCLOSURE OF CONSULTANTS ENGAGED WITH RESPECT THE PROJECT ........... 250

List of TablesTable 1.1 Existing Manufacturing Facilities................................................................................. 18Table 1.2 Production details.......................................................................................................... 18

Table 1.3: Envisaged project capacities ........................................................................................ 19Table 1.4 Existing and Expansion Features .................................................................................. 21

Table 1.5 Proposed Project Details ............................................................................................... 23Table 1.6 Environmental settings around the proposed project site (Within 10 kms radius)....... 24Table 1.7 Siting Criteria................................................................................................................ 25

Table 1.8 List of Industries ........................................................................................................... 27Table 1.9 Scope of work ............................................................................................................... 27

Table 2.1: Land Breakup of the Existing and Proposed Expansion ............................................. 31Table 2.2: Summary of Development- phase wise ....................................................................... 40Table: 2.3 Raw material Requirement .......................................................................................... 41

Table 2.4 Chemical characteristics of Iron ore ............................................................................. 42Table 2.5 Chemical characteristics of Limestone ......................................................................... 42Table 2.6 Chemical characteristics of Dolomite ........................................................................... 42

Table 2.7 Chemical characteristics of Quartz............................................................................... 43Table 2.8: Material balance........................................................................................................... 43

Table 2.9 BF gas generation and utilization ................................................................................. 43Table 2.10 Raw materials required ............................................................................................... 46Table 2.11: Quality of Coal........................................................................................................... 46

Table 2.12 Material balance – Coke Oven plant ........................................................................... 47Table 2.13 Raw material requirement........................................................................................... 48

Table 2.14 Chemical characteristics of coal ................................................................................. 48Table 2.15 Raw materials required ............................................................................................... 53Table 2.16 Chemical analysis of Ferrosilicon............................................................................... 53

Table 2.17 Chemical analysis of Silico manganese ...................................................................... 54Table 2.18 Material Balance- Ductile Iron Pipe plant .................................................................. 54

Table 2.19 Design parameters of sinter plant ............................................................................... 56Table 2.20 Raw materials requirement ........................................................................................... 1Table 2.21 Material Balance- Sinter plant .................................................................................... 60

Table 2.22 Raw material requirement........................................................................................... 60Table 2.23 Chemical analysis of Clinker...................................................................................... 61

Table 2.24 Chemical analysis of Gypsum .................................................................................... 61Table 2.25 Chemical analysis of BF slag...................................................................................... 61Table 2.26 Material Balance for Cement grinding plant .............................................................. 62



Table 2.27 Makeup Water requirement ........................................................................................ 64

Table 2.28 Power Requirement ..................................................................................................... 66Table 2.29 Man power requirements ............................................................................................ 68Table 3.1 Primary data collected................................................................................................... 70

Table 3.2 Location of soil sampling stations ................................................................................ 71Table 3.3 Soil Quality Analysis .................................................................................................... 72

Table 3.4 Data collection for Meteorological data ....................................................................... 73Table 3.5 Meteorological Data (3 years) for Bellary.................................................................... 74Table 3.6 meterological data for the period Oct-Dec 2011........................................................... 76

Table 3.7 Air parameters analysed................................................................................................ 77Table: 3.8 Details of Air Quality monitoring station.................................................................... 80

Table: 3.9 Air quality monitoring results...................................................................................... 81Table 3.10 Concentration of PM10............................................................................................... 82Table 3.11 Concentration of PM2.5.............................................................................................. 82

Table 3.12 Concentration of SO2 ................................................................................................. 82Table 3.13 Concentration of NO2................................................................................................. 83

Table 3.14 Concentration of Lead................................................................................................. 83Table 3.15 Concentration of Ammonia ........................................................................................ 84Table 3.16 Concentration of CO................................................................................................... 85

Table 3.17 Concentration of Ozone .............................................................................................. 85Table 3.18 Noise locations............................................................................................................ 88

Table 3.19 Summary of Ambient Noise Level Monitoring Results ............................................. 90Table 3.20: water sampling station details .................................................................................... 92Table 3.21: Water Quality Results ................................................................................................ 93

Table 3.22 Monthly Annual Rainfall Distributions ...................................................................... 99Table 3.23 Flora found in the study area .................................................................................... 105

Table 3.24 List of major crops.................................................................................................... 106Table 3.25 List of fauna found in the study area ........................................................................ 107Table 3.27 List of aqua fauna ...................................................................................................... 107

Table 4.1 IMPACT IDENTIFICATION MATRIX.................................................................... 110Table 4.2 CHARACTERISTICS OF ENVIRONMENTAL IMPACTS FROM

CONSTRUCTION ACTIVITIES ............................................................................................... 113Table 4.3: CHARACTERISTICS OF ENVIRONMENTAL IMPACTS FROM OPERATIONAL PHASE........................................................................................................................................ 117

Table 4.4 Typical Noise Levels of Construction Equipment...................................................... 122Table 4.5 List of Pollution ways in stacks .................................................................................. 126

Table 4.6 Fugitive emission data .................................................................................................. 128Table 4.7 Summary of Air quality dispersion model: ................................................................... 129Table 4.8 Existing traffic ............................................................................................................ 131

Table 4.9 Generated Traffic Due to the Proposed expansion Project (Operation Phase) ........... 132Table 4.10 Solid waste generated from different operations (after expansion) .......................... 135

Table 5.1 Monitoring schedule for Environmental Parameter during construction phase ......... 137Table 5.2: Monitoring Schedule for Environmental Parameters ................................................ 137Table 5.3 Fugitive emission monitoring ..................................................................................... 139

Table 6.1 Identified Hazards ....................................................................................................... 143Table 6.2 Identified Occupational Health Hazards ..................................................................... 143

Table 6.3 Preliminary Hazard Analysis for Process and Storage Areas ..................................... 144



Table 6.4 List of fire extinguishers ............................................................................................. 158

Table 6.5 Emergency Organisation............................................................................................. 160Table 6.6: Health Register............................................................................................................ 168Table: 7.1 CSR Activities conducted and proposed around factory premises ............................... 189

Table 8.1: EMP for Construction Phase Impacts "Site Clearing".............................................. 193Table 8.2: EMP for Construction Phase Impacts

"Transportation of Construction Materials”................................................................................ 193Table 8.3: EMP for Construction Phase Impacts "Construction Activities”.............................. 194Table 8.4: Characteristics of Secondary Fugitive Emissions ........................................................ 202

Table 8.5 Action plan to control fugitive dust .............................................................................. 203Table 8.6 Solid waste generated from different operations after expansion............................... 206

Table 8.7 Trucks details .............................................................................................................. 211Table 8.8 Capital Cost................................................................................................................. 219Table 8.9 Recurring Cost ............................................................................................................. 219

Table 8.10 Compliance to CREP guidelines............................................................................... 220

List of Figures

Fig: 1.1 Toposheet of the area showing the location of the industry with 15 kms radius

demarcation. .................................................................................................................................. 26Fig 2.1Location of the proposed project site ................................................................................ 32Fig 2.2 Toposheet of the area showing the location of the proposed expansion project site

(Toposheet No.s: 57 A/13, 57 A/14, 57 E/1, 57 E/2 Scale 1:50,000) ........................................... 33Fig 2.3 Aerial view of the proposed project site. .......................................................................... 34

Fig 2.4 Aerial view of the proposed project site with 10 kms demarcation ................................. 35Fig 2.5 Satellite imagery of the study area ................................................................................... 36Fig 2.6 Photos showing the existing Pig Iron Unit ....................................................................... 37

Fig 2.7 Photos showing site surrounding photograph................................................................... 38Fig 2.8 Photos showing the proposed project site......................................................................... 39

Fig 2.9 Flow chart of heat recovery stamping coke oven............................................................. 45Fig 2.10 Power Plant- Flow diagram ............................................................................................ 49Fig 2.12 Typical sinter plant ......................................................................................................... 57

Fig 2.13 Flow chart of sinter plant .................................................................................................. 1Fig 2.14 Mass Balance for the whole plant ................................................................................... 63

Fig 2.15 Water Balance chart........................................................................................................ 65Fig 2.16 Energy Balance chart ...................................................................................................... 67Fig 3.1 Location of Soil sampling stations ................................................................................... 71

Fig 3.2 Monitoring photographs ................................................................................................... 72Fig. 3.3 Meteorological Scenario – Wind Rose diagram.............................................................. 75

Fig. 3.4 Meteorological Scenario – Wind Rose diagram for Oct-Dec 2011................................. 77Fig 3.5 Air quality monitoring stations ......................................................................................... 79Fig : 3.6 Some of the Monitoring photographs ............................................................................. 80

Fig. 3.7 Map Showing Noise Sampling Locations ....................................................................... 87Fig 3.8 Noise monitoring photographs ......................................................................................... 89

Fig 3.9 Water monitoring stations ................................................................................................ 91



Fig 3.10 Photographs of monitoring ............................................................................................. 92

Fig 4.1 Dispersion of particulate matter ..................................................................................... 128Fig 4.2 Dispersion of SO2 ........................................................................................................... 128Fig 4.3 Dispersion of NO2 .......................................................................................................... 129

Fig 6.1 Hazard Chart ................................................................................................................... 142Fig 6.2 Emergency Response Plan.............................................................................................. 167

Fig: 7.1 CSR activates carried out .............................................................................................. 191FIG 8.1 EXISITNG GREENBELT PHOTOGRAPHS ........................................................ 217

Annexures

1. 3 months AAQ data

2. Demographic details

3. Emission data

4. Modeling results

5. greenbelt development drawing and species list

TORs awarded



TEAM MEMBERS

ENVIRONMENTAL CONSULTANCY SERVICES

1 Dr. M. Ravi Kiran (M.Sc, Ph.D), M/s Pragathi Labs and Consultants Pvt Ltd.,

2 Mr. Ch. Vishnu (B.Tech. Chemical), M/s Pragathi Labs and Consultants Pvt Ltd.,

3 Miss. Shaheda Begum (M.Sc Chemistry), M/s Pragathi Labs and Consultants Pvt Ltd.,

4 Miss. Y. Latha (M.Sc Chemistry), M/s Pragathi Labs and Consultants Pvt Ltd.,

5 Mr. Shivanand M Dambal, Managing Director, EHSCPL

6 Mr. Madhu Kumar, Technical Director, EHSCPL

7 Mrs. Praveena Kumari, Senior Environmental Engineer, EHSCPL

8 Ms. Bhavani, Environmental Engineer, EHSCPL

PROJECT CONSULTANTS

9 Mr. George Thomas

GIS CONSULTANT

10 Mr. Ananatha Rama

LAB SERVICES

11 M/s SGS India Pvt Ltd

12 M/s EHSRDC

AIR QUALITY MODELING AND PREDICTION

13 Mrs. Praveena Kumari

TOPOSHEETS

14 Survey of India



CHAPTER I - INTRODUCTION1.0 Company Profile

Shree Ram Electro Cast Pvt. Ltd., was incorporated on 12th August, 2004 havingregistered office 8 Camac Street Shanti Niketan Building 9th Floor Room No. 8 Kolkata-17, West Bengal. Directors of the company are Mr Mukesh Bhandari, Mr. ShaileshBhandari, Mr. Avinash Bhandari and Mr R K Purohit.

Table 1.1 Existing Manufacturing Facilities

Unit Capacity Location

Pig Iron Plant

Captive Power Plant

120,000 TPA

2.5MW

Honarhalli, Hatcholi Post, Sirguppa Talluk, BellaryDistrict, Karnataka

The above unit was earlier owned by M/s Unimetal Ispat Limited and taken over by the company from Debt Recovery Tribunal, Bangalore, through public auction in Nov, 2004, at total consideration of Rs.15.40 Crores. Further, plant was upgraded under the guidance of MECON Limited, Bangalore with an expenditure of 12.00 Crores. As such, company invested total amount of Rs. 27.40 Crores on the plant and started thecommercial production from July, 2005. After the start of commercial operation, the plant was leased out to Kalyani Steels Limited, Pune (A Flagship company of Bharat Forge Limited).

The State Bank of India got the property valued by its empanelled valuer M/s Niketan Consultancy at Rs. 58.14 Crores in the year 2007-08.

The plant has an installed capacity of 120,000 TPA. The plant was again operated by SREPL from 12-07-2009 and achieved the following productions:

Table 1.2 Production details

Year Production (TPA)

2008-09 31893*

2009-10 48,230* Production is for five months only.

Directors

• Mr. Mukesh Bhandari is a businessman, having experience over 30years. He is a graduate in Electrical Engineering and is director invarious Companies. He is the Chairman of the flagship companyElectrotherm (I) Ltd

• Mr.Shailesh Bhandari is a businessman, having experience over 25years. He is a graduate and is director in various Companies. He is the



Managing Director of the flagship company Electrotherm (I) Ltd

• Avinash Bhandari is a graduate in Engineering and has taken M.S and MBA from USA. He is having experience over 17 years and is director in various companies.

• Mr R K Purohit is an Engineering Graduate from Jadavpur University and has got over 30 yrs of experience in steel industry.

1.1 Project Details

After successful operation of existing steel Plant and power plant atHonarhalli/Halkote village, Post – Hatcholi,Taluk- Siruguppa, Dist.- Bellary andkeeping in view growth potential in the steel sectors, the promoters had decided to set up a Ductile Iron Pipe plant of 120,000 TPA as value addition project and obtained the MOEF clearance (vide No J-11011/498/2010-IA-II (I) dated 22nd June 2011). This project is in the implementation phase.Now it is proposed to modernize the Pig Iron Plant to improve the fuel efficiency and capacity from 120,000 TPA to 200,000 TPA and set up the Coke Oven Plant, Expand the Ductile Iron Pipe plant from 120,000 TPA to 200,000 TPA, Sinter Plant, Cement grinding plant and Captive Power Plant at the existing Site for production of Metallurgical coke, D.I. Pipe, Sinter, Slag cement and Power. Due to total integration, the proposed project would improve the overall profitability of the project making it financially more viable. The proposed project envisages the followings manufacturing facilities:-

Table 1.3: Envisaged project capacities

Sl.

No.

Division Proposed Capacity (TPA )

1 Modernisation of Pig Iron Plant toimprove the fuel efficiency andincreasing the production

Increasing the capacity ofproduction from 120,000TPA(EC has been obtained) to2,00,000 TPA

2 Coke Oven Plant 160,000 TPA

3 Power Plant 30 MW

4 Ductile iron pipe Increase in the capacity ofproduction from 1,20,000 TPA (EC has been obtained) to200,000

5 Sinter Plant 300,000

6 Cement Grinding Plant 100,000

The total cost of the project is envisaged at Rs. 415.00 Crores

1.2 Purpose of the Report



As per MoEF Notification, 14th September 2006, and further amended throughnotification No S.O.3067 (E) dated 1.01.2009, the proposed project is falling under ‘A’ category, based on metallurgical industries production capacity and Inter Stateboundary site location. Hence Shree Ram Electrocast Pvt Ltd submitted the Form-I in the prescribed format to MoEF, Govt of India, New Delhi. Subsequently the proposalwas considered by the Expert Appraisal Committee (Industry) in the 28th Meeting held on 27th September, 2011. Based on the information furnished and presentation before MoEF committee at New Delhi by the proponent, the TORs recommended by theCommittee vide letter No: F. No. J-11011/442/2011-IA-II (I) dated 14th October, 2011is also included in the present Environmental Impact Assessment (EIA) andEnvironmental Management Plan (EMP).

The purpose of the preparation of Environment Impact Assessment (EIA) report is not only to obtain Environment Clearance from Ministry of Environment & Forests, Govt. of India, New Delhi, but also to understand the likely impacts and to take Environment Protection measures during and after commissioning of the project.

The EIA/EMP Report is prepared on the basis of the available secondary data/literature along with the on-site data generated during 3 months study period (Octoberto December, 2011).

1.3 Need of the project and its Importance in the Country

SREPL already have a pig iron plant at Siruguppa to produce 120,000 tons per year. The operating margins of the pig iron producers are expected to reduce due to the decline in pig iron prices because of over supply situation.

The present pig iron plant has metallic blast preheater using blast furnace gas. This will be replaced by hot blast stoves to improve the energy efficiency and operatingparameters. Also Coal dust injection, oxygen enrichment, steam injection, etc areplanned to improve the fuel efficiency and productivity of the blast furnace to 200,000 TPA.

DIP due to its superior characteristics with respect to tensile strength, ductility, impact resistance, corrosion resistance, lower weight, easy handling and longer life hasreplaced cast iron pipes in developed countries in the area of water supply andsanitation. India Government has identified water infrastructure development aspriority area and hence there will be higher demand for the DIP in future.Pig Iron is the main raw material for the DIP. Hence SREPL will have better value addition by installing DIP plant at Siruguppa with a capacity of 200,000 tons per year utilizing the pig iron and steel scrap. The company has already got environmentalclearance for 1,20,000 TPA capcity. Now SREPL is proposing to increase the capacity of DIP plant capacity to 2,00,000 TPA



One of the major raw materials for the pig iron plant is the metallurgical coke. The availability and price of this greatly affect the production and cost of pig iron. Indian coke market sustain mainly with the imported coke from China. Hence installingMetallurgical coke plant will benefit SREPL greatly in ensuring the availability of a major raw material for the pig iron production at a reasonable cost.

At present lump ore is used for pig iron production. By installing sinter plant theabundantly available iron ore fines of low cost can be utilized, thus achieving costreduction and increased productivity. Also the coke fines can be utilized in the sinter plant.

The granulated slag from the pig iron plant is currently sold out. This can be ground with clinker purchased to produce slag cement for better value addition. Also part of cement can be utilized for coating the DI pipes

Power plant using biomass/coal /waste heat recovered from the coke ovens to produce30 MW are planned.

Taking the above philosophy to maximize the fuel efficiency, turnover and minimize the production cost, SREPL is setting up the sinter plant, metallurgical coke plant

and Power plant as backward integration and expanding DIP plant, CementGrinding plant, modernizing the existing pig iron plant thereby to achieve better economics

1.4 Comparison of Existing and Proposed PlantsConsidering the experience gained by the group in this sector, M/s Shree RamElectrocast Pvt Limited now proposes to modernize the Pig Iron Plant to improve the fuel efficiency and capacity from 120,000 TPA to 200,000 TPA and set up the Coke Oven Plant, Expand the Ductile Iron Pipe plant from 120,000 TPA to 200,000 TPA, Sinter Plant, Cement grinding plant and Captive Power Plant. The existing and proposed features are summarized below:

Table 1.4 Existing and Expansion Features

PHASE –I PHASE-II (EC Obtained on 30/09/09)

PHASE-III(EC Obtained on

22/06/11)

PROPOSED

Pig IronPlant: 60,000TPA

Pig Iron Plant :Expansion to 1,20,000TPA

Ductile Iron Pipe1,20,000 TPA

Pig Iron Production 80,000 TPA(Total production 2,00,000 TPA)



Ductile Iron Pipe 80,000TPA(Total production 2,00,000 TPA)

Captive Power Plant: 30MW(Total Power: 32.5 MW)

Coke Oven Plant: 1,60,000 TPA

Sinter Plant 3,00,000 TPA

CaptivePowerPlant-2.5MW

Total:Pig Iron Plant- 1,20,000 TPA

Captive Power Plant-2.5 Mw

Total :Pig Iron Plant1,20,000 TPA

Ductile Iron Pipeplant-1,20,000TPA

Captive Powerplant-2.5 MW

Cement Grinding 1,00,000 TPA

1.5 Project locationPlant of SREPL is located at Honnarhalli/Halokote village, Siruguppa taluk, Bellary district in Karnataka state. The boundary of the plant is as under:North : Honnarhalli village road and private lands.South : Private land and private road.East : Siruguppa – Hatcholli road.West : Private lands The plant is located adjacent to the district road joining Siruguppa and Hatcholli village and is about 8.2 km from Karnataka State Highway-19 joining Srirangapatnam and Bidar. Taluka place Siruguppa and district place Bellary are at 13.5 km and 66.4 km respectively, from the site. Nearest Railway station is at Adoni, which is about 36.4 km from the site. The nearest villages to the site are, Honnarhalli: 1.4 km N, Chikkabellary: 2.4km NE, Shigaragadde: 1.6 km S, Kududarahal: 2.5 km S and Hatcholi : 7 km NE. The perennial rivers Thungabhadra and Hagari are located at 1.8 km NW and 1.6 km SW, respectively from the site. A rain water stream Gorchivenka is located at 6 km NE to the site. Both river Hagari and stream Gorchivenka are tributaries to riverThungabhadra.

The land available with SREPL is 114.97 acres. Further 25.42 acres is being acquired through KIADB. 38 acres of land is utilized for pig iron plant and 25 acres for DIP Plant of 120,000. Balance area is available for the proposed project and green belt.

The location of the land confers several advantages, which are summarized below:

• Proximity to major raw material sources, markets and major ports. • Infrastructure facilities exist at this location

• The project site is at a distance of 9.0 km from the State Highway • Ecologically sensitive areas are not in the vicinity.

• Water will be available from Thungabhadra River.



• Electric power will be from the GESCOM Substation at Sirugupa.

• Housing colonies, educational facilities, recreational facilities and other amenities are available at Siruguppa/Bellary.

Considering the above, the location at Honnarhalli/Halokote village is consideredsuitable for the proposed project.

Table 1.5 Proposed Project Details

Sl.No Items Particulars

1 Objective of theProject

Expansion of Pig Iron Plant from 1,20,000 to2,00,000 TPACoke Oven Plant - 1,60,000 TPACaptive Power Plant - 30 MWExpansion of Ductile Iron Pipe Plant from1,20,000 to 2,00,000 TPASinter Plant– 3,00,000 TPACement Grinding Plant – 1,00,000TPA

2 Promoters M/s. Shree Ram Electro cast Pvt. Ltd.

3 Investment forExpansion

415 Crores

4 Project location Sy.No.s 80, 81/A3, 95/A1, 95/A3, 96/A1, 96/A3, 97/1, 97/3, 98/A/1A, 98/A/1B, 98/A3, 98/B1,98/B3, 98/C1,98/C3, 98/D1, 98/D3, 99, 100, 103, 104, 105 and 106 of Honnarahalli Village and Sy, No. 57/C/1, 57/D/1, 57/A/1A, 57/A/2A,57/A/3A, 57/B/A, 57/A/4A, 77/A, 77/B, 78/A and 78/B of Halkote Village, Post – Hatcholi,Taluk- Siruguppa, Dist.- Bellary, Karnataka - 583 114

5 Extent of land The land available with SREPL is 114.97 acres.Proposed additional land to be acquired through KIADB is 25.42 acres.

6 Category ofProject

A

7 Water demandand Source

Existing water consumption 1200 KLD (PIG Iron plant-500 KLD, DIP Plant- 700 KLD) Proposed plant requirement 2215 KLDTotal water requirement after expansion = 3415KLD.



Source: Tungabhadra river. Withdrawalpermission for 4150 KLD for the expansionseeking from Government. (Order No: CI 57 SPI 2011, Bangalore Dated 25.02.2011.)

8 Power demand 26000 KVA after expansion

Table 1.6 Environmental settings around the proposed project site (Within 10 kms radius)

Sl. No Feature Particulars

1. Location Honnarahalli village, Siruguppa taluk, district, Karnataka.

2. Present land use Industrial and agricultural land

3. Altitude above meanMSL

475 m

4. Temp.0C (Range) Max. 31.0 to 41.2 and Min. 10.7 to 20.6

5. Mean Annual humidity& RF

65 % and 645 mm

6. Soil type Black cotton mixed loamy soil

7. Topography Plain terrain sloping towards NW

8. Nearest State Highway S.H.-19(Srirangapatna - Bidar), 8.2 km,

9. Nearest railway station None with in 10 km radius (Adoni-36.4 km in NE direction (S.C. Railway)

10. Nearest airport None with in 10 km radius. Bellary air strip; 63 kms (S) Hyderabad air port is about 227 km in NE.

11. Nearest village Honnarahalli, 1.4 km. in N

12. Nearest town Siruguppa 13.5 km, SW

13. Nearest major city None with in 10 km radius, Bellary, 66.4 km, SW

14. Nearest river Tungabhadra river , 1.8 Km , NW

15. Nearest industry None with in 10 km radius, Siruguppa Sugar 12 km.

16. Sensitive locations No Archeological structures, Historical places, ProtectedForests, Sanctuaries and Biosphere Reserves present within 10 kms from the Industry.



1.6 Siting Criteria

Economic and social factors are recognized and assessed while siting an industry. Environmental factors must be taken into consideration in industrial siting. Proximity of water sources, highway, major settlements, markets for products and raw material resources were desired for economy of production. Industries are, therefore, required to be sited, striking a balance between economic and environmental considerations.

However proposed plant is the extension of the existing pig iron plant. The site isselected because of its proximity to availability of raw materials and proximity to consumer centers and availabilities of infrastructure facilities like land, power, water, communication etc.

Though the proposed expansion plant area falls within allocated land of the existing plant boundary, it is meeting the siting criteria as per respective guidelines. The siting criteria requirement and the existing plant location is described as follows

Table 1.7 Siting Criteria

Details Requirement Existing unit features

Forest No forest land shall beconverted into non-forestactivity for the sustenance ofthe industry (Ref: ForestConservation Act, 1980).

No forest land will beconverted to industrial land.Additional land acquiredthrough KIADB

Agricultural land No prime agricultural landshall be converted intoindustrial site.

Additional land acquiredthrough KIADB

Odour plants For industry having odourproblem it shall be a kilometre wide.

Not applicable. It is not anodour producing industry.

Layout Enough space should beprovided for storage of solidwastes so that these could be available for possible reuse.

The layout plan of theproposed industry providedenough provision for storage

Residential area Major habitation (>300000population) shall be atleast 1km distance

Major habitation is located at a distance of 66.4 km distance(Bellary Town)

Ecologically /Sensitive zones

Shall be at least 1 km distance No ecologically / sensitivezone observed with in 1 kmdistance

Recreation Distance shall be 2 km from the plant

None within 10 km distance

Other similarplants

Radial distance of two similar plants should be 5 km

No similar plant is locatedwith in 5 km distance



distance

High way The distance from the NHshall be 0.5 Km

National High Way: 63 found at a distance of 60 km

State High way The distance from the SH shall be 0.5 Km

State High way is located 8.2km distance

Fig: 1.1 Toposheet of the area showing the location of the industry with 15 kms radius demarcation.

15 kms Radius



1.7 List of Industries The following industries are located within 25 kms from the proposed project site.

Table 1.8 List of IndustriesSl No Name of the Industry Distance, Km

1 Picheshwar Rao Pipe company 3.3 (W)

2 Kothari Sugars (P) Ltd., 11.6 (SW)

3 Shree BhagyaLakshmi Industries 11.7 (SW)

4 Maruthi rice Industries 12.3 (SW)

5 Sri Balaji Rice Industries 21.6 (W)

6 Balaji Brick Industries 21.52 (W)

1.8 Scope of the WorkThe EIA study includes determination of baseline conditions, assessment of the Impacts on the environment due to the construction and operation of the proposed project and making recommendations on the preventive measures to be taken, to minimize the impact on the environment to acceptable levels. A suitable post-study monitoringprogram will be outlined. Preparation of Environment Management Plan will be given based on the emissions and feasibility report. The scope of work is prepared based on MoEF / CPCB guidelines and tabulated below.

Table 1.9 Scope of work

EnvironmentalAttributes

No ofLocations

Observations

Meteorology

1 Hourly observations for Temperature, RelativeHumidity, Wind direction, wind speed & Rain fallduring 3 month study period

AAQ 8 For all the parameters as per National Ambient Air Quality Standards, 2009 for 24 hours duration, 2 times in each week during 12-week study period

Water 9 3 Surface water Locations 6 Ground water locations (including the place near to the plant site) Parameters that are analyzed are as per Analysis of Drinking Water Quality had been carried out

Noise 6 Day and night noise levels once in every location

Soil 05 At 5 locations.

Ecology Flora- Total study period is 90days. However predicted flora



Fauna &Ecosystem

– fauna also included for non-seasonal plant species(ephemerals) based on existing secondary data andfield conditions

Land use 10 kmradiusstudy area

Land use data based and satellite imagery data of the 10 km study area.

Socio-economicdata

Demography&Occupationaldetails

Secondary data from the existing literature (Census2001)

The Generic structure of EIA is given in EIA notification dated 14th September, 2006 is maintained. However as it is an extension of Existing project Chapter 5 is omitted which needs to describe alternative site selection and its merits and demerits.

1.9 Impact Assessment MethodologiesThe baseline data generated were analyzed and compared with applicable standards for each environmental attribute so that the critical environmental areas and also attributes of concern were identified. The short-term and long-term impacts particularly onsensitive targets such as endangered species, crops and historically importantmonuments were identified.

A qualitative and quantitative assessment of pollution aspects of proposed projects (air and dust, wastewater, noise pollution etc.) was done to identify the adequacy of the proposed control measures as well as the likely impact on existing critical areas.Mitigation measures to reduce adverse impacts were suggested.

1.9.1 Air Quality ModelingLakes Environment ISCST-3 was used for prediction of air quality impacts. This model requires hourly meteorological data which were collected from the site, and the same was used for running the model.

1.10 Environment Management PlanBaseline data generated (based on three months study during October, November and December, 2011) in the field and proposed project process studies are used to predict impacts. These impacts are evaluated and final impact assessment is carried out.Environmental Management Plan covers both during construction and operation are given in detail in Chapter 8.

1.10.1 Green Belt Development PlanGreen belt development plan for the project site is included in the EIA report.



1.11 Disaster Management Plan and Occupational SafetyA Disaster Management Plan (DMP) for dealing emergency situation arising due to fire, explosion, leakages of hazardous substances, etc. in the plant site is prepared. The plan includes storage, handling, transportation etc. for the hazardous materials to be used in the proposed project.

Occupational risk involved during construction and operation of the plant is assessed and necessary safety and protective measures are spelt out.

1.12 Post Study Monitoring PlanThe Post Project Monitoring (PPM) plan is prepared considering the following:

• The proposed pollution control measures for air, wastewater, noise and solid waste (hazardous/non-hazardous) disposal;

• Waste minimization; wastewater management, waste reuse andresource recovery; waste segregation to make the treatment anddisposal cost-effective



CHAPTER II- PROJECT DESCRIPTION

2.1 IntroductionThe proposed project is an expansion project with the following units:

• Pig iron plant modernization to improve the fuel efficiency and increase in production capacity from 120,000 TPA to 2,00,000TPA

• Coke Oven Plant - 160,000 TPA

• Captive Power Plant - 30 MW

• Expansion of Ductile Iron Pipe Plant- from 1,20,000 TPA to 200,000 TPA• Sinter Plant – 300,000 TPA

• Cement Grinding Plant – 100,000 TPA

at Sy.No.s 80, 81/A3, 95/A1, 95/A3, 96/A1, 96/A3, 97/1, 97/3, 98/A/1A, 98/A/1B, 98/A3, 98/B1, 98/B3, 98/C1,98/C3, 98/D1, 98/D3, 99, 100, 103, 104, 105 and 106 of Honnarahalli Village and Sy, No. 57/C/1, 57/D/1, 57/A/1A, 57/A/2A, 57/A/3A,57/B/A, 57/A/4A, 77/A, 77/B, 78/A and 78/B of Halkote Village, Post – Hatcholi, Taluk- Siruguppa, Dist.- Bellary, Karnataka

2.2 LocationPig iron plant of SREPL is located at Honnarhalli/Halkote village, Siruguppa taluk, Bellary district in Karnataka state. The boundary of the plant is as under:

North : Honnarhalli village road and private lands.South : Private land and private road.East : Siruguppa – Hatcholli road.West : Private lands

The plant is located adjacent to the district road joining Siruguppa and Hatcholli village and is about 8.2 km from Karnataka State Highway-19 joining Srirangapatnam and Bidar. Taluka place Siruguppa and district place Bellary are at 13.5 km and 66.4 km respectively, from the site. Nearest Railway station is at Adoni, which is about 36.4 km from the site. The nearest villages to the site are, Honnarhalli: 1.4 km N, Chikkabellary: 2.4km NE, Shigaragadde: 1.6 km S, Kududarahal: 2.5 km S and Hatcholi : 7 km NE.

The perennial rivers Thungabhadra and Hagari are located at 1.8 km NW and 1.6 km SW, respectively from the site. A rain water stream Gorchivenka is located at 6 km NE to the site. Both river Hagari and stream Gorchivenka are tributaries to riverThungabhadra.

The land available with SREPL is about 114.97 acres. Further 25.42 acres is being acquired through KIADB. 38 acres of land is utilized for pig iron plant and 25 acres for DIP Plant of 120,000 TPA capacity. The balance area will be available for the proposed



project and green belt. The location of the land confers several advantages, which are summarized below:

• Proximity to major raw material sources, markets and major ports. DIP plant get the Hot metal (pig iron) from the existing Pig iron plant. Hence proximity of the proposed plant to the existing Pig iron plant is a must.

• Infrastructure facilities exist at this location

• The project site is at a distance of 8.2 km from the State Highway • Ecologically sensitive areas are not in the vicinity.

• Water will be available from Thungabhadra River. Electric power will be from the GESCOM Substation at Sirugupa.

• Housing colonies, educational facilities, recreational facilities and other amenities are available at Siruguppa/Bellary.

Considering the above, the location at Honnarhalli/Halokote village is consideredsuitable for the proposed project.

Table 2.1: Land Breakup of the Existing and Proposed Expansion

Description Land in Acres

LAND AVAILABILITY

• Existing 114.97

• Land being acquired through KIADB 25.42

• Total 140.39

LAND UTILISTION

• Existing Pig Iron Plant 38.00

• DIP plant (120,000TPA) 25.00

• Proposed expansion projects 30.00

• Green belt development 47.39

• Total 140.39



Fig 2.1Location of the proposed project site



Fig 2.2 Toposheet of the area showing the location of the proposed expansion project site (Toposheet No.s: 57 A/13, 57 A/14, 57 E/1, 57 E/2 Scale 1:50,000)

10 kms Radius



Fig 2.3 Aerial view of the proposed project site.Existing units

Proposed

units



Fig 2.4 Aerial view of the proposed project site with 10 kms demarcation



Fig 2.5 Satellite imagery of the study area

(Source: Dr. Anantha Rama, GIS consultant)



Fig 2.6 Photos showing the existing Pig Iron Unit

North: Barren landEast: Pig Iron unitWest: RoadSouth: Vacant land



Fig 2.7 Photos showing site surrounding photograph

North: Barren LandWest: Agricultural landEast: Barren LandSouth: Agricultural land



Fig 2.8 Photos showing the proposed project site

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2.3 Project Description with Process Details:

2.3.1 Modernisation of Pig Iron Plant

Hot blast stoves

The existing blast preheater will be replaced with hot blast stoves to achieve optimum thermal efficiency and high blast temperature. It operates on regenerative principles. It is first heated by burning blast furnaces gas in it to raise the temperature of the chequer bricks and then used for heating the blast which passes through it in opposite direction

Pulverised coal injection system

In order to achieve overall economic efficiency and to minimise the coke consumption, pulverized coal injection system will be provided for injection of bituminous or mixed coal with enriched oxygen. The PC injection rate of 150 kg/t of hot metal is envisaged. One integral system with the combination of coal pulverizing and PC injection will be built with the adoption of vertical coal pulverizer, dense phase PC conveying andoxygen enrichment

Oxygen injection unit

Direct injection of hot oxygen into blast furnace tuyers yield improvement in operatingcost, energy consumption and emissions. Also it raises the calorific content in the top gas, minimize coke consumption and raise hot metal productivity. Oxygen and fuel are introduced to a combustion chamber where they react to produce a hot oxygen gas at temperatures up to 2,000oC. This hot oxygen then passes through a nozzle to produce a high-velocity jet, the momentum of which ensures penetration of the oxygen jet into the blast stream and good coal mixing.Oxygen is injected at the tuyer level along with coal dust at a rate of 45-50 Cum/ton of hot metal.

Steam Injection unit

Iron making through the blast furnaces is a very crucial process in an integrated steel works and its optimum operation is essential for overall plant economy and efficiency. One of the critical parameters controlled in the blast furnace is the humidity levels in the 'blast'. Humidity in the blast is maintained by controlling the amount of steam injected into the blast based on operation requirements. About 50 gm/m3 of hot metal is injected.

Table: 2.3 Raw material Requirement

Material Quantity, TPA Source

Iron ore 140,000 E-Auction

Iron ore sinter3,00,000 Sinter plant



Coke1,55,000 Coke oven plant

Lime stone 35,000 Bagalkot

Dolomite 25,000 Lokapur

Manganese 3,000 Sandur

Quartz 11,000 Hospet

Water 250 KLD Tungabhadra River

Power 1000 KVA Captive

Steam 50 gm/m3 of hot metal Captive

Table 2.4 Chemical characteristics of Iron ore

Table 2.5 Chemical characteristics of Limestone

Table 2.6 Chemical characteristics of Dolomite



Table 2.7 Chemical characteristics of Quartz

Table 2.8: Material balance

INPUT OUTPUT

Material Quantity, TPA Material Quantity, TPA

Iron ore 140,000 Pig iron 200,000

Iron ore sinter 3,00,000 Iron ore fines 97,800

Coke 1,55,000 Coke fines 11,000

Lime stone 35,000 B.F.Slag 58,000

Dolomite 25,000 GCP dust 6,720

Mn. 3,000 GCP sludge 5, 430

Quartz 11,000 P.I.Scrap 15,330

BF Gas 66,600 Nm3 / hr

Table 2.9 BF gas generation and utilization

Sl.No Details Quantity,Nm3 / hr

1 Blast Furnace gas generated after expansion to 200,000 TPA 66,600

2 B.F.Gas required for Stoves/air preheating for BF 28,000

3 B.F gas required for Power plant boiler 22,000

4 BF gas for sinter plant 16,600

2.3.2 Coke Oven PlantShree Ram Electrocast Pvt Ltd plans to set-up a heat recovery type stamp chargedcoking plant to produce about 160,000 tons of gross coke per year, generating electricity making use of the waste gas of coking plant.

The production facilities will contain: coal preparation plant, coking plant and coke screening plant. The auxiliary production facilities will include central control room, central testing room; infrastructure works include main power substation, coking plant substation, water supply and sewerage works, fire protection, etc.



The waste heat of gases will be used for power generation. Shree Ram Electrocast Pvt. Ltd. is considering CDM benefits for the said power project for economic viability.

Design parameters

Production CapacityProduce 160,000 tons dry coke per year in the first phase of project Product Range

• BF coke (80 to 25mm) 145,000 tons• Pearl coke (25 to 10mm) 10,000 tons

• Coke breeze (<10mm) 5,000 tons

• Gross coke (dry) 160,000 tons

Quality of coke

• Ash (dry) < 12.0 %• VM (dry) < 1.0 %

• Moisture (max) 6 %

• Sulfur (max) 0.60 %• Phosphorous (max) 0.040 %

• M40 (min) 82 %• M10 (max) 8 %

• CRI (max) 20 %

• CSR (min) 65 %

Heat-recovery Stamping Coke Oven works on negative-pressure operation and the upper and lower structure of oven doors stop the leaks of the dust in the cokingprocess. Volatile substances produced in coking are all burnt completely.

• There is no equipment for the recovery of chemical products and coke oven gas purification in the production of Heat-recovery StampingCoke Oven, which means no chemical sewage is generated during the process. The coke quenching waste water is in a closed-cycle without any let off outside thus realizing real zero discharge.

• Heat-recovery Stamping Coke Oven belongs to the large volumechamber coke oven. The large volume chamber coke oven has many advantages such as big coke block, uniform coke quality, few numbers of input coal/output coke to reduce the leakage of dust and the power consumption as well as to increase the life of coke ovens.

• The coke produced by Heat-recovery Stamping Coke Oven holdsadvantages of big coke block, little coke powder, high strength anduniform coke quality.

• Heat-recovery Stamping Coke Oven adopts the structure of largevolume chamber and the stamping coking technique, which has thehorizontal structure when stamping the cake. It changes the course of



coke oven gas and chemical products flowing in the chamber and the weakly coking coal can be made use of largely. 40 ~ 45% non coking coal can be mixed to the coking coal, which is of great significance to the conservation of coking coal resources.

• Stamping machine is the key coking equipment, the performance ofwhich directly affects the coke quality and normal production of coke ovens. Heat-recovery Stamping Coke Oven adopts the hydraulicstamping technology. This technology makes the cake have suchfeatures as large and uniform density, smooth surface, low noise and little maintenance.

• Heat-recovery Stamping Coke Oven eliminates the coke guide cars used in conventional coke ovens and collects the coke horizontally, which is effective in decreasing the dust falling from the process of output coke and increasing the block of coke.

• All material generated in the coking process is burnt completely inside the coke oven and turns into high temperature waste gas, which is used for steam/power generation by the heat recovery boiler. The electricity can be largely generated in the coking process with a little waterconsumption.

The process flow chart of heat recovery stamping coke oven is given below:

Fig 2.9 Flow chart of heat recovery stamping coke oven



There are coal preparation plant, coking plant and coke sorting plant in the process of Heat-recovery Stamping Coke Oven. The process of Heat-recovery Stamping Coke Oven is very convenient, needs little infrastructure support facilities as well as low investment in the construction with short building period.

There is low power consumption, low operating and maintenance costs during theentire process of production. Coke of various specifications and quality can beproduced in Heat-recovery Stamping Coke Oven through changes in the mixture of coal preparation and the heating system.

Table 2.10 Raw materials required


Coking coal 1,60,000TPA

Weakly coking coal 70,000 TPA

Total coal requirement (dry) 2,30,000 TPA

Total coal requirement (wet) 2,48,400TPA

Indigenous / Imported from Jharkand,Singareni, South Africa, Australia,

China

Water 800 KLD Tunga Bhadra River


Table 2.11: Quality of Coal

1 a) i Size ii Fractions below 0.5 mm

b) Total moisture (on as – received’ basis)

c) Proximate analysis (on as received basis)

i) Volatile matter (dry basis)ii) Ash (dry)

iii) Inherent moistureiv) Fixed carbon

d) i ) Phosphorus ii) Sulphur

0 – 50 mm25%

8% maximum

24 26%9 – 10% maximum

1.5% maximumBy difference

0.06% maximum0.6–0.8% maximum



Table 2.12 Material balance – Coke Oven plant

INPUT OUTPUT


Coking coal 1,60,000TPA Gross Coke 160,000

Weakly coking coal 70,000 TPA Flue gas 96,000 Nm3/hr

Total coal requirement(dry)

2,30,000 TPA

Total coal requirement(wet)

2,48,400TPA

2.3.3 Power PlantThe proposed 30.0 MW Power Plant will have 2 x 22 TPH (MCR) Waste Heat Recovery Boilers which will utilize the sensible heat of flue gas from the Coke oven plant and one AFBC Boiler of 54 x 2 TPH (MCR) using biomass/coal and 2 x 15 MW turbogenerator. Waste gases from the coke oven plant will be let into the waste heat boilers. The boiler will be bi-drum, water tube boiler. The front radiation section is made up of fin welded water walls. Suitable hopper is provided at the bottom of the radiant section forcollection of the dust, which has to be periodically removed for disposal. The gases leaving the radiant section will enter the super heater and then the boiler bank. After this the gas will pass through economizer and the temperature of the gas will bereduced to about 1700C. Then the gas will pass through ESP and ID fan to Chimney. The parameters of the steam at the outlet of the superheater will be 90 kg/cm2 and515+/-5 0C.108 TPH (MCR) Atmospheric Fluidised Bed Combustion Boiler will be fired withbiomass/coal. The parameters of the steam at the outlet of the superheater will be 90 kg/cm2 and 515+/-5 0C. The AFBC boiler will be a bi-drum water tube boiler with Fluidised Bed Combustion. The furnace is made up of fin welded membrane water walls. Evaporative bed coils are provided in fluidised bed zone. The fluidised bedcombustor comprises of Bed plate with fluidizing air nozzles; fuel nozzles and ash drain pipes. Under bed fuel feeding is proposed for admission of fuel on to the Combustor. Necessary fluidizing air is supplied by a forced draft fan and pneumatic transport air is supplied by primary fan. Ash along with bed material has to be periodically removed from the combustor for disposal. The flue gases leaving the membrane wall furnace enters the convective super heater and then on to boiler bank tubes. The flue gas will enter L.T.Super heater section, bare tube economizer and then to air heater. Now the flue gas temperature will be about 1700C. Then the gas will pass through ESP and ID fan to Chimney.Steam from the boilers will be fed to a common steam header which will ultimately take it to two bleed cum condensing type Steam Turbine Generator each rated for 15 MW at inlet steam parameters of 90 kg/cm2 & 515+/-5 0C. The turbine exhaust will be



condensed in water cooled condenser and the condensate will be taken to de-aerator by condensate extraction pumps.The condensate will be de-aerated in the de-aerator and the temperature will be raised normally with the help of extracted steam from turbine. Provision of heating of condensate in de-aerator by the auxiliary steam coming from main steam headerthrough PRDU will also be envisaged. The feed water will be fed to the economizer of each boiler through a common feed water header by boiler feed pumps

Biomass/Coal for AFBC boiler will be stored in adequate quantity. This will bereclaimed by front end loaders and transferred by belt conveyors to the feedpreparation units and then to the boiler bunker. Bottom ash will be collected and stored in the ash storage area for disposal to Brick manufacturers. Fly ash from economiser, ESP, air preheater, etc will be conveyed to the ash silo for disposal.

Table 2.13 Raw material requirement

Raw material Quantity Source

Coal 1,25,000 TPA Jharkand, Singareni, South Africa,Australia, China

Waste gas from Cokeoven plant

96,000 Nm3/hr Coke oven plant



Table 2.14 Chemical characteristics of coal



Fig 2.10 Power Plant- Flow diagram

2.3.4 Ductile Iron Pipe PlantDuctile iron belongs to the family of cast iron which includes grey iron, ductile iron, malleable iron, white iron, etc. The Ductile iron has become the industry standard for water systems. It has proven its strength, durability and reliability in transporting water and sewage across varied terrain. Ductile iron’s corrosion resistance is equal to orgreater than that of cast iron. The added advantage in using Ductile iron pipes is that these pipes resist damage during shipping, and handling and once installed the most demanding operating conditions including water hammer, frozen ground, deeptrenches, areas of heavy vehicular traffic, river crossings and areas of shifting, expansiveand unstable soils. And once installed, the ductile iron pipes are virtually maintenance free.

Ductile iron spun pipes of dia 100 to 1000 mm are made with socket and spigot ends or flanges conforming to national and international standards.

Manufacturing of Dl pipe is a continuous sequential process involving several sub-processes. The process starts with receipt, desulphurization, scrap charging and super heating of molten metal in induction furnace; pipes are centrifugal cast using molten metal; heat treatment follows in annealing furnace to give ductility to the pipes cast; lining and coatings are carried out to manufacture finished pipes.

2 X 22TPH

2 X 54 TPH

2 X 15 TPH



Metal Preparation:

The metal shop is equipped with induction furnaces- 5 nos. of 15 ton capacity each and magnesium treatment convertors. Input raw material to the furnace is pig iron. The raw material is charged into the furnace using overhead bay cranes of 50/ 15 Ton – 1 no. and 5 ton – 1 no. capacity. All the cranes are with AC induction motors and are havingvariable speed AC Drives. The cranes are equipped with complete control systemconsisting of motors and variable frequency AC drives and controlgear for alloperations of Long travel, hoist, auxiliary hoist and cross travel. The speed of thedifferent movements is controlled by varying the speed of the AC induction motors by varying the frequency of the AC supply to the AC motor. The control system hasprovision for operating the crane from master controller (cabin) or from remotecontrols. The metal composition and tapping temperature are controlled to the exact specifications before magnesium treatment. The metal is tapped in ladles and shifted from the furnace to the convertor and then to the casting machine using overhead bay cranes. The metal is treated with pure magnesium in controlled conditions. Thetreatment with pure magnesium is optimized to ensure the total nodularity of graphite.

Mould conditioning:

The permanent moulds are inspected at regular intervals and conditioned at the mould conditioning shop with grinding, penning and honing machines.

Core making:

Core shop is equipped with the core making machine. Precise control of the sand and additives ensure rigid cores. This results in precision socket dimensions contributing to excellent fitment of socket and spigot ends. This ensures leak proof joints.

Spinning:

The ductile iron pipes of 100 – 1000 mm dia. and 5.5 mtr. and 6 mtr. length is made using centrifugal casting machine using sloped, water-cooled steel moulds. Alloperating parameters like mould rotation speed, traverse time etc, are designed and controlled to produce defect free, compact pipes to give best service life. All operations at spinning machine are controlled with latest PLC systems and AC variable speed drives. The pipes are weighed immediately after retrieval from the moulds and visually inspected before allowing to go for next stage of production.

Internal grinding:

The barrel, socket and spigot ends of the pipe are ground on a grinding machine.Grinding ensures perfect socket and spigot profile resulting in perfect fitment leading to leak proof joints.



Heat Treatment:

The pipes are heat treated in a continuous type annealing furnace to change the metal matrix to ferrite to improve ductility and mechanical properties. The pipes are pushed via chain specially designed for resisting heat and roll from one end to other end of furnace on skids made from special heat resistant material. To avoid the heat loss and better heat concentration in each zone special type of refractories are used which are lined in to furnace shell to avoid heating of furnace walls also. The refractories are mainly high alumina bricks they are bonded with each other through suitable castables.

Also to avoid the heat loss at the top of the roof inside modules with blankets are fitted. The proportional controls of the heating system and the variable speed facility conveyor chain ensures the right type of heat treatment for any size pipe. All operations arecontrolled with latest PLC systems. The furnace consists of various zones like heating, soaking, rapid cooling, holding and cooling.

In the annealing furnace bay 1 no. of 5 ton overhead bay crane is provided formaintenance purpose.

The pipes are transferred to the finishing bay using motorized transfer trolley. In the finishing bay 1 no. of 5 ton cap overhead bay crane is already installed and 1 no.additional crane is proposed. These cranes will be used for maintenance purpose and for pipe loading and unloading into the gantries and steam curing pits. All the cranes are with AC induction motors and are having variable speed AC Drives. The cranes are equipped with complete control system consisting of motors and variable frequency AC drives and control gear for all operations of Long travel, hoist, and cross travel. The speed of the different movements is controlled by varying the speed of the AC induction motors by varying the frequency of the AC supply to the AC motor. The control system has provision for operating the crane from master controller (cabin) or from remote controls.A 5 T capacity crane is used to load and unload the pipes from the gantry and on the gantry.

Zinc Coating

Metallic zinc coating is applied by a spray process in which metallic zinc material is heated to a molten state and projected in minute droplets by spray guns on to the pipe surface. The spraying of zinc droplets onto the pipe surface is done through pressurized air fed through compressor. The zinc coating forms a stable protective layer ofinsoluble zinc salts. It provides active protection due to galvanizing effect thusenhancing the inherent corrosion resistance of ductile iron. All operations are controlled with latest PLC systems. Pipe rotation and carriage movements are with AC induction motors and are having variable speed AC Drives.



Cut off and chamfering machine

In case the pipe ends are cracked or broken, then the damaged piece is cut in the cut off machine using a circular saw. After cutting the end are chamfered using a grinding wheel mounted on a trolley. Ductile iron pipes which are OK bypass this process.Hydrostatic pressure testing

Each pipe is tested at the specified test pressure for specified period to ensure trouble free service of pipes. To perform the test, pressure is applied internally by filling withwater and steadily maintained for a minimum period of 10 seconds. Only pipes which pass through this test are accepted for further processing. All operations are controlled with latest PLC systems.

Cement Mortar feeding and lining

Cement and sand are initially collected in a silo and are fed into a mixer with water. The cement mortar thus prepared is fed into the pipe using feeding machine which consists of a moving trolley with a tank and pump. The ductile iron pipes are internally lined with cement mortar by centrifugal process which gives uniform thickness, highercompaction and smoother internal surface providing higher ‘C’ value. Duringcentrifugal casting process the pipes are restricted in vertical and horizontal direction by 3 sets of roller assembly – 2 at the bottom and one in vertical direction. Themovement of vertical cylinder assembly is through pneumatic cylinder, the pressurized air for which is being supplied by compressor. A stand by compressor is also provided in case of breakdown. The trolley movements in the cement mortar feeding machine and pipe rotation are with AC induction motors and are having variable speed AC Drives.

Steam Curing

Steam curing provides better strength to cement mortar lining and minimizes formation of cracks in the lining. This ensures longer life of the lining. Steam is produced in a coal fired steam boiler of 4 ton cap.

Bitumen Coating

Before coating the pipes are pre-heated in a hot chamber to dry out any moisture from steam curing and to give better adherence of paint. Bituminous paint is applied on outside surface by airless spraying gun which ensures uniform thickness of coating on the pipe surface. All operations are controlled with latest PLC systems. Pipe rotation

and carriage movements are with AC induction motors and are having variable speed AC Drives.

Marking and stenciling



Name and logo of the manufacturer, year of manufacture, class of pipe, qualitycertificate number are marked on the external surface of the pipes using stencils. Some of those marked information are requirements of the applicable standards.

Storage, packing and dispatch

Finished pipes are stacked using 5T goliath crane in the stockyard in stacks normally in three ways, viz. square stacks, pyramidal stacks and parallel stacks. Pipes of less than DN 400 size are normally bundled after putting wooden bars between pipe layers for the purpose of separating. Pipes are dispatched in trucks and trailers.

Table 2.15 Raw materials required


Hot metal 2,00,000 Pig Iron plant

Steel scrap 10,000 Bellary, Hospet

Ferro Silicon 1,729 Hospet

Magnesium 333 Kolhapur, Bangalore, Kerala

Core Sand 5,717 Mangalore, Karwar

Cement 20,000 Cement grinding unit

Sand for cement coating 28,580 Local



Table 2.16 Chemical analysis of Ferrosilicon



Table 2.17 Chemical analysis of Silico manganese

Table 2.18 Material Balance- Ductile Iron Pipe plant

INPUT OUTPUT


Hot metal 2,00,000 Ductile Iron pipe 200,000

Steel scrap 10,000 Burnt sand generated in casting section

5,600

Ferro Silicon 1,729 MgO 200

Magnesium 333 Zno 100

Core Sand 5,717 Slag 1000

Cement 20,000

Sand for cement coating

28,580



Fig 2.11 Ductile Iron Pipe Plant- Process Flow Diagram

Hot metal

Sponge iron

Ferro alloy

CENTRIFUGAL CASTING

HOLDING FURNACE

CHARGING, ADDITIVES & SUPERHEATING

MAGNESIUM ADDITION

HEAT TREATMENT IN ANNEALING FURNACE

CUT OFF AND

CHAMFERING

INTERNAL GRINDING

BITUMEN COATING

CEMENT MORTAR LINING

& STEAM CURING

PRESSURE TESTING

STORGE, PACKING &

DESPATCH

MARKING & STENCILING

ZINC COATING



2.3.5 SINTER PLANT

Sintering is a technology for agglomeration of iron ore fines into useful Blast Furnace burden material. This technology was developed for the treatment of the waste fines in the early 20th century. Since then sinter has become the widely accepted and preferred Blast Furnace burden material. Presently more than 80% of hot metal in the world is produced through the sinter. In India, approximately 60% of hot metal is produced using sinter feed in Blast Furnaces.

The major advantages of using sinter in BFs are: Use of iron ore fines, coke breeze, metallurgical wastes, lime, dolomite Better reducibility and other high temperature properties Increased BF productivity Improved quality of hot metal Reduction in coke rate in blast furnaces

The modern large blast furnaces use 100% prepared burden in form of sinter and pellets. The blast furnace burden consists of 70 – 80 % sinter and 20 – 30 % either iron ore or pellets. For blast furnaces, the sinter is a superior burden material than pellets as its higher basicity > 1.6 can totally replace raw flux charging in blast furnace while pellets cannot have basicity > 1.2. The softening temperature of sinter is also higher than that of pellets.In an integrated steel plant, many metallurgical wastes like flue dust in BF, mill scale in rolling mill and CCM, LD/EAF dust, iron ore super fines in bag house and ESPs,calcined lime/dolo dust in calcination plants, etc are generated, which can be directly used in sinter plant. The production cost of sinter is also less than that of pellets.For the pig iron plant of Siruguppa, a sintering machine of 30 m2 sintering area has been proposed. At a productivity of 1.4 t/m2/hour, its designed capacity will be 1000 tpd or 330,000 tonnes/year BF sinter.

Table 2.19 Design parameters of sinter plant

No Item Unit Index

1 Straight line Sinter Machine

Effective Sintering Area m2 30

Productivity (BF sinter) t/m2/h 1.4

Availability % 90.0

Working days d 330

2 Working days of whole plant d 330

3 Annual Production (Design capacity) t 330,000

4 Quality of Finished Product



Fe (T) % 53-55

FeO % 9-12CaO % 8-10

SiO2 % 4-5

MgO % 2-3

Al2O3 % 2-3

S % 0.02-0.03

CaO/ SiO2 1.8-2.0

Granularity mm 80-6

Degradation Index for cooled sinter( -5mm) % =10

ISO Tumbler index( +6.3mm) % =66

A Sinter Plant typically comprises the sub-units as shown in figure below. The raw materials used are Iron ore fines (-10 mm), coke breeze (-3 mm), Limestone & dolomite fines (-3mm) and other metallurgical wastes such as mill scale, flue dust, etc. The proportioned raw materials are mixed and moistened in a mixing drum. The mix is loaded on sinter machine (straight line / circular) through a feeder onto a moving grate (pallet) and then the mix is rolled through segregation plate so that the coarse materials settle at the bottom and fines onto the top.The top surface of the mix is ignited through stationary burners at 12000C. As the pallet moves forward, the air is sucked through wind box situated under the grate. A high temperature combustion zone is created in the charge –bed due to combustion of solid fuel of the mix and regeneration of heat of incandescent sinter and outgoing gases. Due to forward movement of pallet, the sintering process travels vertically down.

Fig 2.12 Typical sinter plant

The hot sinter discharged from the machine is broken in a single toothed roll crusher and screened over a hot screen at a temperature of 800 – 900°C. the undersize (- 6 mm)

Proportioning

bin



hot sinter fines are charged over the charge mix conveyor while the oversized sinter (6 –150 mm) is fed to a straight line or circular cooler where it is cooled to a temperature < 100°C.The cold sinter is screened into three fractions, 0-6 mm (cold sinter return fines), 10-20mm (hearth layer) and 6-150 mm (BF sinter). The process flow sheet of sinter plant is given below:

MATERIAL ANNUALCONSUMPTION

(TPA)

SOURCE

Iron ore fines 3,10,200 E-Auction & Pig iron plant

Lime stone 29,700 Lokapur

Dolomite 25,410 Lokapur

Quicklime 7,260 Dronachalam

Coke breeze 16,000 Coke oven plant

Mill scale 3,300 Pig iron plant

Flue dust 6,720 Pig iron plant

BF gas 1,32,00,000 m3 Pig iron plant

Water 75 KLD Tungabhadra River


Table 2.20 Raw materials requirement



0 - 150 mm

6 - 150 mm

Flue gas

0 – 6 mm

Hot return fi

10 - 20 mm

Hearth layer

0 - 6 mm

Cold return fi

0 - 20 mm sinter

10 - 20 mm

sinter Finished sinter to blast

furnace

Raw material proportioning system

Primary mixing drum

Secondary mixing drum

Hearth layer

hopper

Sintering machine (30

Sinter cake crushing

Hot screening

Sinter cooler, 40 m2

Primary screening

Mixture

hopper

Secondary screening

Headend ESP

Exhaust fan

Tail end ESP

Chimne

Flux fines 0-3 mm

Iron ore fines 0-8 mm

Coke fines 0-3 mm

Return fines and other materials (Mill sale & flue dust fines)

0-10 mm

water

water

20-150 mm

Exhaust fan

Chimney

Fig 2.13 Flow chart of sinter plant



Table 2.21 Material Balance- Sinter plant

2.3.6 Cement Grinding PlantThe raw materials clinker and granulated slag are stocked in separate raw materials hopper through loader. These are discharged from the hopper with the help of two table feeders to the belt conveyor. As required gypsum is added on the conveyor for quick and slow setting of the cement. Some times if the clinker is very top quality, gypsum may not be used in the manufacturing cement. After passing through theconveyor belt, materials are lifted by the another bucket elevator to a third raw mixed hopper. Basically in this position, all the materials are properly mixed and through a feeder materials are charged into the ball mill for grinding into powder form. There are three compartments for grinding the materials. 1st and 2nd chamber are filled up by the grinding media of size 100/90/80/70/60 and 3rd chamber filled by cylpebs of size 25 x 25 / 30 x 30 / 35 x 35. Finally the cement dust are produced in the third chamber andfrom there the cement goes to the silo through a air-lifter and lastly through a packing machine to fill the bags for dispatch.

Table 2.22 Raw material requirement

Material Quantity, TPA Souce

Clinker (CaO-60%) 40,000 TPA Other cement plants

Gypsum(CaSO2.2H2O-75%) 2,000 TPA Gulbarga, Tadipatri,Tumkur

Granulated B.F.Slag 58,000 TPA Pig iron plant

MATERIAL CONSUMPTION(TPD)

ANNUALCONSUMPTION

(TPA)

Iron ore fines 940 3,10,200

Lime stone 90 29,700

Dolomite 77 25,410

Quicklime 22 7,260

Coke breeze 80 16,000

Mill scale 10 3,300

Flue dust 10 3,300

BF gas 40,000 m3 1,32,00,000 m3



Water 25 KLD Tungabhadra river


Table 2.23 Chemical analysis of Clinker

Table 2.24 Chemical analysis of Gypsum

Table 2.25 Chemical analysis of BF slag



Table 2.26 Material Balance for Cement grinding plant

INPUT OUTPUT


Clinker (CaO-60%) 40,000 TPA Cement 100,000

Gypsum(CaSO2.2H2O-75%)

2,000 TPA

Granulated B.F.Slag 58,000 TPA

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2.4 WATER AND POWER REQUIREMENTWater required for the existing unit: 500 KLDWater required for the DIP plant (120,000 TPA) : 700 KLDWater required for the proposed units: 2285 KLD

Table 2.27 Makeup Water requirement

Sl.No Name of the plant/unit Makeup Waterrequirement(KLD)

1 Pig iron plant after modernisation(capacity increase from 120,000 TPA to200,000 TPA)

250

2 Metallurgical Coke Plant 8003 Power Plant 30 MW 900

4 DISP Plant 1005 Sinter plant 75

5 Slag cement grinding plant 256 Water for domestic use 65

7 Water for green belt development 70 Total for the proposed units 2285

Water required for the existing Pig Iron Plant of 120,000 TPA

500

Water required for the DIP Plant of120,000 TPA

700

Total water requirement after theproposed expansion

3485

Present water allocation 2400

Additional water requirement 1085

Source: Tungabhadra River. Commerce & Industries Department of KarnatakaGovernment has given in principle approval for drawal of 4150 KLD of water from Tungabadra River for the expansion projects vide Government order No: CI 57 SPI 2011, Bangalore Dated 25.02.2011.

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Table 2.28 Power Requirement

Sl.No Name of the plant/unit Powerrequirement

(KVA)

1 Pig Iron plant-modernization to increase the capacity from 120,000TPA to 200,000TPA

1000

2 Metallurgical Coke Plant 750

3 Power plant 42004 DIP Plant 3000

5 Sinter plant 2,0005 Slag Cement Grinding plant 450

6 Utilities & auxiliaries 1,600 Total for the proposed units 13,000

Power required for the existing Pig Iron Plant of 120,000 TPA

2,000

Power required for the DIP Plant of120,000 TPA

11,000

Total Power requirement after theproposed expansion

26,000

Power available from Captive powerplants

28,900

Surplus for export 2900

The power demand will be met from the existing power plant of 2.5 MW and proposed captive power plant of 30 MW and a power grid support of 12 MVA.

Energy Balance chart

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68M/s Shree Ram Electrocast Pvt Ltd.,

2.5 MANPOWER

The organization structure for the Company envisages the Board controlling and

directing the overall functions and activities of the company. Managing Director will have a President & CEO supporting him for overall functions of the company. The

company intends to divide the organization on functional lines with Marketing

Managers, Factory Managers, Company Secretary and Finance and Accounts, Human

Resource & Administration each managing their respective functions. The FactoryManager would be responsible for over all Operation & Maintenance, Quality Control

and Material Management. The project implementation will be taken up by the technical team under the overall supervision of Managing Director/President & CEO.

The total man power requirement for the whole unit (existing +expansion) has been

estimated at 800 personnel comprising managerial (17) and supervisory (43) , skilled (162) and unskilled (193) as given below:

Table 2.29 Man power requirements

**Existing manpower including the contract labour for pig iron plant of 120,000 TPA.

There are villages about 4-5 km from the site which should provide the necessary

personnel and the company is not expected to face any problem regarding man power

availability.

Indirect employment will be about 800-900 personnel for transportation, Infrastructure

assistance, ancillaries, etc

Sl.No Name of the plan/unit Manager Super. Skilled Unskilled Total

1 Pig Iron PlantModernization

1 2 10 12 385** +25

2 Metallurgical Coke

Plant

3 6 24 27 60

3 Power Plant 2 4 12 12 304 DIP Plant 6 20 80 94 200

5 Sinter plant 2 4 15 19 40

6 Slag cement grindingplant

1 3 6 10 20

10 Utilities 2 4 15 19 40

Total 17 43 162 193 385**+415



CHAPTER III- DESCRIPTION OF THE ENVIRONMENT

3.0 IntroductionThe proposed project is an expansion project with the following units:

• Pig iron plant modernization to improve the fuel efficiency and increase

in production capacity from 120,000 TPA to 2,00,000TPA

• Coke Oven Plant - 160,000 TPA


• Expansion of Ductile Iron Pipe Plant- from 1,20,000 TPA to 200,000 TPA

• Sinter Plant – 300,000 TPA

• Cement Grinding Plant – 100,000 TPA

at Sy.No.s 80, 81/A3, 95/A1, 95/A3, 96/A1, 96/A3, 97/1, 97/3, 98/A/1A, 98/A/1B,

98/A3, 98/B1, 98/B3, 98/C1,98/C3, 98/D1, 98/D3, 99, 100, 103, 104, 105 and 106 ofHonnarahalli Village and Sy, No. 57/C/1, 57/D/1, 57/A/1A, 57/A/2A, 57/A/3A, 57/B/A, 57/A/4A, 77/A, 77/B, 78/A and 78/B of Halkote Village, Post – Hatcholi,

Taluk- Siruguppa, Dist.- Bellary, Karnataka. Tunga Bhadra River is located at a distance

of 1.8 Kms from the proposed project site and villages like Honnarahalli village,

Hachcholli village, Chickabellary at a distance of around 2-5 kms from the proposed expansion project site. Siruguppa is at a distance of 13.5 Kms from the proposed

expansion project site. Hachcholli - Siruguppa road is adjacent to the project site in the

Eastern Direction.

The plant is located at 66.6 kms from Bellary town, which is proximate to rich deposits

of Iron ore at Bellary, Hospet & Sandur area to provide an assured and continuous

supply of raw materials. Well known fact that Karnataka is the richest in terms of mineral potential in the country, with large deposit of Iron ore. Considering the demand for steel and steel

products, the company proposes to utilise the opportunity and therefore has proposed

to set up the above mentioned units at the existing pig iron plant.

The location is very well connected by Road & Rail. Moreover, the unit will further add

to the Economy of the state and provide additional employment to the people of

neighbouring villages.

This Environmental Impact Assessment Study report will give an assessment of the

various environmental impacts likely to be caused on the surrounding nature in and

around the proposed project. It will also incorporate the appropriate control measures

required to be adopted or implemented in order to minimize the adverse effects thereof. In order to carry out such assessment study, it is first necessary to delineate and define

the existing environmental factors in and around the proposed project on the existing

environmental scenario which will include various environs like ecology, Flora-fauna,

socio economic profiles, environmental quality in respect of air, water, noise & soil etc. This section incorporates the description of the existing environmental settings within

the area encompassed by a circle of 10 km radius around the proposed project site.



The base line study was conducted during the month of October 2011 to December2011.

3.1 Baseline Data • Primary data collected for various environmental aspects

Table 3.1 Primary data collected

Parameter Locations for proposed

data collection

Source

Air Quality 8 locations Primary

Water 9 locations Primary

Meteorology 1 location PrimarySoil 5 locations Primary and Secondary

Noise Level 6 locations Primary

Ecology Study Area Primary and Secondary

Geology and Hydrology Study Area Primary and SecondaryLand use Study area Primary and secondary

Socio-Economic Study Area Secondary

• Secondary data will be collected from published sources and Government

agencies

3.2 Soil Characteristics

The proposed project site has red soil mixed loamy soil and also having partly red sandy

suitable for agriculture and horticulture crops. The taluk is having few RockyMountains with exrophytic vegetation. The soil samples collected from the proposed project site and within the study area too

were analyzed for important parameters and the results of the soil quality are tabulated

below.



Fig 3.1 Location of Soil sampling stationsTable 3.2 Location of soil sampling stations

Sample Location Distance

S1 Project Site -

S2 Shridaragadde 2.0

S3 Road going towards Honnarhalli 1.5

S4 Chikka Bellary 3.0

S5 Walabalary 3.5

S2

S3

S5S4

S1



Fig 3.2 Monitoring photographs

Table 3.3 Soil Quality Analysis

Sl.No

ParametersUnit

S1Project

site

S2Shigaragadde

S3Road going

towards

Honnarhalli

S4ChikkaBellary

S5Walabalar

i

1 pH -- 7.5 7.3 8.1 8.0 9.22 Color -- Brown Brown Black Black Black

3 Conductivity µmho/cm 460 430 353 562 307

4MoistureContent

Percent 2.0 8.5 5.04 5.56 9.07

5 Chloride as Cl mg/Lt 76 285 209 209 190

6 Calcium Percent 12 10.72 17.12 15.44 12.8

7Magnesium as

Mg

Percent 1.6 2.56 6.25 3.92 0.88

8 Nitrogen as N Percent 0.05 0.04 0.04 0.05 0.02

9 Organic MatterPercent 2.81 3.6 3.9 3.47 2.15

10 Phosphorus as P Percent 0.4 0.30 0.30 0.30 0.40

11 Potassium as K Percent 0.05 0.07 0.09 0.08 0.39

12 Sulphur as S mg/Lt 13 12 14 12 13

13 Copper mg/Kg 8.60 8.60 10.30 10.84 19.44

14 Iron mg/Kg 10780.18 6655.05 13215.56 14222.10 10285.61

15 Manganese mg/Kg 2299.28 1176.0 1141.8 425.6 1051.4

16 Sodium mg/Kg 0.04 0.15 0.53 0.59 0.64

17 Zinc mg/Kg 47.68 22.02 20.12 23.20 37.82

18SodiumAbsorptionRatio

Percent BDL 0.01 0.03 0.03 0.05

19 Bulk Density Percent 1.72 1.69 1.82 1.87 1.62

The soil in the study area black and brown in color with pH ranging from 7.3 to 9.2.Moisture content in the soil ranging from 2.0 to 9. The EC varied from 307 to 562

µmho/cm. Organic matter in soils ranged from 2.15 to 3.9. Nitrogen values ranged between 0.02 to 0.05 %. Distribution of available nitrogen in soils is found to be in



sufficient levels. The Phosphorus levels ranged between 0.3 to 0.4 %. Soil potassiumvaried from 0.05-0.39%.

3.3 Air EnvironmentDispersion of different air pollutants released into the atmosphere have significant

impacts on the neighbourhood air environment of an industrial project and forms an

important part of impact assessment studies. The ambient air quality status with respect

to the study zone of 10 km radial distance from the plant site will form the base line information over which the predicted impacts due to the proposed expansion plant can

be super imposed to find out the net (Final) impacts on air environment. From the final

impacts a viable Environmental Management Plan (EMP) can be prepared based on the impact statement for the air environment. The baseline status of the ambient air quality can be assessed thorough scientifically designed ambient air quality monitoring

network. The design of monitoring network in the air quality surveillance program has

to be based on the following considerations.

• Meteorological conditions on synoptic scale

• Topography of the study area

• Representation of regional background levels

• Representation of plant site

• Representation of cross sectional distribution in the downward direction

• Influence of the existing sources if any, are to be kept at minimum

• Inclusion of major distinct villages to collect the baseline status

3.3.1 Micrometeorological Data

Micro-meteorological data within the project area during the air quality survey period is

an indispensable part of air pollution study. The meteorological data recorded during survey period is very useful for proper interpretation of the baseline information as well

as for input, to predictive models for air quality impacts.

To understand meteorological scenario primary and secondary data collected and used in the interpretation of the data and data collected from the both sources are

summarized as followsTable 3.4 Data collection for Meteorological data

Meteorological

data

Primary data: Hourly data of site

Wind speed, Direction, Temperature, RH, station level pressure & rainfall

(Daily maximum, minimum, highest, lowest temperatures,

maximum, minimum humidity, Rainfall and mean wind speed

mean monthly wise data)

3.3.1.1 Historical Data

Historical data on meteorological parameters also plays an important role in identifying

the general meteorological status of the region. The data generated in the field iscompared with the historical data.

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3.3.1.2 Meteorology – Data generated at plant site

Meteorology of the study zones plays an important role in the study of air pollution.

Micrometeorological conditions at the proposed expansion project site regulate the

dispersion and dilution of air pollutants in the atmosphere. For this purpose a weather station was installed near the plant site for three months (Oct to Dec, 2011) and

recorded hourly observations for the parameters like Maximum and minimum

Temperatures (ºC), Relative Humidity (%), Wind Speed (km/hr), Wind direction, Solar

radiation and Rainfall mm.



The hourly-recorded observations (wind velocity and wind directions) during 12 weeks

study period are used in computing percentage frequencies (0-7 morning, 8-15 noon,

14-24 evening & 0-24 hrs) and are depicted in the form of ‘wind roses’.Table 3.6 meterological data for the period Oct-Dec 2011

WindDirection,

°from North

WindSpeed,kmph

Temperature,°C

RelativeHumidity,

%

StationLevel

Pressure

in hPa

Rainfall,mm

OctoberMax 360 20.8 33.7 100 964 6

Min 9.1 0.2 20.9 37 956 0

Avg 170 5.8 26.5 81.0 960.2 0.02

November

Max 360 18.2 32.8 95 967 1.5Min 10 0.2 16.1 27 957 0

Avg 127.7 5.7 23.8 70.4 962.0 0.007

December

Max 360 27 31.9 100 967 10

Min 10 1 12.6 20 957 0Avg 139.3 7.7 22.9 71.3 962.1 0.02



Fig. 3.4 Meteorological Scenario – Wind Rose diagram for Oct-Dec 2011

3.3.2 Selection of AAQ stationsA network of eight ambient air-sampling locations has been selected for assessment of

the existing status of air environment within the study zone. The heights of the

sampling locations were kept between 3-5 ft in all the locations. After reconnaissance of

the area and observing the topographical features and review of the availablemeteorological data and local conditions the sampling sites were chosen which will be

the representative of the local areas under study.

3.3.3 Existing AAQ (Pre-project) statusAmbient levels of pollutants listed in NAAQS, 2009 were determined. The methodology

of sampling and analysis in detail are given in the following tables.

Air – Parameters analyzed and sampling durationTable 3.7 Air parameters analysed

Attribute Parameter Frequency of Monitoring

AAQ

PM10,PM 2.5

SO2& NOx, O3, CO,

NH3, C6H6, BaP, Pb, As, Ni

24 hr sampling , Sampling height varies between 3-5ft above

ground level.



Ambient Air Quality - Methodology

Pollutant Method of analysis

PM10 Particulate Matter Gravimetric method

PM2.5

Particulate Matter Gravimetric method

Du

st

Dust PAHs Filter paper extraction with methylene

chloride

SO2 Sulfur dioxide Improved West and Geake Method

Va

ria

ble

s

NO2 Nitrogen Di Oxide Jacob & Hochheisser Modified Na- Arsenate

O3 Ozone Chemiluminescence (Instrument ) method

CO Carbon monoxide Instrumental method

NH3 Ammonia Indophenol Blue method

C6H6 Benzene GCMS method (Instrumental)

Ga

ses

BaP Benzo(a) pyrene GCMS method (Instrumental)

Pb Lead AAS method (Instrumental)

As Arsenic AAS method (Instrumental)

meta

ls

Ni Nikel AAS method (Instrumental)



Fig 3.5 Air quality monitoring stations



Table: 3.8 Details of Air Quality monitoring station

Station No Location Distance

(Kms)

A1 Project Site -

A2 Shridaragadde 2.0

A3 Walabalari 3.5

A4 Ginwal 5.5

A5 Upla 5.0

A6 Kadlabalu 4.3

A7 Hachcholli 6.9

A8 Dhadesugur 9.2

Fig : 3.6 Some of the Monitoring photographs



Table: 3.9 Air quality monitoring results

Sl

No

Location PM10

µg/m3

PM2.5

µg/m3

SO2

µg/m3

NO2

µg/m3

Lead

µg/m3

Ammonia

µg/m3

CO

mg/m3

Ozone

µg/m3

NAAQ Standards 100 60 80 80 1.0 400 4.0 180

A1 Project Site 72.5 29.8 4.5 13.2 0.07 12.5 0.65 1.5

A2 Shridaragadde 76.7 30.2 4.9 14.0 0.06 12.2 0.6 1.4

A3 Walabalary 70.0 25.6 4.6 14.1 0.02 12.8 0.7 1.5

A4 Ginwal 88.8 32.4 5.7 14.5 0.04 12.1 0.7 1.4

A5 Upla 94.8 33.6 4.9 15.2 0.03 13.1 0.8 1.5

A6 Kadlabalu 83.4 36.6 5.9 16.3 0.04 13.2 0.91 1.5

A7 Hachcholli 95.8 39.3 5.8 15.7 0.02 12.8 0.7 1.5

A8 Dhadesugur 85.4 25.3 5.5 14.7 0.03 12.5 0.7 1.6

Nickel (ng/m3), Arsenic (ng/m3), Benezene (µg/m3) and Benzo(a) pyrene(BaP)( ng/m3)

values are observed BDL at all the times

3 months data used for modeling is enclosed as Annexure -1

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3.4 NOISE ENVIRONMENT

The word noise arose from the Latin word ‘nauseas’, it is a loud outcry or commotion that is unpleasant, unexpected, or undesired with various frequencies over the audible

range due to the regular activities of the Mankind primarily Noise pollution (or

environmental noise) is displeasing human, animal or machine-created sound thatdisrupts the activity or balance of humans or animals life. The source of most outdoor noise worldwide is mainly evolved from Industries, constructions and transportation

systems, including motor vehicle noise, aircraft noise and rail noise, poor urban

planning may give rise to noise pollution

Industrial Noise resulting to noise pollution has many reasons such as industries being

close to human habitats which prevent the noise from decaying before it reaches human

ear.

A determination is made of the micro scale impact by predicting anticipated noise levels for each alternative during both construction and operational phases. Predicted noise

levels are compared with applicable standards or criteria in order to assess the impact.

The physical description of sound concerns its loudness as a function of frequency.

Noise in general sound which comprises of many frequency components with different variations in loudness over the audible frequency range.

Various noise scales have been introduced to describe, a single number, the response of

an average human to a complex sound made up of various frequencies at different loud levels, the response of the human ear to sound is dependent on the frequency of the sound and this has led to the concept of weighting scales. In the "A -weighting" scale, the

sound pressure levels for the lower frequencies and higher frequencies are reduced by

certain amounts before they are being combined together to give one single sound

pressure level value. This value is designated as dB (A). The dB (A) is often used as it reflects more accurately the frequency response of the human ear. A perceived loud

noise has a high dB or dB (A) value and a soft noise has a low one. The human ear has

peak response around 2,500 to 3,000 Hz and has a relatively low response at low

frequencies

3.4.1 Impact Assessment of Noise Environment

The environmental impact assessment of noise for the proposed project was carried out

by taking various factors into consideration like potential physiological responses,annoyance and general community responses and also taking all the factors mentioned

in the above lines in to considerations the existing status of noise levels within the Study

zone, which is a primary requirement for impact assessment studies has been

undertaken for the monitoring of baseline noise levels.

3.4.2 Existing Noise Levels

Existing pre -project noise levels have been monitored at different points within the

study zone. Keeping in view of various local activities such as residential, commercial



and Industrial activities 10 noise level measurement locations were identified and the sites are depicted in the Figure

Fig. 3.7 Map Showing Noise Sampling Locations



Table 3.18 Noise locations

Code Location Distance

N1 Project Site -

N2 Shigaragadde 2.0

N3 Road going towards Honnarhalli 1.5

N4 Pol Chik Bellai 3.0

N5 Walbalari 3.5

N6 Upla 5.0

3.4.3 Methodology of Noise measurement

For Noise levels measured over a given period of time interval, it is possible to describe

important features of noise using statistical quantities. This is calculated using the

percent of the time as certain noise levels are exceeding the time interval. The notations

for the statistical quantities of noise level are given below:

L10 is the noise level exceeded 10% of the time.

L50 is the noise level exceeded 50% of the time and

L90 is the noise level exceeded 90% of the timeEquivalent Sound Pressure Level (Leq)

The L eq is the equivalent continuous sound level, which is equivalent to the same sound

energy as the actual fluctuating sound measured in the same period. This is necessary because sound from noise source often fluctuates widely during a given period of time.

This is calculated from the following equation

Leq=L50+(L 10–L90)2/60

Lday is defined as the equivalent noise level measured over a period of time during day

(6 am to 10 pm). Lnight is defined as the equivalent noise level measured over a period of

time during night (10 pm. 6 am).

A noise rating developed by Environment Protection Agency, USEPA for specification

of community noise from all the sources is Day-Night Sound Level, (Ldn).

Hourly noise recorded data and Lday values (15 hours) Lnight (9 hours) and L dn (24 hours)

are computed and tabulated.

Day–Night Sound levels (L dn):



The noise rating developed for community noise from all sources is the Day-NightSound Level, (Ldn). It is similar to a 24 hr equivalent sound level except that during

nighttime period (10 pm to 6 am) A 10 dB (A) weighting penalty is added to the

instantaneous sound level before computing the 24 hr average.

This is time penalty is added to account for the fact that noise during night when people

usually sleep is judged as more annoying than the same noise during the daytime.

The L dn for a given location in a community may be calculated from the hourly

Leq’S, by the following equation.

Ldn = 10 log {1/24 [15(10 Ld/10) + 9 (10 9Ln + 10 ) /10 ) ] }

Where Ld is the equivalent sound level during the day time (6 am to 10 pm) and Ln is the

equivalent sound level during the night time (10 pm to 6 am).

The statistical analysis is done for measured noise levels at 10 locations.Fig 3.8 Noise monitoring photographs:



Table 3.19 Summary of Ambient Noise Level Monitoring Results As per Residential Limits Standards- Leq Day- 55 dB(A) and Leq Night- 45 dB(A)

Code LocationLeq Max

dB(A)Leq min

dB(A)

Distancefrom the

Project site (Kms)

N1 Project Site 42.5 35.5 -

N2 Shridaragadde 44.5 39.8 2.0

N3 Road going towards Honnarhalli

48.6 40.51.5

N4 Chikka Bellari 35.4 31.5 3.0

N5 Walbalari 42.7 33.8 3.5

N6 Upla 46.8 37.5 5.0

3.5 WATER ENVIRONMENTStudies on Water Environment aspects of ecosystem is important for Environmental Impact Assessment to identify sensitive issues and take appropriate action by

maintaining ‘ecological homeostasis’ in the early stages of development of the project.

The objective of this report is to define the present environment in which the proposed action is to occur, to evaluate all possible eventualities, to ensure that all negative

impacts are minimized, and to demonstrate that proposed project has beenappropriately announced to all interested parties so that their concerns can be

considered.

3.5.1 Water quality monitoring

Three surface water sample and six Groundwater (Bore well water) samples were

collected in the study area and have been analyzed for describing the baseline water environment. Water is a vital essential commodity necessary for the survival ofvegetation, animals and human beings and for proper balance of eco system itself.

Hence it is necessary to study the quality of water in the study area to find out if

industrial activities in and around the area have caused any deterioration in the

environmental quality with respect to surface and ground water sources, so that the health and growth of humans, flora, fauna and soil conditions are not affected

adversely. This assessment may also serve as a baseline to compare with the post

establishment data for taking necessary corrective measures; if at all any of the

parameter tends to exceed the prescribed limit.The details of these water-sampling stations are given below and their locations are as shown



Fig 3.9 Water monitoring stations



Table 3.20: water sampling station details

Station No Location Distance GPS reading

Ground water

GW1 Project Site - 150 44’ 47.3” N760 57’ 24.3” E

GW2 Honnarhalli 1.3 150 45’ 24.6” N760 56’ 43.2” E

GW3 Shridaragadde 1.6 150 43’ 59.75” N760 56’ 38.75” E

GW4 Walaballary 2.3 150 45’ 55.97” N760 56’ 24.72” E

GW5 Ginwal 4.9 150 45’ 59.64” N

760 55’ 07.81” E

GW6 KottolaChintal 6.4 150 43’ 23.6” N770 00’ 55.72” E

Surface Water

SW1 Tungabhadra River upstream

7.4 150 46’ 44.09” N770 00’ 40.05” E

SW2 Tungabhadra River Downstream

2.3 150 44’ 20.16” N760 55’ 43.14” E

SW3 Hagari River near to Kudadarahalu

1.2 150 43’ 52.58” N760 56’ 41.62” E

Fig 3.10 Photographs of monitoring



Table 3.21: Water Quality Results

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98

Hydrology, Geology, hydromorphology and water quality studies have been carried out in the study area to understand the availability of water resources, possibility of water

contamination and existing water quality

3.6 HydrologyReconnaissance survey of the study area was carried out during the post-monsoonseason and various sampling locations for monitoring various

hydrological/hydrogeological parameters have been identified. Subsequently, field

study has been commenced for collecting information on water levels, aquiferparameters, surface storage etc., at the selected locations. The other studies such as

climate/rainfall, geology, historical water levels etc., have been based on secondary data

collected from various government and semi-government agencies.

3.6.1 Hydrometeorology

The climate of an area is the synthesis of weather conditions that have prevailed over a long period of time. This synthesis involves both average of the climatic elements and

measurements of variability (such as extreme values & probabilities). Climate is acomplex, abstract concept involving data on temperature, humidity, precipitation type

and amount, wind speed and direction, atmospheric pressure, sunshine, cloud types

and coverage and such weather phenomena as fog, thunderstorms and frost and the

relationships among them. Climate is never stable but is subject to continuingoscillations and therefore it is time dependent.

3.6.2 Rainfall

In the study area and environs, the rainfall occurs mainly in the form of rain. Theamount of annual rainfall recorded at the Bellary station for the period from 2006 to 2010 is presented in tabular form below.

The onset of southwest monsoon is normally during the first week of June and iswithdrawn by the end of September.

During this period, the area receives 699.4 mm of rainfall on an average.

In 2010, area received 861.8 mm rainfall out of which, during August maximum of 298.8 mm rainfall was observed. This rainfall accounts for 42.7% of the annual rainfall. Period

from October to December constitute the northeast monsoon season. During this period, the area receives 226.5 mm of rainfall on an average accounting for 32.3% of the annual

rainfall.

During March to May about 114.8 mm of rainfall was occurred.

Overall, the area receives 699.4 mm of rainfall annually on an average (from 2006-10).

The annual rainfall data for the period 2006 to 10 has been taken into consideration for

studying the variability or rainfall over study area with time. The year to year variation

of rainfall is conspicuous. The heaviest rainfall of 914.5 mm was recorded in 2009 and


99

the lowest rainfall of 528.3 mm was recorded in 2006. The 5 years moving average and the line of best fit indicate zigzag trend of rainfall. The annual trend of rainfall for the

period 2006-10 is given in Table below.

Table 3.22 Monthly Annual Rainfall Distributions

Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Annual

Rainfall

2006 0 0 26.2 14.4 95.6 87.1 47.0 28.1 130.6 38.1 61.2 0.0 528.3

2007 0 0 2.1 3.2 51.9 143.1 71.3 65.1 225.4 82.0 6.1 0.2 650.4

2008 0 10.7 100.0 2.6 36.6 33.6 31.6 100.4 139.7 57.4 29.6 0.0 542.2

2009 0 0 6.3 6.7 69.4 76.9 34.9 108.8 266.2 265.2 68.0 12.1 914.5

2010 19.2 2.7 0.0 25.9 88.9 58.7 76.3 298.8 64.8 98.6 127.4 0.5 861.8

Source: IMD

3.7 Geology and Structures

3.7.1 Regional Geology

The geological history of Karnataka is largely confined to the two oldest eras.

1. The Archean

2. The Proterozoic

The rest of the great periods from Cambrian to recent hardly represented but for minor

sediments of recent age along the coastal margin to the west. Thus the belt of the rocks

of Karnataka are Archean in age going back to the very dawn of geological history. The

study area largely falls in the basin of Tungabhadra river. The area is marked with undulating topography with granite hills and few chains of hills composed of Dharwar

schist. The geological Time-Scale in Karnataka is as given below.

• Laterite, alluvium black soils

• Coastal Teritary,

• Deccan Volcanic

• Bhima

• Badami

• Closepet Granite

• Dharwar Schist Belt

• Kolar type auriferous schist belt

3.8 HydrogeologyHydrogeologyNumerous small streams flowing in southern direction towards the Thungabhadra river

crisscross the study area. The prominent stream in the study area is Garchi vanka which

flows in the northern direction and ultimately empties into Thungabhadra river near

Maturu. There are no major ponds in the area. The small ponds and streams carry water only during and just after monsoon season.


100

Thungabhadra river is located in the North West direction and flowing east. All the streams finally join with the Thungabhadra river. The left and right bank canal from the

Thungabhadra river caters to most of the agricultural irrigation needs.

Occurrence and movement of ground water in Rock FormationsThe joints and other openings in the gneiss and granites, the pore spaces in the zone of

weathering and bedding planes of the metamorphosized sediments determine the rate

of percolation of water into sub-surface and the yield of the wells in the region. Black

cotton soil allows water to infiltrate slowly after saturation. The impervious calcareous clay bed, below the black cotton soil prevents the downward movement of water.

Whether, the areas covered by red loam/sandy soils have relatively greater percolation

because of its relatively high porosity and permeability.Occurrence of ground water thus, is mainly controlled by water conditions. The

recharge of the ground water is mainly due to the rainfall, which is scanty in the region. Therefore, the depth of water table is just near the surface in the wells bordering the

canals.

Due to the inadequate data available on ground water conditions, estimations of ground

water movement in the study area could not be possible. However, considering the overall features, the ground water movement appears to be from north-west to south

and from south-east towards the Thungabhadra river.

Hydrogeological study conducted within 10 kms radius of the proposed project site is as follows:


101


102


103


104


105

3.9 ECOLOGICAL STATUS (TERRESTRIAL AND AQUATIC)

Ecosystems play a key role in balancing the human environment relations. Their plant species consume solar radiation along with water and minerals and produce food and

oxygen for other components of ecosystem. Plants also accumulate the toxic air

pollutants whereas the animal population consumes the organic wastes. Theseecosystems are particularly valuable as repositories of many unique varieties of flora and fauna.

It is obvious the large-scale developmental projects alter the natural surrounding and

hence have an impact on the ecosystem and its components flora and fauna. Before

implementing such projects, it is vital to understand the baseline status of flora and faunal diversity. The baseline data helps to design the project in such a way that any

harmful impacts on the vegetation and fauna can be avoided. It also provides an insight

to mitigate plans to reorganize adverse impact on the natural surroundings.Terrestrial Ecology

Visual survey was conducted to record the available flora and around the area of the

industry. Some of the information was gathered from the local habitats and forest

department. All the collected data were classified to interpret the impact of pollution on the flora and fauna of that region. Survey of the mild plants as well as cultivated crop plants was made and all the available information was recorded. Mesophytic trees were

found along the bunds of the cultivated fields and also on either side of the streams. The

list of some abundant species found in the region is given below.Table 3.23 Flora found in the study area

Sl. No Botanical FamilyHerbaceous Flora

1 Hydrill verticillata presl Hydrocharitaceae

2 Euphorbia hirta L Euphorbiaceae3 Cassia unifloral Caesalpiniaceae

4 Lemna sp. Lemnaceae

5 Marseilea Poraceae

Exotic flora

1 Araucaria sp. Araucariaceae

2 Jail gobli Mimosaceae

3 Bidulu Poaceae

4 Kusumba Asterraceae

5 Belijali Acacea leocophioea

6 Babul jail Acacia arabica

7 Paragimara Caricaceae

8 Sisu Agavaceae

9 Ganda Paiasha Annonaceae

10 Hirejali, Goddajali Acacia latronum11 Chandan Santaiance

12 Madi Epherdraceae

13 Navilumettu Soymida fegrifuga


106

Grass

1 Cyperus sp Cyperaceae

2 Cyndon Dactylon Poraceae

3 Sorghum sp PoraceaeWeeds

1 Indigoflora sp Fabaceae

2 Sida cordifolia Malvaceae

3 Urena tobata MalvaceaeHerbs & Shrubs

1 Solanum melongena linn Solanaceae

2 Musa paradisiacal linn Musaceae

The main land use in and around the area is farming mainly cultivated with crops are

given below. The cultivated of crop plants in mainly depended on the rain, although

well irrigation is common in some places. The major crops are:Table 3.24 List of major crops

Sr. No Common Name Botanical Family Name

1 Jower Zeamays Poaceae

2 Sugarcane Sacchrum officinale Poaceae

3 Sunflower Carthus tinetoria Asteroceae

4 Maize Sorghum vulgase Poaceae

5 Bengal gram Cicar anictinum Papilionaceae

6 Red gram Cajanus cajam Papilinoceae

7 Wheat tricum aestivcum Poraceae8 Tomato Lycopesicum escilentum Salanaceae

9 Ground Nut Arachis hypogea Papilionaceae

10 Red pepper Capsicum annuum Solananeace

11 Gram Cajanus cajan

12 Banjara Peucedanum graveolens

Important fruit plants

1 Banana Musa paradisica2 Papaya Papita

Animals observed in the study area are fox, pugs, dears, wild pores etc. Based on the type of contribution of organisms and its physical setting the study area can be classified into cropland ecosystem and terrestrial ecosystem. The forest ecosystem in the study

area has no suitable habitat for moiré diversification of the flora and fauna. There is no

endangered or rare flora or fauna in the region. Similarly, there are no important

medicinal plants.Other than for domestic animals no suitable habitat is found for wild animals. Similarly,

no migration route for any fauna is observed in this area. No important sanctuaries or

ecologically sensitive areas are located near proposed site to take any special attention. Mammals, Reptiles and Amphibians are found in the study area are:


107

Table 3.25 List of fauna found in the study areaSr. No Common Name Scientific name Feeding Niche

Mammals

1 Bat Rhinolopus spp. Fruits, insects etc

2 Jungle cat Felis chous Carnivorous

3 Bannet Monkey Macaca radiate Fruits, leave, spiders

4 Field mouse Rattus rattus Grains, insects, etc

Reptiles

1 Cobra Naja naja

2 Krait Bungarus coeruleus

3 Rat snake Ptyas mucosus

4 Wall lizard Hemidactylus brooki5 Garden lizard Calotes versicolor

Amphibians

1 Common Frog Rana tigrina2 Toad Bufo melanostictus

Birds

1 Domestic sparrow Passer domesticus

2 Golden headed woodpecker Dinopium benghalense

3 Koel Eduynamys scolopacea

4 Indian myna Acrodontherus tristis

5 Spotted dove Streptopela chiensis

6 Small blue king fisher Alcedo atthis

Aquatic EcologyThe perennial river Thungabhadra and its tributaries Hagari and Chikhagari are

flowing in the region of the project site. Other surface water sources are the seasonal

nallahs and these seasonal nallahs will drain the rain water from the area during rainy season. Since, these nallahs are seasonal in nature. There are some valley/drains spread

over the surrounding area, all join together and flowing towards North-west, joining Thungabhadra River.

List of Phytoplanktons and zooplanktons in Thungabhadra river is given below.Table 3.27 List of aqua fauna

Phytoplankton Zooplankton

Aphanizomeenon flos-aque Rotifer

Melosira granulate Brachionus sp

Scenedesmus obliquus Ephiphanus sp

Nostoc pruniforme Dapnia sp

Euglena acus Crustacean larva sp

Euglena pisciformis

Microcystis flos aque

Nitzschia sigma


108

3.1 0 Demographic dataExtract of demographic details obtained from Census department is enclosed as Annexure-2


109

CHAPTER-IV ANTICIPATED IMPACTS

4.0 Introduction

Prediction of impacts is the most important component in the environmental impact

assessment studies. Several scientific techniques and methodologies are available to predict impacts of project developmental activities on environment. Such predictions

are superimposed over the baseline (proposed project) status of environmental quality

to derive the ultimate (post-project) scenario of environmental conditions. Theprediction of impacts helps to prepare the Environmental Management Plan (EMP)required to be executed during the on-going activities for the proposed project to

minimize the adverse impacts on environmental quality.

The mathematical models are the best tools to quantitatively describe the cause-effectrelationships between sources of pollution and different components of environment. In

case, mathematical models are not available or it is not possible to identify/validate a

model for a particular situation, predictions could be made through available scientific

knowledge and judgments.

The environmental impacts can be categorized as either primary or secondary. Primary

impacts are those, which are attributable directly to the project, secondary impacts are

those, which are indirectly induced and typically include the associated investment and changed pattern of social and economic activities by the proposed action.

The impacts have been prepared for the proposed expansion assuming that the

pollution due to the existing activities has already been covered under baselineenvironmental monitoring and continue to remain the same during the operation of the

project. The proposed project would create impact on the environment in two distinct

phases.

• During the construction phase which may be regarded as temporary or

short term; and

• During the operation phase which would have long-term effects.

The construction and operational phase of the proposed expansion project comprises various activities each of which may have an impact on some or other environmental

parameters. Various impacts during the construction and operation phase on theenvironmental parameters have been studied to estimate the impact on the

environment. The details on impact of the project activity on each of the above

environmental attributes are discussed below.

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eS

ho

rt-

Ter

mR

ever

sib

leH

igh

Lan

d u

se/

So

il

En

vir

on

men

tD

evel

op

men

t o

f R

oa

ds

Dir

ect,

Neg

ativ

eL

on

g T

erm

Irre

ver

sib

leM

ediu

m

Eco

log

yL

oss

of

veg

etat

ion

Dir

ect,

Neg

ativ

eS

ho

rt-T

erm

Rev

ersi

ble

Med

ium

Air

En

vir

on

men

tB

urn

ing

of

Fu

els

Dir

ect,

Neg

ativ

eS

ho

rt-T

erm

Rev

ersi

ble

Lo

w

Wat

er E

nv

iro

nm

ent

(Su

rfa

ce a

nd

Gro

un

d)

Dis

po

sal

of

Sew

ag

eD

irec

t,N

egat

ive

Sh

ort

-Ter

mR

ever

sib

leH

igh

Lan

d/

So

il

En

vir

on

men

tD

isp

osa

l o

f S

ewa

ge

InD

irec

t,

Neg

ativ

eS

ho

rt-T

emR

ever

sib

leM

ediu

m

So

cio

-Eco

no

mic

Em

plo

ym

ent

Op

po

rtu

nit

ies,

In

flu

x o

f

peo

ple

InD

irec

t,

Neg

ativ

eS

ho

rt-T

erm

Rev

ersi

ble

Med

ium

Lab

ou

r C

amp

s

Hea

lth

Dis

po

sal

of

Sew

age/

So

lid

was

tes

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Hig

h

Air

En

vir

on

men

tT

ran

spo

rta

tio

n o

f C

on

stru

ctio

n M

ater

ials

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Med

ium

Mo

vem

ent

of

Veh

icle

sN

ois

e E

nv

iro

nm

ent

Veh

icu

lar

mo

vem

ent

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Lo

w

Co

nst

ruct

ion

Deb

ris

Lan

d/

So

il

En

vir

on

men

t

Var

iou

s co

nst

ruct

ion

wo

rks

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Lo

w

Ex

cav

ate

dE

art

h/

Mu

ckL

and

/S

oil

En

vir

on

men

tF

ou

nda

tio

n w

ork

sD

irec

t,N

egat

ive

Sh

ort

–Ter

mR

ever

sib

leM

ediu

m

Dis

po

sal

of

Sew

ag

e

Wat

er E

nv

iro

nm

ent

(Su

rfa

ce a

nd

Gro

un

d)

Do

mes

tic

acti

vit

ies

fro

m

La

bo

ur

cam

ps

Dir

ect,

Neg

ativ

eS

ho

rt-T

erm

Rev

ersi

ble

Hig

h

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

11

6

Aes

thet

ics

Od

ou

r n

uis

an

ceIn

Dir

ect,

Neg

ativ

eS

ho

rt-T

erm

Rev

ersi

ble

Med

ium

Hea

lth

Dis

po

sal

of

Sew

ag

eD

irec

t,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Hig

h

Lan

d/

So

il

En

vir

on

men

t

So

lid

was

te g

ener

atio

n,

La

nd

co

nta

min

ati

on

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Med

ium

Aes

thet

ics

Od

ou

r n

uis

ance

InD

irec

t,

Neg

ativ

eS

ho

rt-T

erm

Rev

ersi

ble

Med

ium

Dis

po

sal

of

So

lid

was

tes

Hea

lth

Deg

rad

atio

n o

f S

oli

d

was

te,

attr

acti

on

of

flie

s

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Med

ium

Sta

gn

atio

n o

f W

ater

Hea

lth

Mo

squ

ito

bre

edin

g s

ites

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Hig

h

Wat

er E

nv

iro

nm

ent

(Su

rfa

ce)

Co

nst

ruct

ion

sit

e ar

eas

Dir

ect,

Neg

ativ

eS

ho

rt-T

erm

Rev

ersi

ble

Med

ium

Sto

rm w

ater

R

un

-off

Lan

d/

So

il

En

vir

on

men

tF

loo

din

gD

irec

t,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Hig

h

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

11

7

Tab

le 4

.3:

CH

AR

AC

TE

RIS

TIC

S O

F E

NV

IRO

NM

EN

TA

L I

MP

AC

TS

FR

OM

OP

ER

AT

ION

AL

PH

AS

E

Imp

act

char

acte

rist

ics

Act

ivit

yE

nv

iro

nm

en

tal

Att

rib

ute

sC

ause

Na

ture

Du

rati

on

Rev

ersi

bil

ity

Sig

nif

ica

nce

Air

En

vir

on

men

tO

per

atio

n o

f B

last

furn

ace

Dir

ect,

Neg

ativ

e

Lo

ng

-

Ter

mR

ever

sib

leH

igh

Op

erat

ion

of

Pig

Ir

on

pla

nt

No

ise

En

vir

on

men

t

Op

erat

ion

of

Bla

st

furn

ace

Dir

ect,

Neg

ativ

e

Lo

ng

-

Ter

mR

ever

sib

leL

ow

Op

erat

ion

of

cok

e o

ven

pla

nt

Air

En

vir

on

men

tO

per

atio

n o

f co

ke

ov

enD

irec

t,N

egat

ive

Lo

ng

-T

erm

Rev

ersi

ble

Hig

h

Air

En

vir

on

men

tO

per

atio

n o

f

ann

eali

ng

fu

rnac

e

Dir

ect,

Neg

ativ

e

Lo

ng

-

Ter

mR

ever

sib

leL

ow

Op

erat

ion

of

DIP

pla

nt

No

ise

En

vir

on

men

t

Op

erat

ion

of

ann

eali

ng

fu

rnac

e

Dir

ect,

Neg

ativ

e

Lo

ng

-

Ter

mR

ever

sib

leL

ow

Air

En

vir

on

men

tO

per

atio

n o

f b

oil

erD

irec

t,

Neg

ativ

e

Lo

ng

-

Ter

mR

ever

sib

leH

igh

Op

erat

ion

of

Po

wer

pla

nt

No

ise

En

vir

on

men

tO

per

atio

n o

f b

oil

erD

irec

t,N

egat

ive

Lo

ng

-T

erm

Rev

ersi

ble

Lo

w

Op

erat

ion

of

Cem

ent

gri

nd

ing

un

it

Air

en

vir

on

men

tO

per

atio

n o

f g

rin

din

g

un

itD

irec

tn

ega

tiv

eL

on

g-

Ter

mR

ever

sib

leH

igh

Op

erat

ion

of

sin

ter

pla

nt

Air

En

vir

on

men

tS

inte

rin

gD

irec

t

neg

ati

ve

Lo

ng

-

Ter

mR

ever

sib

leH

igh

Air

En

vir

on

men

tO

per

atio

n o

f D

.G S

et

du

rin

g p

ow

er f

ailu

re

Dir

ect,

Neg

ativ

e

Lo

ng

-

Ter

mR

ever

sib

leL

ow

D.G

Set

op

erat

ion

No

ise

En

vir

on

men

t

No

ise

gen

erat

ion

D.G

Set

Dir

ect,

Neg

ativ

e

Lo

ng

-

Ter

mR

ever

sib

leL

ow

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

11

8

Eco

log

yP

lan

tin

g o

f

tree

s/D

evel

op

men

t o

f L

and

scap

e/P

ark

s

Dir

ect,

Po

siti

ve

Lo

ng

-

Ter

mIr

rev

ersi

ble

Hig

h

Aff

ore

stat

ion

/

Gre

en b

elt

dev

elo

pm

ent/

Pa

rks

Aes

thet

ics

Pla

nti

ng

of

tree

s/D

evel

op

men

t o

f L

and

scap

e/P

ark

s

Dir

ect,

Po

siti

ve

Lo

ng

-T

erm

Irre

ver

sib

leH

igh

Lan

d/

So

il

En

vir

on

men

t

So

lid

was

te

gen

era

tio

n, L

an

d

con

tam

inat

ion

Dir

ect,

Neg

ativ

e

Lo

ng

–

Ter

mR

ever

sib

leM

ediu

m

Wat

erE

nv

iro

nm

ent

(Su

rfa

ce a

nd

Gro

un

d)

Lea

chat

e g

ener

atio

n,

Lan

d c

on

tam

inat

ion

Dir

ect,

Neg

ativ

e

Lo

ng

–

Ter

mR

ever

sib

leM

ediu

m

Aes

thet

ics

Od

ou

r n

uis

an

ceIn

Dir

ect,

Neg

ativ

eL

on

g-

Ter

mR

ever

sib

leM

ediu

m

So

lid

Was

te

gen

erat

ion

Hea

lth

Deg

rad

atio

n o

f S

oli

d

was

te,

attr

acti

on

of

flie

s

Dir

ect,

Neg

ativ

eL

on

g–

Ter

mR

ever

sib

leM

ediu

m

D.G

mai

nte

nan

ceL

and

/S

oil

En

vir

on

men

tU

sed

oil

gen

erat

ion

Dir

ect,

Neg

ativ

e

Sh

ort

–

Ter

mR

ever

sib

leL

ow

Air

En

vir

on

men

tV

ehic

le o

per

atio

n a

nd

fuel

co

mb

ust

ion

Dir

ect,

Neg

ativ

e

Sh

ort

-

Ter

mR

ever

sib

leM

ediu

m

Veh

icu

lar

traf

fic

No

ise

En

vir

on

men

t

No

ise

gen

erat

ion

fro

m

veh

icle

s

Dir

ect,

Neg

ativ

e

Sh

ort

-

term

Rev

ersi

ble

Lo

w

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

11

9

Qu

alit

y o

f Lif

eS

oci

o-

Eco

no

mic

Em

plo

ym

ent

gen

erat

ion

,Qu

alit

y o

f li

fe,

In-f

low

of

fun

ds

in t

he

reg

ion

,

Incr

ease

in

ho

usi

ng

acc

om

mo

da

tio

n

InD

irec

t,P

osi

tiv

eL

on

g-

Ter

mIr

rev

ersi

ble

Hig

h

Sto

rm w

ater

Ru

n-o

ff

La

nd

En

vir

on

men

tF

loo

din

gD

irec

t,

Neg

ativ

e

Lo

ng

term

Rev

ersi

ble

Med

ium


M/s Shree Ram Electrocast Pvt Ltd., 120

4.2 Impact on Environment during Construction Phase

This includes the following activities related to levelling of site, construction anderection of main plant structures and equipment.

4.2.1 Impact on Land use

The total available land with SREPL is 114.97 acres. Additional land of 25.42 Acres will be acquired through KIADB. The proposed plant area is more or less flat which require minimum levelling.

Under this project program there is need for additional process control rooms andworkmen rooms. The construction under this expansion program would bring certain immediate changes in the land use pattern of the proposed area as well as in thevicinity. There will be permanent change in the land use pattern of the existing scenario of land use. No demolition of existing structure will take place during the expansion phase. But these changes can cause any significant negative impacts. Temporary sites will be used for construction works or housing of construction workers.

In view of the country’s economic growth due to industrialization such extension projects are more advantages both economic and conservation of land point of views.

As it is an existing project, the construction activities would not attract a sizable labour population and the influx of population is minimal and likely to be associated with construction of temporary hutments is also minimal. The construction period envisaged for the plant is approximately 24 months. Any changes during the construction phase are temporary.

4.2.2 Impact on Soil

The proposed land is having flat profile; therefore the earthwork involved in levelling the land is very less. The maximum topsoil cover thickness at the plant site is about 1-m. The topsoil removed during the levelling will be stacked separately and will be used during the greenbelt development. Herbs and shrubs will be removed prior tocommencement of bulk earthwork. Removal of trees will be avoided as far as possible based on the construction plan. Medium trees size trees will be uprooted and planted in the designed green belt.

Greenbelt development program will start simultaneously along with civilconstructions.



If the civil activities are not monitored properly the concrete and cement will fall haphazardly and will not project good aesthetic look, there by upper soil strata will be contaminated with concrete. Proper planning during construction period will minimize the upper soil contamination. So proper planning in civil activities will not cause any negative impact on the soil.

4.2.3 Impact on Air Quality

Impact of construction activities on air quality is a cause for concern mainly in the dry months due to settling of dust particles. The main sources of emission during theconstruction period are the movement of equipment at site and dust emitted during the levelling, grading, earthworks, foundation works and other construction relatedactivities. The dust emitted during the above mentioned activities depend upon the type of soil being excavated and the ambient humidity levels. The impact is likely to be for short duration and confined locally to the construction site itself. The composition of dust in this kind of operation is, however, mostly inorganic and non-toxic in nature.

Exhaust emissions from vehicles and equipment deployed during the construction phase also result in marginal increase in the levels of SO2, NOx, SPM, CO and unburnt hydrocarbons. It may, therefore, be deduced that construction activities may causechanges in the PM10 levels locally. The impact will, however, be reversible, marginal, and temporary in nature.

4.2.4 Impact on Water Quality

The construction water requirement will be met from Tungabhadra river water. Impact on water quality during construction phase may be due to sewage generated from the construction work force stationed at the site. As the construction being carried out on the flat terrain and relatively small area, the soil losses will be negligible. Further, the construction activities are more related to mechanical fabrication, assembly anderection, the need of water requirement will be small. Temporary sanitation facilities (soak pits/septic tanks) will be set up for disposal of sanitary sewage generated by the work force as per the prevailing labor laws. The overall impact on water environment during construction phase due to proposed plant is likely to be short term andinsignificant and they will be managed by providing drinking water facility andsanitation facilities at the site during construction phase.

4.2.5 Impact on Noise Levels

Heavy construction traffic for loading and unloading, fabrication and handling ofequipment and materials are likely to cause an increase in the ambient noise levels. The areas affected are those close to the site. However, there is no habitation within 1.0-kmradius area, no habitation to be affected due to noise. At the peak of the construction,



marginal increase in noise levels is expected to occur but they are temporary. Thetypical noise levels of some construction equipment are given.

Table 4.4 Typical Noise Levels of Construction Equipment

Description Noise Levels dB (A)

Earth Movers

Front End Loaders 72-84

Backhoes 72-93

Tractors 76-96

Scrapers, Graders 80-93

Pavers 86-88

Trucks 82-94

Material Handlers

Concrete mixers 75-88

Concrete pumps 81-88

Cranes (movable) 75-86

Cranes (derrick) 86-88

Stationary Equipment

Pumps 69-71

Generators 71-82

Compressors 74-86

Source: US EPA, 1971, WSDOT

The peak noise levels from continuous construction activity may be about 90 dB (A). Since the populated areas are away. (>1.5 km) from the proposed site, the noise levels are considered to have insignificant impact. The noise control measures duringconstruction phase include provision of caps on the equipment and regularmaintenance of the equipment. Workers would be provided with earmuffs andearplugs.

Overall, the impact of noise generated on the environment is likely to be insignificant, reversible and localized in nature and mainly confined to the day hours.



4.2.6 Impact on Terrestrial Ecology

The removal of herbaceous vegetation generally causes loosening of topsoil. The land available with SREPL is about 114.97 acres. Additional land to be acquired through KIADB is 65.13 Acres. However, such negative impacts would be reversible in topositive impacts by development of thick green belt and in a course of time that will develop as a sustainable ecosystem.

4.2.7 Impact on Aquatic Ecology

The construction of the plant is not likely to have any impact on aquatic eco-system, as there are no major surface water bodies in the immediate vicinity of the plant.

4.2.8 Demography and Socio-economics

As the proposed plant site lies in the existing plant premises, there are no persons who will be affected due to land acquisition and no rehabilitation is required.

During the construction period, there will be increase in floating population. Additional strain on civic amenities like road, transport, communication, drinking water, sanitation and other facilities will take place, to meet the work force requirement. The project will provide temporary employment of skilled and highly skilled manpower. Most of the people will be employees of contractors/sub-contractors.

The non-workers [including marginal workers] in the study area constitute about43.06%. This indicates the availability of sizeable manpower required for theconstruction activity.

• Most of the manpower deployed during the construction period will be from local area. During the construction phase there will be increased demand ofservices. These include hotels, lodges, public transport (including taxis), etc.There will also be ample opportunities for providing these services. In addition to the opportunity of getting employment as construction laborers, the localpopulation would also have employment opportunities in related serviceactivities like petty commercial establishments, small contracts/sub-contractsand supply of construction materials for buildings and ancillary infrastructures etc. Consequently, this may lead to economic upliftment of the area.

• The influx of population is very limited it is anticipated that there will be no social conflicts between the guest and host communities in the initial stages of development.

• The movement of work force to and from the place of work and the movement of vehicles carrying equipment and construction material is expected to increase the stress on the local transport and road network. However, considering the



number of people deployed, the impact on road/traffic is marginal andtemporary.

• Labor Rate: As work on plant construction begins, the inflationary push willmanifest itself in increase in labor rate.

• Consumer Prices: Usually the local population will be affected by inflationarytrend sometime later, when prices of local services and produce, egg, fish,vegetables, milk, etc. start rising. This will happen only when a sizeable staff of the project and other associate companies settle permanently in the area.However any such rise in consumer prices is anticipated because the influx of population due to the project activities is minimal.

• Transport and Civil Construction: The transport companies would benefit from the construction of the plant.

• Services: The services like retail shops, banks, and automobile workshops; health care, etc. will expand in and near the proposed township.

• Employment: Large-scale influx of material and money tend to increase the employment opportunities.

• Literacy: The setting up of the proposed plant would increase literacy ratesmarginally.

• Traffic: The plant construction phase will also see a moderate increase in traffic.

• Development of Slums:. The contractors have to necessarily provide basicamenities like water supply, sanitation, electricity etc. at the labor camp tomaintain hygienic condition and aesthetics.

4.2.9 Public Expectation

Major occupation of the people in this area is agriculture. The overall income from agriculture is not constant and largely depends upon the climatic factors. Most of the unemployed literates prefer to work in any industry rather than farming or ownings to small land. The people in the area welcome the project, anticipating more jobs and more infrastructure facilities to the local people, provided that the industry will not cause any pollution in the nearby environment. More over being an economically backward area, the plant will have more positive impacts by creating direct or indirect employment.

4.3 Identification of Potential Impacts during Operational Phase

Both beneficial as well as potential adverse impacts may be expected on environment from any development project due to its various activities associated with theoperations. The impacts may be direct or indirect, short or long term and reversible or irreversible. However during the installation of expansion project, the size of the major civil activities are minimum and the impacts are of temporary. On the basis of the above analysis, the potential significant impacts on the environment from the proposed project are identified as below:

• Soil Quality & Topography and Climate;



• Ambient Air Quality; Traffic

• Water Resources; Water Quality;• Noise Levels;

• Ecology; and Demography and Socio-economics.

4.3.1 Impact on Soil

The generation of solid waste from the proposed expansion project are the likelysources of negative impact on the soil characteristics. The negative impacts will beminimized by proper disposal of solid waste generated in the plant. The solid waste generated from the air pollution control equipment will be collected and disposed off in a scientific manner. The sludge generated from the sanitary waste treatment units will be organic in nature and will be used as manure for the green belt. This will not have any adverse impact on the soil quality. The fugitive dust from the plant duringoperation is likely to be deposited in the nearby areas. However, the proposed dust extraction and suppression measures at the source will significantly reduce thispossibility. Further, the proposed greenbelt comprising diversified species not onlyincreases the biomass, soil fertility, and productivity but also helps as pollution sinks and control of soil erosion. Hence, the likely impact on the soil characteristics will be minimal in terms of aerial spread and will not affect the sub-surface soil, as all precautions will beimplemented during the construction of the plant itself.

4.3.2 Topography and Climate

4.3.2.1 Impact on Topography

The major envisaged topographical changes would be due to the manmade structures like civil structures and including erection of stacks. The land available with SREPL is about 114.97 acres. Additional land to be acquired through KIADB is 65.13 Acres. The impact is not significant however; it will invite positive benefits in the form of land leveling and tree plantations in the plant vicinity.

4.3.2.2 Impact on Climate

The existing vegetation in the study area and the proposed green belt in the plantpremises will always have a cooling effect to offset any increase in temperature. The thermal pollution is only confined to small distance and the proposed greenbelt not only nullifies the thermal emissions but also it helps to keep surrounding ambient air cool.

4.3.3 Impact on Air Quality

The following table shows the emission pathways of pollution from the proposed plant



Table 4.5 List of Pollution ways in stacks

Sl No Emission sources

DIP plant

1 Annealing furnace

2 Mg converter3 Zinc coatingPower Plant

1. FBC BoilerSinter Plant

1 Sinter M/c Head End Exhaust- Dedusting system2 Sinter M/c Tail End Exhaust- Dedusting system

3 Fuel Crushing dedusting system

4 Flux crushing & screening dedusting system5 Cold sinter screening dedusting systemCoke Oven plant with waste heat recovery boilers (2)

1 Coke Oven batteries (2) with waste heat recovery boiler N0.1

2 Coke Oven batteries (2) with waste heat recovery boiler No.2

Cement Plant

1 Dedusting unitPig Iron Plant

1 BF gas fired boiler

2 MBP/BF Stoves3 Gas flare

4.3.3.1 Air Pollution Impact Identification by use of Air Modeling

Prediction of impacts on air environment has been carried out employing mathematical model based on a steady state Gaussian plume dispersion model designed for multiple point sources for short term. In the present case, the software provided by ‘Lakes Environment’, Canada ISC-Aermod view is used for prediction of pollutants. It is a complete and powerful air dispersion modeling package which seamlessly incorporates the popular U.S.EPAmodels ISCST3, ISC Prime and Aermod into one interphase without any modifications to the models.

ISCST3 (Industrial Source Complex-Short Term Version 3) dispersion model is a steady state Gaussian plume model which can be used to assess pollutant concentrations from a wide variety of sources associated with an Industrial Source Complex.

4.3.3.2 Pollutants/Model Options Considered For Computations



The model simulation deal with three major pollutants viz. Particulate Matter (PM10),Sulphur Dioxide (SO2) and Nitrogen dioxide (NO2) emitted from the proposed stack. The model options used for computation is as follows

• The plume rise is estimated by Briggs formulae, but the final rise is alwayslimited to that of the mixing layer;

• Stack tip down-wash is not considered;

• Buoyancy Induced Dispersion is used to describe the increase in plumedispersion during the ascension phase;

• Calms processing routine is used by default;

• Wind profile exponents is used by default, 'Irwin';• Flat terrain is used for computations;

• It is assumed that the pollutants do not undergo any physico-chemicaltransformation and that there is no pollutant removal by dry deposition;

• Washout by rain is not considered;

• Cartesian co-ordinate system has been used for computations; and

• The model computations have been done for 10-km with 1000-m interval.

4.3.3.3 Model Input Data

The proposed expansion plant will have 15 stacks. The details of stack emissions from plant are given below. The flue gas from two coke oven batteries will pass through one Waste heat recovery boiler and then through chimney. The flow of volume of air is calculated based on stack diameter, velocity and temperature. The emission rates are calculated based on sulphur and ash content in the fuel used. Apart from stack discharge details, field generated meteorological conditions such as anemometer height; pre-processed meteorological data (temperature, wind speed, direction, cloud cover etc) are also used as in put data. The height of the stack is calculated based on the sulphur dioxide and particulate emission rate and which ever more is used in modelcalculations. Based on the topography simple flat terrain is chosen. The site location is indicated in the form of latitude and longitude and Mean Sea Level (MSL). Total 10 km radius around site is chosen and x, y coordinators and receptors are given accordingly.

Emission data used for modeling is enclosed as annexure-3

Results of air quality modeling carried out to the proposed expansion plant is enclosed as Annexure-4

4.3.3.4 Fugitive Emissions

As the release height is less, the impacts of fugitive emissions are localized. Fugitive emission are predicted using following emission factors (USEPA emission factors).



Table 4.6 Fugitive emission data

Sl.No.

Operation PM 2.5 PM 10

1 Near Blower House 112.0 266.02 Near Boiler House 146 345.0

3 Near RMHS 46.0 102.04 Near Workshop 325.0 125.0

5 Near Group Hopper 91.0 102.0

Fig 4.1 Dispersion of particulate matter

Fig 4.2 Dispersion of SO2



Fig 4.3 Dispersion of NO2

Table 4.7 Summary of Air quality dispersion model:

SlNo

Pollutant NAAQStandards(µg/m3)

MaximumBaselineconcentration

(µg/m3)

MaximumIncrementalconcentration

(µg/m3)

Totalconcentration(µg/m3)

Remarks

1 Particulatematter

100 78.0 5.077 83.077 Theconcentrationis well

within thestandard.

2 SO2 80 5.6 1.567 7.167 Theconcentrationis well

within thestandard.

3 NO2 80 15.3 0.943 16.24 Theconcentration

is wellwithin thestandard.



4.3.4 Impact on Traffic

The product generated in the existing plant being used for the proposed plantproduction. Hence there is only insignificant increase in the existing traffic levels. The raw material and finished products of the proposed plant will be transported by road.



Existing Traffic loadTable 4.8 Existing traffic

MAIN APPROACH ROAD- TOWARDS HATCHOLLI

MAIN APPROCH ROAD TOWARDSSIRUGUPPA

Total

VEHICLES3

WH

EE

LE

R

2 W

HE

EL

ER

CY

CL

ES

VEHICLES

3 W

HE

EL

ER

2 W

HE

EL

ER

CY

CL

ES

VEHICLES

3 W

HE

EL

ER

2 W

HE

EL

ER

CY

CL

ES

TIME(HRS)

HEAVY MEDIUM LIGHT HEAVY MEDIUM LIGHT HEAVY MEDIUM LIGHT

00.30-

01.302 0 0 0 3 0 1 0 0 0 0 0

3 0 0 0 3 0

01.30-

02.301 0 0 0 4 0 0 0 0 0 0 0

1 0 0 0 4 0

02.30-03.30

2 1 0 0 3 0 1 0 0 1 0 03 1 0 1 3 0

03.30-04.30

0 2 1 1 4 3 2 1 3 0 2 02 3 4 1 6 3

04.30-05.30

1 0 2 2 3 1 1 0 2 0 1 12 0 4 2 4 2

05.30-06.30

3 1 1 1 4 1 2 2 1 2 5 35 3 2 3 9 4

06.30-

07.300 3 3 3 5 2 1 3 4 3 4 2

1 6 7 6 9 4

07.30-08.30

4 2 2 2 8 4 3 7 6 1 8 57 9 8 3 16 9

08.30-09.30

1 4 4 5 7 5 2 5 8 3 12 33 9 12 8 19 8

09.30-10.30

2 5 5 4 13 3 4 4 3 4 6 46 9 8 8 19 7

10.30-11.30

5 3 7 7 9 2 7 2 2 2 3 212 5 9 9 12 4

11.30-

12.306 8 5 5 8 4 5 8 7 1 5 4

11 16 12 6 13 8

12.30-

13.302 7 9 9 10 1 4 6 5 3 4 2

6 13 14 12 14 3

13.30-14.30

1 4 3 3 11 3 2 2 9 4 3 33 6 12 7 14 6

14.30-15.30

3 6 4 4 8 5 2 4 13 2 7 15 10 17 6 15 6

15.30-16.30

0 4 5 5 9 2 1 5 4 0 8 01 9 9 5 17 2

16.30-17.30

0 2 2 2 6 5 0 2 5 1 10 20 4 7 3 16 7

17.30-

18.302 1 1 1 8 7 1 3 4 4 4 1

3 4 5 5 12 8

18.30-

19.301 0 3 3 9 4 3 7 3 2 3 3

4 7 6 5 12 7

19.30-20.30

0 0 3 3 4 2 3 2 3 4 5 13 2 6 7 9 3

20.30-21.30

2 3 2 2 5 1 4 1 0 1 3 06 4 2 3 8 1

21.30-22.30

4 2 0 0 2 0 1 0 2 0 1 05 2 2 0 3 0

22.30-23.30

1 2 1 1 0 1 1 1 0 0 0 12 3 1 1 0 2

23.30-

00.300 0 1 1 0 0 0 0 1 1 1 0

0 0 2 2 1 0

TOTAL 43 60 64 64 143 56 51 65 85 39 95 38 94 125 149 103 238 94

Avg. 2 2 3 3 6 2 2 3 3 1 4 1 4 5 6 4 10 4

Max. 6 8 9 9 13 7 7 8 13 4 12 5 12 16 17 12 19 9



Table 4.9 Generated Traffic Due to the Proposed expansion Project (Operation Phase)Proposed+existing TPA working

days/annum

TPD truckcapacity

trucksrequired

Total no of trcuks

Limestone 29700 330 90 16 5.625 5

Iron ore fines 212400 330 643.63636 16 40.22727273 40

Dolomite 25410 330 77 16 4.8125 5

Quick lime 7260 330 22 30 0.733333333 1

Iron ore 140000 330 424.24242 16 26.51515152 26

limestone 35000 330 106.06061 16 6.628787879 6

Dolomite 25000 330 75.757576 16 4.734848485 5

Manganese 3000 330 9.0909091 16 0.568181818 1

Quatrz 11000 330 33.333333 16 2.083333333 2

Clinker 40000 330 121.21212 16 7.575757576 7

Gypsum 2000 330 6.0606061 16 0.378787879

Ferro silicon 1729 330 5.2393939 16 0.327462121

Magnesium 333 330 1.0090909 16 0.063068182

Steel Scrap 10000 330 30.30303 16 1.893939394 2

core sand 5717 330 17.324242 16 1.082765152 1


28580 330 86.606061 16 5.412878788 5

Coking coal(dry) 230000 330 696.9697 30 23.23232323 23

Coking coal(wet) 248400 330 752.72727 30 25.09090909 25

Non coking coal 125000 330 378.78788 30 12.62626263 13

167

PI scrap 15330 330 46.454545 16 2.903409091 3

Burnt Sand 5600 330 16.969697 16 1.060606061 1

MgO 200 330 0.6060606 16 0.037878788

ZnO 100 330 0.3030303 16 0.018939394

Slag from DIP 1000 330 3.030303 16 0.189393939

Fly ash/bottom ash 17,500 330 53.030303 16 3.314393939 3

Cement 80000 330 242.42424 16 15.15151515 15

Ductile Iron Pipe 200000 330 606.06061 16 37.87878788 38

60

Existing:




PI scrap 9198 330 27.872727 16 1.742045455 2

Burnt Sand 3360 330 10.181818 16 0.636363636 1

MgO 120 330 0.3636364 16 0.022727273

ZnO 60 330 0.1818182 16 0.011363636

Slag from DIP 600 330 1.8181818 16 0.113636364

Slag from BF 34800 330 105.45455 16 6.590909091 7

32

Iron ore 84000 330 254.54545 16 15.90909091 16

Coke 93000 330 281.81818 30 9.393939394 9

Limestone 21000 330 63.636364 16 3.977272727 4

Dolomite 15000 330 45.454545 16 2.840909091 3

Manganese 1800 330 5.4545455 16 0.340909091

Quatrz 6600 330 20 16 1.25 1

Ferro silicon 1037 330 3.1424242 16 0.196401515

Magnesium 200 330 0.6060606 16 0.037878788

Steel Scrap 6000 330 18.181818 16 1.136363636 1

Core sand 3430 330 10.393939 16 0.649621212

sand for cement coating

17148 330 51.963636 16 3.247727273 3

Cement for coating 12000 330 36.363636 16 2.272727273 2

39

In Summary

Existing and Proposed

Total raw material Coming in 167 trucks

Total products and solid waste going out in 60 trucks

Existing

Total raw material coming in 39 trucks

Total products and solid going out in 32 trucks

Proposedexpansion

Raw material coming in 128 trucks/day 8

trucks/hr

Product and solid waste going out 28 trucks/day

2truck/hr

Total no of trucks/hr is 10

Total No of trucks per hour due to expansion is= 10 trucks



It is clear from the above table that total number of trucks per hour is 10. Hence the impact on traffic is minimum.

Internal Transportation

Hot metal to pipe plant will be transported on a track by car-mounted ladle, which will be moved by a winch. Pig casting machine is adjacent to the blast furnace and the hot metal ladle will be moved by an overhead crane. There will be transportation of spare parts and consumables from stores and repair shops to respective departments and transportation of spare parts for repair-to-repair shops. This will be done by roadvehicles. Steel scrap and ferro silicon to pipe plant will be also moved by internal road vehicles.

4.3.5 Impact on Water Resources

Water requirement can be met through the current allotted water from TungabhadraRiver, which is 1.8 km from plant site. Use of water for industrial purpose causesnegative impact on the environment. The selected process is eco-friendly. Water will be recirculated and reused and there is zero discharge out side the plant premises. The proponent is going for rain water harvesting which will also be used in development of green belt. Recharge pits are also proposed to improve the ground water potential of the area. The development of green belt improves the moist conditions in the soil and control thermal radiation.

4.3.6 Impact on Water Quality

The water system will be of re-circulating type and no process wastewater will bedischarged. The entire process water requirement is kept in closed circuit and noprocess wastewater is discharged out side the premises. The clean water after the treatment of the blow down water will be reused in dust suppression on roads, fugitive emission suppression in raw material handling area, plantation etc.

Domestic effluents from the various buildings / sheds of the plant are conveyedthrough separate sewer line to STP of capacity 50 KLD. The treated water from STP will be used for greenbelt development

There will not be any wastewater generation from the proposed DIP plant.

4.3.7 Impact of solid waste

The solid waste generated in plants are listed below:



Table 4.10 Solid waste generated from different operations (after expansion)

Pig iron plant Iron ore fines (97800 TPA)

Coke fines (11000 TPA) B.F.Slag (58000 TPA) GCP dust (6720 TPA)GCP sludge (5430 TPA)

P.I. Scrap (15330 TPA)

Used in sinter plant

Used in sinter plant Used in cement grinding plant Used in sinter plant Used in sinter plant

Sold out

DIP PLANT200,000TPA

Burnt sand generated in casting

section (5600 TPA)MgO (200 TPA)ZnO (100 TPA )Slag (1000 TPA)

Stored in the dump yard. Can be

used for land fillingSold out to approved vendors. Sold out to approved reprocessorsUsed for land filling

Metcoke plant Coke fines (5000 TPA) Will be used in sinter plant

Power Plant Coal ash/Fly ash (17500 TPA) Will be sold out

Sinter plant Sinter fines (6000) TPADust from ESP (5200 TPA)

Circulated backCirculated back

Slag Cementgrinding plant

Nil

4.3.8 Impact on Noise LevelsDuring the operational phase, noise will be generated from the DG set, crushers,turbogenerators, vehicles movement, and general noise characteristic of proposedindustry. Noise generation is also noticed from the blowing station, compressed air station. The DG set room will be isolated from the outside environment and proper acoustic arrangements will be made to control the noise generated from the rooms. Plant and equipment will be selected restricting the noise pollution within thepermissible limits. Silencers and soundproof insulation/cover will be provided tocontrol the noise pollution.

4.3.9 Impact on EcologyThe impacts on natural vegetation and species diversity will remain unaffected due to the expansion of plant. The plant is already in existing. There will be few tree cuttingand shrub removal will take place. Wherever possibility is there, the entire tree will be uprooted and planted at different place. The proposed green belt development scheme will enhance the biomass and leads to sustainable development. The green belt willenrich soil organic matter thereby nitrogen. It will help as noise barrier. Green beltcontrol temperature and keep the surroundings cool. It will attract avifauna and create



suitable habitat to micro flora and fauna. The green belt will help as a sink to dust and gaseous pollutants. On the whole it has a positive impact on the environment.

There are no wild life sanctuaries with in the study zone. Forest is located at a distance of 4 km in the western direction. The released pollutants get diffused and get diluted before it reaches to the ground layer. The impact on flora is insignificant.

As there are no major leveling activities no impact on existing landscape is anticipated. The development of green belt will attract avifauna.

4.3.10 Socio-EconomicsThe impacts of the proposed expansion would begin to be felt with the start-up of the operational activities.

• The present trend of out migration for employment is likely to reduce due to better economic opportunities available in the area;

• The plant will result in considerable growth of service sector and will alsogenerate new industrial and business opportunities in the area. The ancillary facilities, would act, as an active nucleus for new industries and businessactivities, a shift of population towards this center and peripheral area is likely to occur.

The socio-economic impacts discussed in the construction phase of the proposed plant will also be manifested during the operation phase in the following manner.

• Increase in consumer prices of indigenous produce and services, land prices, house rent rates and labour prices.

• Some increase in services catering to the additional population will occur due to the setting up of the plant.

• Influx of persons with higher spending power and different socio-culturalbackground will improve the socio-cultural environment of the area, though occasional tension as a result of this influx cannot be totally ruled out.

• Improvement in transport, communication, health and educational services.• Increase in employment due to large flow of financial and material resources

through increased business, trade commerce and service sector.

Additional land will be acquired through KIADB and the land is not inhabited. Hence rehabitation is not required.



CHAPTER V-ENVIRONMENTAL MONITORING PROGRAMME

5.1 Environmental Monitoring

M/s Shree Ram Electrocast Pvt Ltd will implement various productivity management

programs in the plant to improve the work environment, effective house keeping and

environment quality. All the necessary steps will be taken in the plant to meet

standards prescribed by the Karnataka State Pollution Control Board and Central

Pollution Control Board and Department of Ecology and Environment, Government of

Karnataka.

Table 5.1 Monitoring schedule for Environmental Parameter during construction phase

Environmental ComponentsFrequency of monitoring during

Construction phase

Ambient Air Quality Monitoring Monthly(PM

10, PM

2.5, SO

2, NO

2)

Ambient Noise Level Monitoring Monthly

Water Quality Monthly

Table 5.2: Monitoring Schedule for Environmental Parameters

Sl.No.

ParticularsMonitoringfrequency

Duration ofmonitoring

Importantparameters formonitoring

I Air Quality

1 Ambient Air QualityMonitoring withinpremises

Once in amonth

Grab, 24 hrlysample

PM10, PM 2.5, SO2,NO2.

2 Stack/ChimneyMonitoring

Once in amonth

Grab Temperature,Velocity, SO2, PM,NOx, HC, CO

3 Fugitive emissionsmonitoring

Once in amonth

24 hourly PM 10 and PM 2.5

II Water Quality

1 Ground Water Analysis Once in a Grab As per KSPCB



month requirements

III Soil Quality1 Soil quality analysis Pre monsoon

and postmonsoon

Grab Colour, TexturalClass, pH, C,Infiltration rate,Moisture retentioncapacity, Organicmatter, Na,K,P,Pb,Cu,Zn,Cd,Fe

V Noise QualityMain Gate/BoundaryPower PlantD.G Set RoomCrushing AreasVibratorsCompressorPower plantLoading and UnloadingOthers as notices

Once in aMonth

24HrsMonitoring

Noise levels indB(A)

5.2 Environmental Monitoring PlanRegular monitoring in a systematic and standardized manner helps in assessment of current environment and provides information on operational performance of installed pollution control facilities.

Following are the Environmental aspects will be strictly considered in conducting

routine Environmental Monitoring:

• Monitoring of Stack emissions for Temperature, Velocity, PM, SO2, NOx and

CO. This will be carried out once in a month.• Monitoring of Ambient Air Quality at plant boundary and other required

locations for PM10, PM2.5, SO2 and NO2. This will be carried out once in amonth.

• Work Zone Air Quality Monitoring will be carried out in areas like Orecharging place near Hopper, Coal Handling Plant and others as specified by the KSPCB. This will be carried out once in a month.

• Monitoring of Fugitive Emissions for RSPM. This will be carried out once in a

month.• Monitoring of ground water quality of the plant premises area and surrounding

area will be carried out once before monsoon and after monsoon.• Ambient Noise Level Monitoring near the RMH Yard, Compressor Room, Stock

House, Plant Boundary and other areas as specified by KSPCB. This will becarried out once in a month.



• Monitoring of solid wastes quantity and utilization potential (Dust, Fly Ash,

etc.,).Fugitive Emission Standards: The fugitive emissions of suspended particulate matter

(SPM) should not exceed 1000 µg/m3 at a distance of 10 m (approx.) from the sources, identified and mentioned below, where fugitive dust emissions are anticipated. The measurement may be done, preferably on 8-hour basis with high volume sampler.However, depending upon the prevalent conditions at the site, the period ofmeasurement can be reduced.

Table 5.3 Fugitive emission monitoring

Sr. No. Area Monitoring Location

1. Raw material handling area Screen area, Transfer Points, Stock Bin area

2. Crusher area Crushing plant, vibrating screen, transfer points 3. Raw material feed area Feeder area, Mixing area, transfer points

4. Product processing area Screening plant, Transfer Points, Over sizedischarge area, Product separation area

5. Other areas Areas as specified by State Pollution ControlBoard



CHAPTER-VIOCCUPATIONAL HEALTH AND SAFETY AND DISASTER

MANAGEMENT PLAN6.0 Introduction Rapid development has posed wide-ranging hazards threatening safety and health of people. Accidents may adversely affect the environment and the people living in the vicinity. These accidents can be minimized to a great extent by proper procedures,handling and training. But it may be difficult to reach zero risk or absolute safety level. Whenever such incidents do occur in order to prevent loss of lives and damage to property, it becomes necessary to take immediate steps to control the situation. This can be achieved through a planned advance preparation to face such a situation with respect to both on site and off site emergencies.

6.1 Quality, Environment and Occupational Health and Safety Policy



Hazard: Anything (e.g. condition, situation, practice, behavior) that has the potential to

cause harm, including injury, disease, death, environmental or property and equipmentdamage.Hazard Identification: This is the process of examining each work area and work task

for the purpose of identifying all the hazards which are “inherent in the job”. Work areas include but are not limited to machine workshops, laboratories, office areas,agricultural and horticultural environments, stores and transport, maintenance. Tasks can include (but may not be limited to) industrial equipment, hazardous substances and/or dangerous goods, driving a vehicle, dealing with emergency situations,construction.Risk: The likelihood or probability that a hazardous event (with a given outcome or

consequence) will occur. Risk Assessment: Is defined as the process of assessing the risks associated with each of the hazards identified so that appropriate control measures can be implemented based on the probability, i.e. likelihood that harm, injury or ill health may occur and how severe the consequences of exposure might be.

6.2 HAZARD CHART

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use

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The environmental risk assessment will identify the potential area of hazardous andenvironmental disaster, which will enable for safety planning and design to minimize the accidents and disastrous events. A well planned, disaster management program and on site emergency plan will be taken up to manage emergency situation of any disaster event if occurs during the plant operation.Periodic health check up, Hazard Monitoring, Industrial psychology, Laboratory facilities & training & awareness will be done. OHS will also conduct regular occupational health training programs for employees. Periodic health status of all the employees will be monitored & indexed by a statistics group attached to OHS.Large industries, in general and proposed plant in particular where multifarious activities are involved during construction, erection, testing, commissioning, operation and maintenance, the men, materials and machines are the basic inputs. Along with the boons, the industrialization generally brings several problems like occupational health and safety.Risk assessment is carried out by understanding the objective, identifying risks, existing control and net risk after factoring for relevant probability / frequency/ severity and adequacy of existing control for each process.The choice and the implementation of specific measures for preventing workplace injury and ill health in the work-force of the iron and steel industry depend on the recognition of the principalhazards, and the anticipated injuries and diseases, ill health and incidents. We have identified several probable hazards which may occur in the plant:

(i) slips, trips and falls on the same level;

(ii) falls from height;

(iii) unguarded machinery;

(iv) falling objects;

(v) engulfment;

(vi) working in confined spaces;

(vii) moving machinery, on-site transport, forklifts and cranes;

(viii) exposure to controlled and uncontrolled energy sources;

(ix) exposure to mineral wools and fibres;

(x) inhalable agents (gases, vapours, dusts and fumes);

(xi) skin contact with chemicals (irritants (acids, alkalis), sol-vents and sensitizers);

(xii) contact with hot metal;

(xiii) fire and explosion;

(xiv) extreme temperatures;

(xv) noise and vibration;

(xvi) electrical burns and electric shock;



(xvii) manual handling and repetitive work;

(xviii) failures due to automation;

(xix) ergonomics;

(xx) lack of OSH training;

(xxi) poor work organization;

(xxii) inadequate accident prevention and inspection;

(xxiii) inadequate emergency first-aid and rescue facilities;

(xxiv) lack of medical facilities and social protection.

In view of the above we need to ensure that adequate measures to prevent such occurrences and if any such incident happens measures to protect the men, the plant and the surroundings have to be in place. Appropriate occupational health, safety including fire plans is to be implemented for the wellbeing of employees. All these activities again may be classified under construction anderection and operation and maintenance. The proposed safety plan is given below:

6.3 Occupational HealthOccupational health needs attention both during construction and erection and operation and maintenance phases. However, the problem varies both in magnitude and variety in the above phases.

• Construction and Erection

The occupational health problems envisaged at this stage can mainly be due to constructional accident and noise. To overcome these hazards, in addition to arrangements to reduce it, personal protective equipment’s will also be supplied to workers.

• Operation and Maintenance:

The problem of occupational health, in the operation and maintenance phase is due to noisehearing losses. Suitable personnel protective equipment will be given to employees. The working personnel will be given the following appropriate personnel protective equipment:

• Industrial Safety Helmet;

• Crash Helmets;• Face shield with replacement acrylic vision;

• Zero power plain goggles with cut type filters on both ends;

• Zero power goggles with cut type filters on both sides and blue color glasses;• Welders equipment for eye and face protection;

• Cylindrical type earplug;• Ear muffs;

• Canister Gas mask;

• Self contained breathing apparatus;



• Leather apron;

• Aluminized fiber glass fix proximity suit with hood and gloves;• Boiler suit;

• Safety belt/line man's safety belt;• Leather/ rubberized hand gloves;

• Electrically tested electrical resistance hand gloves;

• Industrial safety shoes with steel toe; and• Electrical safety shoes without steel toe and gumboots.

Full fledge medical facilities are available round the clock for attending emergency arising out of accidents, if any. All working personnel are medically examined periodically once in every year. This is in addition to the pre-employment medical examination.

6.4 Safety PlanM/s Shree Ram Electrocast Pvt Limited is a private limited company, producer of Pig Iron. The company is already having an internal safety policy towards ensuring safety and healthy working conditions. Concomitantly employees safety, health and wellbeing are of paramount importance to the company.Importance of safety cannot be undermined either at home or at place of work. This assumesspecial importance in the steel Industry where technological processes and working environment are more challenging, compared to other process industries.It is the endeavour and management policy to establish and encourage safety at all work places. This policy aims to promote safe behavior, attitude and safe practices towards minimizinghazards. M/s Shree Ram Electrocast Pvt Limited recognizes that safety and occupational health of employees is an important management function along with its other objectives of incorporation.Therefore, it is necessary that every employee should develop a serious attitude towardsobservance and compliance of general and special safety rules, regulations, guidelines andlegislative provisions, towards his own safety and that of others around him.The managerial and supervisory personnel should derive the spirit of management philosophy towards safety and will make every effort in protecting the personnel and property from industrial hazards.The management supports activities of hazard identification, prevention of unsafe actions and situations and safety promotional programmes.It should be recognized that just knowing safety rules is not enough to make the plant safe. Whole hearted co-operation of every one in the organization is essential, at all the places and at all the times. The management reiterates its belief in this.The safety promotional programmes envisaged by management become meaningful only by active participation of employees.6.4.1 General

The company aspires its organization to be a very safe and hazard free setup. All efforts are being made to achieve this aspiration by providing protective equipment to men and machines,



educating the personal about the safe practices to be followed by conducting mock drills, lectures for employees, contract labor and exhibiting the safety posters at suitable work places. As a part of this unending continuous activity a safety manual is brought out for guidance and followed by all its employees and various departments.

6.4.2 House – keeping

i. All work places, aisles and work surrounding areas will be kept clean and free from all obstructions.

ii. On completion of job, all tools, equipments, left over materials will be removed to proper places for storage.

iii. Waste, oily rags and other inflammable materials will be kept in proper replaces.iv. Slippery substances such as grease or ail if spilled on floor will be cleaned immediately or at

least covered with sand, saw-dust or anti-slippery materials until it is cleaned.v. Nails, planks with protruding nails and such sharp objects will not be left on the floor.

6.4.3 Wearing apparel

No person working on or near moving machinery will wear loose clothings such as Dhoties, shirts with dangling sleeves, gloves and jewellery like rings, ear- ring, wrist-rings and chain lockets etc. All persons engaged in oiling or cleaning of machinery will put on tight fitting clothes shoes and boots must be properly laced.

6.4.4 Protective equipment Protective equipment and safety appliances like goggles, face shields, aprons, gloves, ammunition boots/safety boots, helmets, respirators, gas masks etc. are issued for personal protection for jobs, where special hazards exist and these will be used by workers where provided, while engaged on such work.

6.4.5 Stacking of materialsAll materials will be stacked tidily and upto safe height to prevent them from falling or causing some other pile to fall. No material will be stacked in passages, aisles or walkways.

6.4.6 Loading of material i. While loading in truck or wagon, all materials will be so loaded that no portion thereof

projects from the sides or falls off in transit.ii. The loaded material will be properly distributed and securely tied as far as possible and

practicable.iii. All materials projecting beyond the front or rear of a truck will be indicated by red flag

during day and red light during night.

6.4.7 Eye protection



I. Goggles or face shield will be used by all workers engaged in operation involving hazards to eyes.

II. No person will attempt to remove any foreign body or material from his own eye or those of other employees. All such cases will be reported to the foreman who will immediately direct the person concerned to report to the First Aid Station.

6.4.8 Safety belts

I. All employees working on elevated places not adequately protected by railing or suitable enclosure will wear safety belts with lifeline tied securely to a firm structure or other support independent of the equipment on which they were working.

II. All workers will wear safety belts with Gas Masks/Oxygen Breathing Apparatus while working at confined places, where they are exposed to such conditions or elements which might affect their consciousness. Lifeline of such belts will be held by one or two persons stationed in location not affected by gas so as to render aid or call for help.

III. The foreman or supervisor- in –charge of the work involving the use of safety belts will during the course of its execution provide stand-by personnel consisting of one or more men wherever necessary.

6.4.9 TransportI. Speed of the vehicles within the plant area will be restricted to below 20 kms/hr

6.4.10 Short cutsII. Roads and regular passages should normally be used for moving from one place to another.

III. Crossing of mill tables, metal runners except by stairs provided is strictly prohibited.IV. No employees will cross any operating unit unless his duty requires him to do so.V. Avoid short cuts. Use of short cuts may cut short the life.

6.4.11 Defective toolsI. All defective tools, e.g. chisels with mushroom heads, spanners with worn jaws, broken file

handles, hammers with broken shafts etc. will be brought to the notice of the Foreman immediately.

II. No tools will be put to use for which they are not meant.

6.4.12 Power rails or transmission lineNo person, except those specially authorized by competent authority to so, will have access to power rails or other electric supply lines and apparatus.

6.4.13 GuardsMachine guards and other safety devices will not be removed except for making repairs,lubricating or cleaning and that too only by authorized persons. Those must be replaced before starting machinery.

6.4.14 Refueling



The engines of all vehicles will be stopped before filling with petrol or other fuel.

6.4.15 Permit to work Permit to work and danger board on electrical equipments or machineries run by power

i. Issue of PERMITS ON PRINTER FORM along with associated safe – guards is

mandatory on planned shutdown work, all major breakdowns and any other work,

which is likely to last for more than one hour.

ii. When a switch is isolated for carrying out any maintenance work, hang, a personal

DANGER BOARD, on the switch, which serves as a warning to others, not to touch that

switch so long as the danger board is hanging on it.

6.4.16 Starting and repairing machinery i) No person will attempt to operate or set in motion any machine or equipment to which

he is not authorized

ii) Oiling, cleaning or repairing of machinery normally will not be carried out without first

stopping the machinery completely. Where it becomes necessary to examine any part of

machinery, while it is in motion or to carry out lubrication or other adjustment

operation, such work will be done by only specially trained adult male workers wearing

tight fitting clothing.

iii) All persons engaged in oiling or cleaning machinery will wear tight – fitting cloths.

iv) No worker will switch on electricity, turn on gas, steam, air, acid or water or set in

motion any machinery without first making sure that no one is in a position to be injured

thereby. Supervisor-in-charge of the work will see that effective measures are taken to

ensure the safety of personnel and equipments before the equipments are operated.

v) All exposed moving parts of machine such as pulleys, belts, coupling, chains, fly-wheels;

rotating collars with projecting set screws will be properly guarded.

vi) The machine guards and safety devices will conform to the statutory provisions and will

be in position, when the machine is in motion.

6.4.17 Lifting or carrying weights



i) No person will be allowed to lift or carry excessive weights. While lifting or carrying a

load manually, correct method should be followed so as to avoid sprain on lumber

region. If the weight is too heavy or bulky help of other workers will be sought.

ii) When the load is carried by two workers neither of them will let the load come down,

without cautioning the other.

6.4.18 Overhead cranei) No person will stand in unsafe position while a wagon is being loaded or unloaded by

crane.

ii) No one will ride on load being carried by crane.

iii) No one will ride stand or walk under loads suspended from cranes.

iv) The access to overhead crane runway for any purpose whatsoever is strictly prohibited

except with the permission of the shift office/supervisor and after notifying the crane

driver concerned.

v) When any defect is observed in a crane, it will be reported to the office/supervisor

concerned for rectification.

vi) While any person, is employed in work on or near the wheel track of a travelling crane

in any place where he would be liable to be struck down, effective measures will be

taken to ensure that crane does not approach within 20 feet of that place.

vii) If the crane driver feels that some one is in a position to be injured by moving or lifting a

load, he will inform the Foreman/Man-in-charge to caution against danger.

viii) A crane driver will not make a lift without standard signals from the person with the job

and he will take signal only from one person at a time.

ix) All persons in places over which a crane is operating, will listen for crane bells and other

signalling devices.

x) The hooters bells, etc., on the crane will always be maintaining in good condition and be

audible from the required distance.

xi) Stand clear of loaded magnets. If the power is cut off, the load will fall.



6.4.19 Electricityi) No work will be done on or in close proximity to electric supply lines and apparatus

without the approval of the competent authority.

ii) The use of defective plugs, sockets and flexible cables will be avoided. All broken or

missing covers of switches, etc., will be replaced immediately.

iii) No one, except a person duly authorized by the electrical department, will operate any

switch gear or other electrical equipment except for routine starting and stopping of low

and medium voltage motors and ‘SWITCHING ON’ of ‘SWITCHING OFF’ lights and

fans etc.

iv) The repairs to electrical apparatus and electric supply lines will not be carried out by

unskilled men and without effectively cutting off supply thereto, and taking necessary

precaution to prevent accidental or inadvertent charging thereof.

v) The use of water or foam chemical fire extinguishers for extinguishing electrical fires will

be strictly avoided and only CO or CTC type of fire extinguishers used for dealing with

electrical fires.

vi) In case of electric shocks, the victim will be detached from the electrical circuit. If he is

still in contact with the same, the victim will not be touched by the rescuer, unless the

power is cut off or insulated material like wooden log, wooden stick etc., will be used to

prevent the rescuer from getting the electric shock himself. Medical help should

immediately be requisitioned and artificial respiration given unit the arrival of the

medical officer.

6.4.20 Ladders and scaffoldsi) Ladders with broken or missing rungs or split side rails or otherwise defective will not

be used Ladders with safety shoes will be used as far are possible and practicable.

ii) Ladders will rise sufficiently above the place of landing, and will be securely tied at the

top with rope or held at the foot by workers. This rule does not apply to mould cleaning

ladle repairs etc.

iii) No metallic ladders will be used for electrical work or any work to be executed in close

proximity to the electric supply lines or apparatus.



iv) The use of defective scaffolds will be strictly avoided. All scaffolds will be inspected by

the person in charge of the work, before commencement of the work.

v) Suspended scaffolds should be of sound construction and good material and of sufficient

strength and lifting appliances of these should be tested by subjecting to 50% more load

than the rated capacity.

6.4.21 Working overheadNo tools or material will be left in places from where they may accidentally drop on persons

below.

6.4.22 Chains and slings

i) All bad slinging practices will be strictly avoided.

ii) No defective chain and sling will be used.

iii) No bolt or nail will be inserted or knot tied to shorten a lifting chain.

iv) All wrought iron lifting chains are to be annealed, examined and tested periodically as

per Factory Regulations.

6.4.23 Welding and gas cutting

welding and gas cutting operations will be prohibited in proximity to places where combustible

materials are stored and in proximity to materials and plant where explosive or flammable dusts,

gases vapours are likely to be present or given off, except with special precautions.

6.4.24 Hot metal and slag

Sudden break out of molten metal and slag has been known to take place during furnace

operation. The break out may take place from weak portions of furnace. Spillage of hot metal or

slag can cause severe burn injuries and fires. Explosions may also occur due to hot metal or slag

falling in a pool of water resulting in injuries and fire due to flying hot splinters and splashing of

hot metal or slag. The spillage of hot metal can also be due to hearth breakage, mould breakage

and during transportation. The accidents can occur due to failure of water-cooled panels, puncture



in water-cooled lances, leakage of water from the walls of mould. Through regular checks and

proper upkeep of furnace refractory and cooling panels such incidents can be avoided. The

consequences will result in death (extreme case), severe burn and mechanical injury and limited to

working personnel near the site of incident. By adopting good engineering design and quality

equipment and regular maintenance, risks due to such incidents can be minimised.

i) No one will pass under or go near a ladle from which hot metal is being poured.

ii) No hot metal or molten metal will be dumped on damp or wet ground to obviate its

causing an explosion.

iii) No one will go near slag ladle or hot metal ladle, when the furnace is casting, unless the

circumstances so require.

6.4.25 Fire in coal yard

This is the most common accident known to occur in any plant storing and handling coal. Since

such incident takes sufficient time to get widespread, enough response time is available for plant

personnel to get away to safer distance. An elaborate fire hydrant network and fire fighting system

comprising of trained crew and facilities will mitigate the risk of such incidents. In case of bunkers

/ tunnel, alarm system and smoke detectors will be installed.

6.4.26 Open manholes

All manholes will be closed with suitable covers. When opened these should be suitably guarded

or a red flag during day and red light during night should be installed by the side of the manhole,

for warning the passers by.

6.4.27 Excavationsi) No excavations of any description will be undertaken in the plant area without obtaining

prior permission in writing from the Electrical and Civil Engineering Department in

order to avoid possible damage to electric and telecommunication cables or water

sewerage or gas lines.



ii) The under cutting of banks will be strictly avoided.

iii) All excavations or ditches exceeding five feet in depth will be sloped to safe angle or

properly shored before permitting any worker to work in them

iv) All timbering and planks used therein will be inspected by a competent person of the

Civil Engineering Department.

v) No loose material or load will be placed or stacked near the edge of any excavation

thereby endangering the life of person working below.

vi) All excavations inside the plant will be properly fenced and marked with suitable

warning sign board at all times and red lights at nights. This will apply to all uncovered

trenches or drains or opening on platforms.

6.4.28 Vehiclesi) All vehicles will comply with all the traffic signs and regulations within the plant and

they will not exceed the safe speed limits.

ii) Vehicles playing within the precincts of the factory must observe the Traffic Rules The

drivers of the vehicles will be particularly careful at the railroad crossings.

iii) Riding on the running board of any vehicle or any part of the vehicle except on a proper

seat is strictly prohibited.

iv) Riding on hand trolley is strictly prohibited

v) Double riding on cycles is strictly prohibited

vi) Sitting on the side flaps or standing in a truck while in motion is strictly prohibited

6.4.29 First aid boxes First aid boxes will be provided in suitable places in every department.

6.4.30 Fire fighting equipmenti) Department will be equipped with the required types of fire fighting equipments,

namely fire hydrants, fire hoses, sand buckets, water buckets, fire extinguishers, etc.,

wherever necessary.

ii) Extinguishers using water must not be used on electrical lines or equipment.



The existing plant is having a well-equipped fire-fighting group for the existing plant with 3

Officers, 50 Workers trained in this field. Following fire-fighting equipment will be in place when

the proposed expansion project is fully commissioned:

o Fire Tender 1 No.

o Jeep 1 No

o Portable Extinguishers Lot

o Foam generator Lot

o Static tanks Lot

List of fire extinguishers required at different locations

Table 6.4 List of fire extinguishers

Sl No Unit Type1 Furnace Area CO2 Foam Type, Dry Chemical Type

2 Crusher house CO2 Foam Type, Dry Chemical Type3 Turbo generator area CO2 Foam Type, Dry Chemical Type

4 High voltage panel CO2 Foam Type, Dry Chemical Type5 Various control room CO2 Foam Type, Dry Chemical Type

6 Guest houses and offices Dry Chemical powder type

7 Godowns Foam type8 Pump house CO2 Foam Type, Dry Chemical Type

6.4.31 Unfamiliar equipmentNo person will use or operate any machine or tool which he has not been authorized or taught to

operate.

6.4.32 HorseplayHorseplay of any kind is prohibited inside the plant. Do not distract attention of others on work.

6.4.33 Work permitsProcedure of work permits is essential when working at Height or working enclosed space,

Electrical Repairs, any critical maintenance jobs, civil Excavations or Hot working near hazardous

areas.

6.5 Administrative Controls



Administrative controls largely involve the development of safe working practices and procedures.

These controls may include:

• rescheduling hot work to cooler parts of the day and maintenance to cooler seasons;

• encouraging workers to take short breaks;

• allowing new workers or workers returning from holidays to acclimatise to the heat;

• decreasing heat exposure duration e.g. by rotation of workers;

• scheduling regular work/rest breaks in cool, shady areas with protective clothing removed;

• isolate hot work practices to times/locations distant from other workers;

• consider job sharing/rotation or using extra workers;

• screen workers for heat intolerance (e.g. those with heart and blood pressure problems or

previous heat illness);

• training of workers in the hazards associated with working in heat and recognising heat

related illnesses, safe work practices, control measures and the use and maintenance of

personal protective equipment;

• introduction of a ‘buddy system’ where workers and supervisors in hot work environments

look out for early signs of heat illness in fellow workers;

• limit consumption of diuretics e.g. caffeinated drinks and alcohol;

• workers to seek medical advice - if on medication that may interfere with heat tolerance

(e.g. blood pressure medication, sedatives, and antidepressants);

• Provision of reasonable access to an adequate supply of clean and cool drinking water. (e.g.

as a rule of thumb, workers doing hot work should drink a cup of water every 15 to 20

minutes.); and

• Develop a contingency plan for the treatment of affected workers.

6.6 Personal Protective Equipment (PPE)

Where exposure to heat cannot be prevented or reduced by any other form of control, all exposed

persons must be provided with PPE. PPE may be used in addition to other control measures.

PPE designed to protect persons in hot environments will include:



• eye wear, such as ultra-violet glasses

• non-flammable and heat reflective clothing and equipment

• protective gloves and footwear

PPE will be used in addition to other control measures.

In general, for long life of a furnace, it is necessary to take necessary steps from time to time. Its

maintenance is easy and cheap. Certain steps will be taken on a regular basis which will include

the following:

• Before performing any maintenance, make sure to switch off the electrical power and the fuel supply.

• The combustion chamber generates the fire therefore there is a buildup of carbon soot which can corrode the chamber wall hence the chambers should be cleaned on the regular basis.

• Leakage or possibility of leakage in the pipe should also be repaired from time to time as it may cause the seeping of the carbon monoxide.

• The oil filter must be cleaned from time to time. Any defect in the oil filter may lead to the clogging of the oil-burner nozzle, which could result in a misfire that shuts down the system. It is therefore necessary that defective filter should be replaced.

• In case of electric furnace the heating element should be checked and defective piece should be replaced.

Furnaces are important device that are used in the industry. However for their safe and operations

it is necessary to take certain precautions which are as follows.

• During operation of furnace make sure that furnace panels and grills are in place whereas the fan compartment door is closed. If these doors open it could cause carbon monoxide to build up in living areas.

• Air filters should be cleaned and if there is any problem in the filter change it immediately.

• Discoloration, soot or build-up around the burner access door and vents indicates a problem which should be redressed immediately.

• The water must not be allowed to come in close proximity of furnace as contact can cause the molten alloys used in the furnace to explode.

• The venting system should be proper and the soft, rusted, or broken vent piping can release combustion products into the environment.

6.7 Emergency OrganizationTable 6.5 Emergency Organisation

Sl.No Role of Emergency Organization Name & Designation of the Employees

1 Site Manager VP / General manager

2 Incident Controller Dept Head (CC /CE)



3 Emergency Co Ordinator

Services & Communication

Admin Dept

4 Emergency Co - Ordinator first

Aid/Medical

Medical officer

5 Emergency Co - Ordinator

Security & Supply

Security Officer

6 Emergency Co- Ordinator

Lab / Production Unit

Shift Engineers & Shift Chemist

7 Assistant – Communication Assistant – Personnel

8 Rescue, First Aid Safety Squad members

9 Medical Medical officer

When more than one shift – In – charge (incident Controller) is present then the person who took

charge of operation from the previous Shift Incharge will be the incident controller.

6.8 ROLES AND RESPONSIBILITIES OF EMERGENCY ORGANISATION6.8.1 Site Controller

• Upon hearing announcement on personnel accounting system, he will proceed to

emergency control center.

• Establishing contact with the incident controller through telephone.

• Declares emergency in consultation with controller.

• Informs OHC about the possible injured cases treatment and ensures adequate treatment.

• Maintains continuous review of possible action plan and assesses in consultation with

incidents controller and other emergency organizing personnel and directs the evacuation

of personnel.

• Arranges for additional help from neighbouring industries.

• Exercises direct operational control over the works out-side the affected area, with the help

of the emergency coordinator (Services/ Communications) and First Aid & Medical

emergency coordinator.



• Liaison with government officials Viz, District Commissioner, Pollution Control Board, Fire

Services, Department of Explosives and Inspector of Factories and Boilers if required.

• Once the situation is brought under control, call-off onsite emergency in consultation with

incident controller and instructs security for blowing all clear signal.

6.8.2 Incident Controller• As soon as incident controller receives the message of incident he will rush to spot.

• Use public address system to call safety squad of other departments.

• Organizes to switch on flashlights relevant to the building affected.

• Send all visitors and contact people to assembly point.

• Start controlling emergency with available safety squad.

• Depute safety squad for rescue of injured persons.

• Assess the situation and advise site controller to call for emergency by phone.

• Organize for safe shut down of the plant if deemed necessary and evacuate employees of

the department (in the event of public address system failure).

• Assigns jobs to safety squad viz. a) rescue, b) leakage control, c) fire fighting d) evacuation

as per the need of situation.

• Inform to the site controller by phone regarding the steps taken to mitigate the emergency

from time to time.

• Organize to barricade the area by using warning tape.

• Depute safety squad from search of missing people as per information received from the

site controller.

• Upon completion of controlling operations, ensures area is free of toxic material and inform

to the site controller to declare “ALL CLEAR”.

6.8.3 Emergency Coordinator (Services & communication)• Upon hearing the siren he will rush to the emergency control center and reports to the

controller with the attendance record for the employees list workmen and visitors.

• Act as per the instruction of site controller and maintain log of incident.



• Arrange for transport of injured and ensure transport for additional injured persons.

• Arrange for external medical treatment for injured and casualties.

• Report to the hospital and make arrangement for likely more cases of injuries.

• Appoint responsible personnel from factory to assist injured who is under medical

treatment.

• Communicate information to ESI and Labor Commissioner.

• Communicate information to the relatives of the injured/ deceased.

• Calling neighboring factories for help like transport, fire fighting services, paramedical and

antidotes.

• If required communicate to the Fire Services, pollution Control Board, Inspectorate of

Factories, or other departments in consultation with site controller.

• Appoint three people to act as a runner incase of communication failure.

6.8.4 Emergency Coordinator (First Aid & Medical Management)

• Upon hearing the siren rush to OHC (Occupational Health center).

• Take charges of safety squad reported to OHC and retain one /two safety squad at OHC.

• Arrange for first aid and specific treatment with the advice of doctor.

• Organize to the shift injured to clinic with relatives MSDS, first aid manual (for specific

chemical exposures ref. first Aid manual) and antidotes. Accompanies the victim if the case

is critical based on doctor’s advice.

• Incase of need arrange for shifting to other medical centers as the case may be, maintain

contact with site controller from time to time

6.8.5 Emergency Coordinate (Security & Supply)

• Upon hearing the siren, all material transport vehicles will be sent out and close the gate.

• Restricts visitor entry inside the premises.

• Direct the ambulance to the vicinity of the incident.

• Ensures all security guards are reporting to main gate. Send one person to main road to

bring fire tender if it is called.



• He will rush to the scene with shift security inspector and reports to the incident controller

except in cases of toxic release.

• Additional fire extinguishers, hoses, nozzles, form compound located in various points shall

be drawn and arrange for fire fighting

• Organize to open the main gets as soon as the ambulance reaches OHC

• Co-ordinates with fire bridge group and help them.

6.8.6 Emergency Coordinator (Production Unit)

• Upon hearing the siren / message rushes to the site of the incident and reports to the

Incident Controller and Emergency Coordinator (Services & communication).

• If anyone is injured on the job, immediately send them to OHC .

• Arrange for Shut-down the plant/ unit as per the instruction of Emergency coordinator

(Utility and Maintenance) and Incident Controller.

• Arrange the workers at the production unit to assemble at the assembly point.

6.8.7 Emergency Coordinator (Utility & Maintenance)

• Upon hearing the siren / message rushes to the site of the incident and reports to the

incident controller

• Appoints one technician as in charge of fire extinguisher

• In consultation with incident controller, arrange power supply cut –off to the affected area.

Ensures that, emergency power and water supply is on.

• Arrange for shut down of non – essential utilities as per instruction of incident controller

• Consults incident controller and with the help of Eng Dept. and safety executes the leakage

control operations.

• Arranges for changeover of pumps and systems with standby incase of difficultly

6.8.8 Assistant – Communication

• Upon hearing emergency siren, she / he will immediately contact site controller. Incase if

telephone system becomes inoperative she / he receives the information regarding fire or

toxic release from a person who detected it, thereafter immediately informs to the incident

controller and site controller.



• Directs all visitors in the reception to assembly point.

• She / He will continue to operation the EPABX board and pass all class connected with

incident to the site controller emergency controller center.

6.8.9 Safety squad

• Upon hearing the emergency instruction from public address system, informs to the

available superior and rush to the location of emergency.

• Carry at least one fire extinguisher or stretcher, artificial resuscitator and reports to the

incident controller and works as per his direction.

• Do fire fighting / rescue / first aid / evacuation and leakage control as directed by the

incident.

6.8.10 Drive – Ambulance

• Upon receiving instruction from emergency coordinator (Security and supply) he, should

proceed to the vicinity of spot and reveres the vehicle.

• Parks the vehicle nearer to the incident place in case of toxic releases as directed by the

Emergency coordinator (Security & supply)

• Keeps engine in running condition

• Opens the back door of the ambulance

• Goes back to the seat

• Takes the injured to the OHC, the vehicle and opened the back door and reports to in charge

OHC.

6.8.11 In Charge – Occupational Health Center• Stays on alert for first aid and medical treatment for chemical poisoning and other injuries.

• Goes to the ambulance at OHC gate to receive the injured, examines and quickly assess the

condition and treats. Shifts the injured to Health Center if required advance the emergency

coordinator to accompany the victim incase of the condition is critical. He stays in OHC for

treatment of subsequent injury cases if any or till all clear siren is blown.



• Gathers feed back from primary Health center and communicates to the site controller /

Emergency / coordinator medical

6.8.12 Department heads / shift / in charge / supervisors

• Upon hearing the emergency announcements through PAS, send the safety squad members

of their departments to the site of incident.

• Sends contract workers and visitors to reception / assembly point indicating correct

evacuation path

6.8.13 Duties of Receptionist / Telephone Operator

• At the time of emergency, direct one line to the Site Controller’s office.

• On receipt of instructions from the Site Controller, notify the fire Brigade / Police /

Hospitals for any assistance as required.

• Keep the switchboard open for emergency calls.

• Refrain from exchanging any information pertaining to the emergency and reference about

the incident from the authorized personnel to the Site Controller.

• Keep logging of the calls received for the possible call back.



6.9 Emergency Response Plan

Fig 6.2 Emergency Response Plan

6.10 Health register will be maintained as follows:

ALERT, EVACUATE & ASSEMBLE

INCIDENT CONTROLLER

FIRE FIGHTING

TEAM

SHIFTINCHARGE

RESCUE

TEAM

SEARCH

TEAMSECURITY

TEAM

FIRST AID TEAM

TRANSPORT MAINT &

UTILITY

WELFARETEAM



Table 6.6: Health Register

6.11 Emergency Action Plans

6.11.1 Emergency Action Plan for Cylinder Fire:

1. When filled container containing LPG is involved in fire, internal pressure

if not relieved, will build up above 70KG/SQ.CM and ultimately rupture

the container. Ruptured containers can be propelled at distance by jet

action.

2. If container’s pressure is not raised upto 70KG/SQ.CM, leakage from

screwed valve joint can occur due to different expansion of steel and brass.

3. Ignition of the escaping gas would aggravate the fire but release of fire

reduces the possibility of rupture.



4. No attempt should be made to extinguish the burning gas but the

container under fire and other containers in vicinity should be kept cool by

water spray.

5. If the gas leakage does not ignite, the container should be approached

from up and removed to the place of safety away from the source of

ignition.

6.11.2 Emergency Action Plan for Electric Fire:

1. Disconnect the affected areas electric supply.

2. Attempt to extinguish fire with the help of CO2, DCP

3. If fire is not extinguished, extinguish by spraying water with fog nozzle

after ensuring complete isolation of electric circuit.

6.11.3 Emergency Action Plan for Office Fire:

1. Disconnect electric supply of the affected area.

2. Attempt to extinguish the fire with the help of CO2, DCP and sand.

3. If large fire, use hydrant system.

4. Attempt to save the record.

5. Attempt fire extinguisher.

6.11.4 Emergency Action Plan for Oil Fire:

1. Attempt to extinguish small fire with the help of DCP

2. If the fire is not controlled, use water foam to blanket the fire and

further action is to be taken

The proposed project will provide elaborate arrangements for managing any

incidents of fire:

• Portable Pump

• Wireless set

• Water Hoses

• Hot line Telephone etc.,



6.11.5 Emergency Action Plan for Medical Aid:

i. Emergency Action Plan for Electric Shock Casualties:

Electric shock results in:

Irreversible damage to brain cell begins followed by deterioration of the organs.

Rescue and first aid:

Do first aid quickly and without fuss and panic

� Switch off the supply if this can be done at once.

� If not possible use a dry stick, dry cloth or other non-conductor to separate the

victim from electrical contact.

� The rescuer must avoid receiving shock himself by wearing gloves or using a jacket

to pull the victim.

� Always keep in mind that delay in rescue and resuscitation may be fatal. Every

sound counts.

ii. Artificial Respiration:

Give artificial respiration if breathing has stopped. There are several methods of

artificial respiration, if the victim is nit injured over the face, try mouth to mouth.

a) Mouth to Mouth Method:

1. If there is obstruction to breathing, remove it with your fingers if it in

mouth. Several sharp blows between shoulder blade may help to is

lodge an obstruction.

2. Lay casually on his back, put something under his shoulder to raise

them & allow his head to fall backwards. The head should be, if possible

be a little lower than the trunk. Remember that speed is essential.

3. Kneel at the causalities head and grasp his arms at the wrists then cross

them firmly over the lower chest. This movement should force air out of

his lungs. Press with the hands crossed on the lower part of the chest

and maintain pressure for two seconds.

4. Release this pressure and pull out his arms with a sweeping movement



upwards and outwards above his head and backwards as far as possible.

5. This movement should cause air to be drawn in to his lungs. Retain the

arm in this position for three seconds.

6. Repeat these movements rhythmically about twelve times a minute

checking the mouth frequently for obstructions. Each cycle will thus take

give seconds- two seconds for chest pressure and three seconds for arm

lift.

7. With the causality on his back there is danger of aspiration of vomit,

mucus or blood reentering the system. This risk can be reduced by

keeping his head extended and a little lower than the trunk.

8. If an assistant is available, he can press the causality lower jaws so that

the chin is jutting out.

9. The assistant should also ensure that the mouth is kept open as far as

possible and head is tilted to one side.

10. When natural breathing begins, your movement should be adapted to

correspond to it.

11. If burns are present, cover them with a dry sterile dressing

12. Handle the causality gentle

13. Do not allow people to crowd around and block fresh airflow.

14. Arrange to remove the injured to the care of a doctor as early as possible.

6.12 Natural Hazards

6.12.1 Emergency Action Plan for Tornado/High Winds:

a. Weather reports will be monitored from broadcast warnings regarding

threatening conditions.

b. If the tornado has been sighted or effect is felt, following steps should be

taken by plant personnel.

� Persons will be notified over public address system or through siren.

� Emergency services will be alerted for assistance.



� Plant personnel should be advised to assemble in the administration building

basement, staff room, recreation room and rest rooms.

� All safety systems should be kept on alert and all nonessential utilities should be

put off.

c. After the status is restored, personnel should inspect all the facilities for resource,

first aid and damage control activities, damage assessment, and clean up,

restoration and recovery.

6.12.2 Emergency Action Plan for Earthquakes

1. When first tremors are sensed during an earthquake, all personnel

should evacuate buildings and assemble at safe place away from

structures, walls and falling objects. Emergency shut down should be

declared.

2. Emergency services should be contacted for assistance.

3. After the status is restored, personnel should inspect all the facilities for

rescue, first aid and damage control activities, damage assessment,

cleanup, restoration and recovery.

6.12.3 Emergency Action Plan for Bomb Threat

When bomb threat call is received the following measures are to be taken.

• Inform the message to the highest local police authority and seek their

assistance for patrolling and security need.

• Inform Controller of Explosives the details and nature of the anonymous

message and read operations.

• Request the Local Fore Brigade to position at least on fire te nder at the

Location immediately.

• Keep the Concerned Department at the Regional Level informed with

the developments at regular intervals.

• Alert the Local Government / Private Hospitals and seek their help for

providing Ambulances if necessary



6.12.4 In T he Location Premises:

• Keep the Fire Hydrant System/all Fire Fighting and Personnel

protective Equipment in readiness.

• Every one entering the Location must be frisked at the Gate/check all

Hand Bags, Parcels etc., for suspected explosive/dangerous objects.

• Have thorough inspection of the Location for any suspected dangerous

object.

• Materials and other Boxes to be brought in to the Location must be

deposited at Gate for minimum curing period of 48 Hrs.

• Organize Employees Vigilance cell for round the clock observation of

industry Premises.

6.12.5 If The Suspected object is found:

• In case of finding of suspected Article, do not disturb its position, but the

area around it should be cordoned off to a distance of 100 meters and

more depending upon the gravity of situation.

• Adequate Staff or Police Squad posted to prevent any unauthorized

entry into the enforced cordon.

• Contact Controller of Explosives immediately, who on reaching the Site

will decide suitable action for defusing and disposal of the suspected

object.

• Evolution of thick billowing smoke is an indication of impending

explosion and in such a case, with draw or evacuates all personnel from

the spot, which has been identified.

• As a general measure regulate the movement of the outsiders inside our

Premises and restrict their entry with permits.

6.13 GUIDELINES FOR SHUTDOWN OF PRODUCTION BLOCKS

The only major potential hazard that may occur in the factory is fire immediate action to

be taken in each of the section for the purpose of emergency shut down would be as

under



Manufacturing Unita) Cut – off electrical mains

b) Shut down the plant.

As decided by the incidents controllers efforts will be needed to shut down and make

the production block safe with the guidance of shift in charge.

• Remove chemicals stored ne ar vicinity of fire.

• Ensure that the power supply for firewater pump, emergency lighting, UPS

systems, cooling water, brine circulation are ON

• Isolate power supply to centrifuges, reactor agitators and pumps

• Ensure circulation of cooling water to all reactors jackets for 60 minutes.

• Stop thermo fluid heater firing and keep the pump in cooling mode.

• Stop material transfer operations in the production block. Cut-off solvent supply

to crab block from tank area.

6.14 EMERGENCY PLANNING

6.14.1 TRAINING AND RE HEARSAL

The electrical system as well as the areas where high temperature prevails in the

working areas precautionary measures may guards, caution boards, foolproof measures

will have to provide accidents.

• It is most essential for all the teams to act in accordance with patience in the

emergency condition. To act accordingly the workers are trained in the first aid

treatment and fire fighting. The training and the rehearsals for fire fighting an

emergency evacuation is carried out to avoid, confusion that might arise during

the actual emergency.

• For fire fighting given by the security officer to the staff and also the government

Fire force training institute personnel will be asked to give further training and

the Red Cross Association personnel will train personnel in first aid procedures.

• It is also the responsibility of the emergency declarer / controller to train the

teams in their respective area of operation during emergency and to carry out

mock drills at least in 6 months.



6.14.2 ACTION PLAN / TRANING

• To evacuate the persons unnecessary in that section

• Sooner grasp the situation/ hazards, issue instructions to the helping hands to

curb/ control the situation.

• Incase of fire, fire brigade will be called.

• Along with the fire brigade, the trained workers in the fire fighting procedure

and organize controlling / extinguishing the fire.

With a view to ensure that declarer/ controller of Emergency shall have assistance that

is required at his/ their disposal at the time of occurrence of the emergency teams of

personnel are formed to take up positions when the situation arises.

6.14.3 GENERAL SAFETY

• Ensure that surrounding facilities do not emit any chemical waste or gases,

which affects the health of personnel at the facility. Continuous monitoring

should be ensured.

• The designing of the drains within the plant and surroundings of the facility

should be of closed type, which would prevent the back flow.

• Any drains outside the facility should be closed and if open spray them with

disinfectants and pesticides. Also ensure water does not stagnate in the drains.

• The area surrounding the processing areas should have a uniform floor level,

without any humps or ditches, which leads to stagnation of waste water during

the rainy season and in turn helps in the breeding of insects or flies which play a

major role in spreading of many diseases.

• Floor openings in the form of pits/ sumps should be properly manned, so that

manoeuvring becomes easy and safe. The pit / sump should be highlighted with

a red flag/ cloth with a sign “Danger” marked on the cloth and hoisted near the

pit/ sump.

• Ensure there is no growth of grass beneath the electrical transformer.

• Design, installation of generators as an independent block away from the

processing area.

• Ensure adequate fire safety measures near the diesel tanks.

• Avoid misuse of sand buckets meant for fire extinguishing.



• Store the organic solvents in a separate storage area away from the main

warehouse.

• Whenever an order is placed for procurement of organic solvents in bulk, ensure

that they are transported by an open vehicle.

• Conduct pest control activities, during the closing hours of the factories and

ensure there are no men or material movement from or to the facility.

• In no circumstances should the, hazardous and toxic materials handled within

the licensed premises.

• Do not enter the processing area, until unless a need arises and also ensure

authorization to enter the area.

• In the processing area, insist safety aspects by displaying appropriate

signboards. For Example: “Mind steps”, “Entry Restricted”, “Danger”,

“Emergency Exit”, etc.

• Provide emergency exists whenever designing any facility. The Emergency exit

should be easy in manoeuvring. They should never be locked at any time.

• Smoking should strictly be restricted in and around the processing area, as a

precautionary measure against fire accidents.

• Ensure ladders are being used wherever necessary instead of using shortcuts,

like climbing through pipes etc.

• Avoid spillage of any material during processing. In case it happens, this should

be immediately brought to the notice of the production officer and ensure

immediate cleaning as per the standard operating procedures.

6.14.5 SAFETY WHILE HANDLING EQUIPMENT

• Only trained and authorized personnel should operate the Equipment.

• Operate all equipments, only through approved operating procedures.

• Do not operate any machine without safety guards in place.

• Do not bypass the safety locks whenever there is an automatic locking system.

• Do not touch or alter any part of the machine, while machine is in operation.

• Ensure that all moving parts of the equipments are fixed properly to the machine,

prior to operation.



• Do not wear loose garments when operating machinery.

• Do not indulge in maintenance activities during the operation.

• Ensure there is no spillage of oil or grease around the machinery, during

maintenance.

• If oil or grease is spilt, clean the area immediately with a cloth and store it in a

separate container till they are incinerated.

• Ensure that the Dust extraction system is working, when the machine is in

operation.

• If any abnormal sound is heard, report it immediately to the production

supervisor.

• Ensure that the surrounding area of the machinery is neat and clean.

• Do not run the machine when it is empty.

• Do not stand below any lifting, positioning or tippling devices.

• Ensure arrest of electricity supply on equipments prior to cleaning.

• Wherever pressure gauges are provided, ensure their functioning prior to

initiating operation.

• Whenever the equipment is provided with steam supply ensure proper draining

of the condensate.

• Do not try to operate any equipment, which is labeled “Under Maintenance”.

• Carryout planned preventive maintenance as per the schedule, to avoid any

discrepancy in equipment operating parameters.

6.14.5 ELECTRICAL SAFETY1.Electrical maintenance should be carried out only by trained and authorized

personnel of engineering department.

2.If any equipment gives an electric shock, disconnect the equipment from the

electricity supply and immediately inform the engineering department and the

hand over the equipment to them.

3.Whenever working on live circuits or during maintenance of electrical equipment

wear rubber gloves and rubber foot wear.

4.Ensure adequate earthing for all equipments.



5.Whenever any electrical fuse is replaced, ensure that the fuse replaced is of same

capacity.

6.Ensure closing of power cabinet, after maintenance works.

7.Avoid usage of unsuitable switches or plug-pins.

8.Whenever any equipment, which is power driven, is taken for maintenance, ensure

there is no power supply. Remove all the fuses of the equipment ad store it in a

secure place. After completion of maintenance job, ensure replacement of fuses.

9.Do not use water or wet mop to clean the electrical panels. Use only dry, non-

shredding cloth for cleaning.

6.14.6 FIRE SAFETY

NOTICING EMERGENCY

6.14.6.1 FIRE

Any person noticing the fire will start shouting “ fire”, “fire” till assistance is arrives.

Simultaneously he shall attempt to extinguish the fire by using a suitable fire

extinguisher. Any person who hears shall intimate the shift in-charge / safety officer

personally shift in charge / safety officer will reach the incident spot by protecting

himself and upon assessing the situation he shall seek help of safety squad by using

public address system. He will also inform to the site controller and chief executive by

telephone or through a messenger immediately.

The safety squad soon after reaching the fire spot shall start fire fighting to the extent

possible by standing in upwind direction and keeping the passages and doors clear. If

necessary shift in-charge / Safety officer will instruct the senior chemist for plant shut

down of the affected area immediately. All visitors and contract employees will be

directed to assembly point by respective departmental head or his alternate, upon

hearing message on personnel accounting.

Upon assessing the situation the incident controller will advice the site controller to

declare emergency through siren hooting followed by evacuation of all employees.

All production, quality control and utility areas of the facility are provided with fire

safety instruments.



Whenever there is a fire, the following actions are to be taken of:

� All the equipments shall be switched off along with the mains.

� Rescue men and machines followed by the documents.

� The fire -hit area should be blazed off with water, and the head of the department

should be summoned immediately.

Fire Extinguishers are to be used by the trained in-house personnel. At least two people

from each department shall be given training in operating fire extinguishers.

6.14.6.2 FIRE FIGHTING, RESCUE AND FIRST AID TEAMAction taken by Trained Volunteers

The trained volunteers who are available at the site at the time of emergency will report

to the incident controller. They will wear their identification badges for identification.

First Aid Team

• Chief : Admin Executive

• Alternate : Shift Operator

Functions

First aid is given to persons before sending them to hospital. First aid team has to bring

all the first aid items at the control room to administer first aid.

1. Injured / affected workmen shall be given immediate first aid with the help of

trained personnel amongst the workmen.

2. Following antidotes should be kept ready for use. Suffocation: remove the person

to the fresh air and administer the oxygen.

Rescue Team

• Chief : Process Engineer

• Deputy : Shift Operator


Functions

1. Rescue the victim in the affected area

2. Bring the people out of the area and hand over to first aid team.

3. Use stretcher, breathing apparatus, fire suits etc., if and when required.



Fire Fighting Team

• Chief : Security Head

• Deputy : Shift Operator


Functions

1. Fire should be controlled in the incipient stage. Use portable fire

extinguisher depending upon the classification of the fire like A, B, C, D or

E.

2. When it starts spreading, use fire hydrant system.

3. Use hydrant as water curtain to avoid spreading.

4. Keep checking the water level in the reservoir. If less than 40 % then call

outside help.

6.15 DECLARATION OF EMERGENCYUnder this plan the following post occupier are nominated as the Declarer / controller

of Emergency

Managing Director/Chief Executive Officer/ General Manager

As soon as they get information from the shift in-charge, they / he will arrive at the

place of hazard and assess the situation and decide to declare the emergency pertaining

to the particular section or entire plant and sound the siren accordingly.

a) If emergency is declared is to be declared only in one plant / Section the other

plant/ section will work normally.

b) They / he shall take over the situation and shall start functioning in such a

manner have to control the situation and curb the situation as soon possible.

6.1 6 EMERGENCY SIRENShift security Inspector will sound the emergency siren following instruction received

from the incident / site controller. Intermittent hooting will be made continuously 3

minutes to declare emergency the purpose is to advise a personal that emergency has

occurred in the plant.



6.1 7 EVACUATION OF PERSONNELWhen a major accidents occur and there is only cause or trouble in which case any

employee or any human life faces the problem of self evacuation even though having

the knowledge of evacuation plan, then it is the entire responsibility of the team for to

evacuate all the persons and provide all the medical facility of the team for to evacuate

all the persons and provide all the medical facilities. In first place the trained persons in

the ambulance room shall give first aid treatment, and they may be transported to the

factory hospital or medical center nearby in the ambulance. There are clearly marked

gangways inside the plant and around the factory premises with fire exists provided on

ground floor which are also clearly marked with evacuation plan along with fire

extinguishers and fire alarm. The employees are trained to choose the safest and nearest

gangways to come out of danger area and arrive at safe place as early as possible.

6.1 8 SAFE ASSEMBLY POINTSSafe Assembly Point is located in front of the main gate

6.19 ACCOUNTING OF PERSONNELWhen person engaged the emergency, the section in-charge are responsible to bring out

the employees to safe place and make the arrangements for their medical treatments,

Department head also visit site of emergency to ensure that nobody has been trapped.

The person who has engaged/trained in the First – Aid and fire fighting also check up

for ensuring that nobody has been trapped.

It shall be the responsibility of the Emergency Coordinator (Security and Supply), to

verify the persons on duty and check whether all the persons have come out of

hazardous zone also shall coordinate with Emergency Coordinator (Production) and

checks and recheck so that all personnel are around and also Incident Controller will

counter check with the security of any visitors, transport workers and contract labors

have entered the plant and is so, they should also be accounted for.

6.2 0 ARRANGEMENT FOR MEDICAL TREATMENTGeneral First aid will be given within the factory and Injured will be transferred to

Government Hospital which is at a distance of 2 KM from the site.



Sl.No. Hospital name. Location. Phone Nos.

01 Govt. Hospital Siruguppa. 220249

02 Laxmi Nurseing Home. Siruguppa. 220470

03 Sneha Helth Care Unit. Siruguppa. 22077104 Sulochana Clinic Siruguppa. 220517

05 Vijay Marie Hospital Siruguppa 220203

06 V.I.M.S Bellary siruguppa 242312,242099

6.2 1 INFORMATION TO RELATIVES OF INJUREDThe relatives of injured will be informed by emergency coordinator (Services &

Communication) only. The employee’s residential address file will be available at

emergency control center and also in the residence of emergency coordinator (Services

Communication). The communication to the relatives of injured will be passed on

through telecom or by messenger with a car. The clear details of the injured person

(local residential address, address if hospitalized) will be communicated to his relatives.

6.2 2 INFORMATION TO LOCAL AUTHORITIESIncase of emergency the Director of factories and Assistant Director of Factories will be

informed. The information will be passed on over telecom, telegram or through a

messenger deputed by emergency coordinator (Services & Communication)

The company will implement the advice of local authorities in improving the safety in

dealing with the event.

Karnataka State Pollution Control Board authorities will be informed in case of

accidents like toxic release, leakage of hazardous chemicals.

Govt. Authorities. Address. Telephone Nos.

Tahasildar Siruguppa. 230238.Dy. Commissioner cum D.C.compound, Bellary. 277100,250089.

District magistrate

Sr.Asst.Director of Factories Bellary 277474

Superintendent of Police Bellary 276000Fire officer Siruguppa 220100

Chief fire officer Bellary 231933

Pollution control Board Bellary 258365Electrical Inspictor (KPTCL) Bellary 267648

6.2 3 INFORMATION TO DISTRICT AUTHORITIES



The Emergency Coordinator (Services & Communication) is authorized to inform to the

police. The Inspector of Police will be informed for the control of law & order situation

at the plant or vicinity or at hospital where injured are under treatment. The

communication will be made to the Deputy Superintendent of Police and also police

department will be required for protecting the lives of the workers, control of the traffic

arrangements, for evacuation of personnel outside the plant. Deputy Commissioner and

Superintendent of Police also will be informed regarding emergency.

6.2 4 LAW & ORDERThe information regarding emergency is set to government authorities/ general public

by the Declarer/ Controller of emergency to ensure law and order situation is fully

under the control.

Sl.No. Designation. Address. Telephone Nos.

01 Sub Inspector of Police Rural police station 241613Hatcholli.

02 Circle Inspector of Police Police Station Siruguppa. 220333

6.2 5 ALL CLEAR SIGNALAfter the situation is brought under control the emergency will be called-off by incident

controller.

2 Minutes continuous blast will denote all clear and restoration normalcy. Once the

emergency is called-off, detailed inspection is conducted by emergency organizing

personnel. On their satisfaction of the situation the incident controller will give

clearance to resume the plant operations over PA system.

An OSH management system will contain the following main elements:

(a) OSH policy;

(b) Necessary conditions for the executing organization, i.e. establishment of

responsibility and accountability, competence

and training, documentation, communication and in-formation;

(c) hazard and risk assessment, planning and implementation of OSH activities;

(d) evaluation of OSH performance and action for improvement.



6.2 6 Occupational Health Surveillance ProgrammeOccupational health problems of personnel working in the main plant will be of concern

for the management.

Pre-placement Assessment

Procedures for pre -placement health examination are as follows:

• Baseline health data such as height, weight and vital statistics

• A detailed history of previous diseases and occupational exposures.

• A history of personal hobbies or activities that might involve exposure to

potential toxicants

• Past or present history of any allergies including astama

• Identification of personal habits (smoking, hygiene, alcohol consumption,

fingernail biting, etc.,) that may be relevant to work

• Complete physical examination with special attention to respiratory, dermal and

possible renal problems.

In addition to the items listed above, number of clinical tests will be performed to better

characterize the baseline data. These include:

• Posterior/anterior chest x-ray

• Lung function tests using classical spirometry

• Audiometric testing and

• Visual testing

The employees working in the main plant area will be subjected to regular health check

up. Auditory examination by qualified doctor upon the first employment and thereafter

periodic examination at least once a year will be conducted which will include the

following:

• determination of auditory threshold

• respiratory functions

• lung function test

• sputum test



• visual testing

• X-ray test

• Complete physical examination with special attention to respiratory, dermal and

possible renal problems.

All workers exposed to high level of noise as well as other mechanical accident prone

areas will be provided with 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 or asbestos aprons, asbestos

and rubbers gloves, shoes with non skid soles gum boots, safety shoe with toe

protection which will be provided to workers.

All safety and health codes prescribed by the Department of Factories and Boilers will

be strictly implemented in the plant. The standardized codes are related to mechanical,

products, electrical, transportation, construction, chemicals, fire protection, personal

protection and health care. All appropriate fire protection and safety measures will be

provided in the plant.



CHAPTER-VIIPROJECT BENEFITS

The proposed project will benefit the local area in the following ways.

7.1. PHYSICAL INFRASTRUCTUREOnce the activity is commissioned, the socio-economic status of the local people will

improve and there by infrastructure facilities like communication systems will improve.Most of the villages at present do not have protected water supply. After the

implementation of the project, the affordability of the public to spend on water

treatment, supply & distribution will more along with the aid from the state

government.

7.2. SOCIAL INFRASTRUCTUREWith the implementation of project, the socio-economic status of the local people will

improve substantially. The land rates in the area will improve in the nearby areas due tothe proposed activity. This will help in upliftment of the social status of the people in

the area. Educational institutions will also come-up and will lead to improvement of

educations status of the people in the area. Primary health centre will also come-up and

the medical facilities will certainly improve due to the proposed project.

7.3. EMPLOYMENT POTENTIALThe proposed project creates employment to 100 people during construction and 415

people during operation of the project.

7.3.1. SKILLEDTotal skilled employment in the proposed plant will be 162.

7.3.2. SEMI- SKILLEDTotal semi -skilled employment in the proposed project will be 43. Priority will be given

to local people for semi-skilled jobs.

7.3.3. UNSKILLEDTotal unskilled employment in the proposed project will be 193. Top priority will be

given to local people for unskilled jobs.

7.4. OTHER BENEFITSThe following are the other benefits to the area due to the proposed project.

• Educational status will improve in the area.• Medical standards will improve due to the proposed project.

• Overall economic upliftment of socio-economic status of people in the area.

• Ancillary developmental activities will be created due to the establishment of theproposed unit.

To summarise the benefits from the project, listed as follows:

• Increase in direct and indirect employment opportunities



• Zero discharge of water

• The proposed green belt development program will increase biomass andbiodiversity and leads to sustainable environment

• The proposed green belt will not give opportunities for suitable habitat toanimals but also attracts avifauna

• The existing infrastructure will be utilized as far as possible, and thereforedisturbance ecosystem balance is negligible due to infrastructure facilities

• The industry spend money for their social activities for the benefit of the nearly living people with in 10 km radius

7.5 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIESThe company has take up developmental activities as follows:

Table: 7.1 CSR Activities conducted and proposed around factory premises

Programme Conducted Proposed Time frame

Conducted medicalcamp at

Honnarahalli Village

Construction of ladies toiletin Kudadarahal Village

Before April2013

Free medical checkup camp at Kudadarahal and

Hatcholli villages

Twice in amonth. Started

from Jan,2012

Up gradation of toilets and

wash rooms in the GovtSchools

December 2013

Health

Free eye check up camps at villages and provision for

free cataract operation foraged persons will be made

December 2012

Distribution of note

books to schoolchildren (each child7 note books) of

Kudadarahal

villages

• Higher educationprogramme:

Sponsership tomeritorious and

under previllaged

students for Diploma

Courses at the private& Govt. polytechnics.

• Opportunity for

employment upon

completion of course

• Distribution of notebooks to school

children (each child 7

note books) ofKudadarahal villages

Started from

academic year2011.

Started fromacademic year

2011.

Education

Workshop was Workshop will be conducted Started from the



conducted tofarmers on scientific

irrigation, soil

management and

economic feasibilityof crops by

agricultural

scientists

to farmers on scientificirrigation, soil management

and economic feasibility of

crops by agricultural

scientists

year 2010.

Electrification:Distribution ofstreetlights to

Kudadadarahal,

Sridharagadda andNagalapura Villages

Training on vocationalcourses in tailoring, candlemaking, book binding, etc.,

for economic upliftment of

poor woman.

During financialyear 2012

Provided temporary

shelters and food toflood affectedpopulation of

Honnarahalli,

Chikballary,

Shridharagaddavillages (about 65

families still

dwelling in our

premises)

Distribution of tricycle to

physically handicappedpersons in Kudadarahal and Hatcholli Villages.

Before December

2012

Welfare

Distribution of streetlights to

Honnarahalli, Chikballary

and Bagevadi Villages

December 2012

Upgradation of MDR roadfrom Siruguppa junction to

Hatcholli with state PWD

under PPP scheme

On or before2015

Concreting of village internal roads in Kududarahal,

Honnarahalli and

Hatchcholli

grampanchayaths

On or before2015

Road barricades will be

distributed to Hatchollivillage police station.

Jan- Feb 2012

Shelter to traffic police Jan- Feb 2012

Traffic signage/ controlboards

Jan- Feb 2012

Providing safe drinkingwater, scientifically.

During financialyear 2012

Infrastructuralwelfare

Distribution of saplings to Before March



panchayaths & schools. 2012

Sports Distribution ofsports kits and

materials to schools

at KudadarahalVillage

Conduct of Inter SchoolAthletic meet with sports

materials.

September 2012

The budget for CSR activities will be 5% of the project cost to be spent over 5 years period.

Paper cuttings showing the CSR activities conducted last year.

Fig: 7.1 CSR activates carried out



CHAPTER-VIIIENVIRONMENTAL MANAGEMENT PLAN

8.1 Introduction

Environmental Impact Assessment (EIA) is the process used to integrate environmental

management with planning for proposals. EIA is an established process for: • Ensuring that proponents assume primary responsibility for protection of any

environmental values that may be affected by their proposals;

• Addressing the environmental management of the life of proposals;

• Forming a basis for statutory decisions on whether a proposal meets ecologically sustainable development principles, and if so, relevant environmental

management and monitoring conditions;

Industrial development is an important constituent in our pursuits for economic

growth, employment generation and betterment in the quality of life. On the other hand, industrial activities, without proper precautionary measures for environmental

protection are known to cause pollution and associated problems. Hence, it is necessary to comply with the regulatory norms for prevention and control of pollution. Alongside,

it is also imperative to go beyond compliance through adoption of clean technologies and improvement in management practices. Commitment and voluntary initiatives of

industry for responsible care of the environment will help in building a partnership for

pollution control.

Preparation of Environmental Management Plan (EMP) is required for formulation,implementation and monitoring of environmental protection measures during and after

commissioning of the proposed pig iron Plant and Captive Power Plant project. This Environmental Management Plan has indicated the details as to how various measures

have been or are proposed to be taken. The base line settings of different relevantenvironmental components in the study area are predicted potential impacts on those

components due to the proposed project are documented. In this plan, mitigation

measures for the identified environmental impacts are documented for both

construction and operational stages of the proposed project in the form of anEnvironmental Management Plan (EMP).

8.2 Environmental Management during Construction Stage• During excavation and transportation on roads at the plant site, there is a scope

for local fugitive dust emissions. Frequent water sprinkling in the vicinity of the

construction activity should be done.

• There is a likelihood of fugitive dust from the construction activity and material handling from the truck movement in the premises of the proposed plant. The

industry will take up tree plantation program around the plant site.

• It will be ensured those construction vehicles are properly maintained. The

vehicle maintenance area will be located in such a manner, so as to preventcontamination of water sources by accidental spillage of oil.



• Proper care will be taken for storage of LSD etc. Location will be identified for the storage of such flammable liquids, away from the main plant. The storage will be as per institutional safe ty standards.

• The construction workers will be provided with sufficient and suitable toilet

facilities to allow proper standards of hygiene.

• Onsite workers using high noise equipment will adopt noise protection devices. Noise prone activities will be restricted to daytime hours only.

• Hazardous material will be stored in proper areas.

• After completion of construction activities, the rubbish will be cleared and

disposed to nearby authorized sites.Table 8.1: EMP for Construction Phase Impacts "Site Clearing"

EnvironmentalImpacts

Mitigation Remarks

Soil erosion Extent of vegetation removal will be

minimized to prevent extent of soil

erosion.Vegetative cover will be reprojected

/rehabilitated at the earliest practicable

time to minimize duration & extent of soilerosion.

Implementation responsibility:

Contractor

M/s Shree Ram Electrocast Pvt Ltd.

Noise

generation

Selection of equipment with less noise

generation to be used.

The earth moving equipment will be

periodically checked and maintained for noise levels. Since the site is more or less even use of these earth-moving

equipments may not be necessary.

The workers will be provided withadequate PPE such as earplugs to reduce

impact of high noise levels.


Contractor

M/s Shree Ram Electrocast Pvt

Ltd.

Dust

generation

The site cleared will be periodically

watered to reduce emission of dustparticles.

The workers will be provided with PPE

such as nose masks and goggles to reduce

impact on health.


ContractorM/s Shree Ram Electrocast Pvt

Ltd.

Table 8.2: EMP for Construction Phase Impacts"Transportation of Construction Materials”


Mitigation Remarks

Noisegeneration Periodic maintenance of vehicles is

required

Implementation responsibility: Contractor


Pvt Ltd.



Dust generation Construction materials will becovered with tarpaulin sheets to

prevent the material from being air

borne.

The vehicle speed will be regulated.The workers transporting materials

will be provided with PPE such as

nose masks to reduce impact of air

borne dust on their health



Pvt Ltd.

Vehicularemissions

Periodic emission check for vehicles is required.

Clean fuel will be used for vehicles.



Pvt Ltd.

Table 8.3: EMP for Construction Phase Impacts "Construction Activities”


Mitigation Remarks

Noisegeneration

Personnel Protective Equipment (PPE)such as ear plugs and helmets will be

provided for construction workers.

The working hours will be imposed on

construction workers.

Implementationresponsibility:

Contractor

M/s Shree Ram

Electrocast Pvt Ltd.Dust generation PPE in the form of nose masks will be

provided for construction workers.

Use of water sprays to prevent the dust

Contractor from being air borne.

Implementation

responsibility:

Contractor

M/s Shree RamElectrocast Pvt Ltd.

Air Emissions

from

constructionmachinery

Periodic check and regular maintenance

of construction machinery for emissions

Clean fuel will be used in equipments

Implementation

responsibility:

ContractorM/s Shree Ram

Electrocast Pvt Ltd.

8.2.1 Water Resources and Quality

Following mitigation measures will be adopted to avoid impact on water resources

• Construction equipment requiring minimum water for cooling and operation for optimum effectiveness will be chosen

• High pressure hose will be used for cleaning and dust suppression purposes.

• Water harvesting measures would be taken.

• Appropriate sanitation facilities, septic tank and soak pits will be provided for

the workers onsite and offsite to reduce impact on water resources. Regular

maintenance will be done during the entire life cycle.

• No discharge of construction wastes to surface water bodies or ground water will be allowed during construction.



• Efforts will be made for reuse of water and its conservation.During Construction period in rainy season, the water quality is likely to be affected due to the construction work and loosening of topsoil. This is likely to increase the

suspended solids in the run – off during heavy precipitation. In order to reduce the

impact on water quality, temporary sedimentation tanks will be constructed for the settlement of the suspended matter. However, it is envisaged that the monsoon period

will be avoided for cutting and filling of earthwork. Additionally, following measures

will be taken to avoid the surface water pollution.

• Soil binding and fast growing vegetation grass would be grown around the construction site before commencement of construction activity to reduce soil

erosion;

• Appropriate sanitation facilities will be provided for the construction workers to

reduce impact on ground water resources and also to maintain hygienicconditions.

There is no likely hood of ground water contamination, as no waste will be discharged

to ground water bodies during construction. However sewage generated during the

construction phase will be treated in the Septic Tank and Soak Pit. Wherever

construction wastes need to be disposed off on land or offsite, the same will be disposed off in a proper manner and permission will be taken from the concerned

statutory authorities.

8.2.2 Air Quality

During Construction period, there is likelyhood of generation of dust and NOx

emission. This can be attributed to leveling activity and vehicular movement. Thetransport vehicles using petrol or diesel will be properly maintained to minimize smoke

in the exhaust. Since, there is likelihood of fugitive dust from the construction activity,

water sprinkling will be done. In addition to this following measures will be taken

during the construction phase to reduce the impact on the air quality.• Any vehicle not meeting the vehicular pollution standards will not be allowed

within the construction activity.

• Water will be sprayed by high-pressure water hoses during dust generating

construction activities e.g. excavation, crushing/demolishing, concrete mixing,material handling etc. to suppress dust; and

• Vehicles delivering loose and fine materials like sand and fine aggregates will be

covered by tarpaulin to reduce spills on roads.

• The height from which excavated materials are dropped will be controlled to a minimum practical height to limit fugitive dust generation from unloading.

• The random Ambient Air Quality Monitoring will be done to ensure that the

significant impacts are being mitigated adequately.

8.2.3 Noise Level



The popul ation in nearby villages from the proposed site are located at a distance of 4-5Kms away. Hence, the noise impact on the surrounding population during the

construction phase will be within the acceptable limits. High noise generation

equipment, if used will be operated during the daytime only and completely restricted

during night hours and this eliminates any possible discomfort to the nearbycommunities. Community noise levels are not likely to be affected because of the

vegetation and likely attenuation due to the physical barriers.

The following recommendations will be implemented:

• Provision of insulating caps and ads at the exit of noise source on the machinery;

• Construction equipment generating minimum noise and vibration be chosen:

• The use of damping materials such as thin rubber / lead sheet for wrapping the

work places line compressors, generators sets.

• Shock absorbing techniques will be adopted to reduce impact;

• Inlet and outlet mufflers will be provided which are easy to design;

• Ear muffs will be provided to the workers and it will be enforced to be used by

the workers; and• Greenbelt will be developed along the periphery of the proposed site.

• Ambient Noise Level Monitoring will be conducted at suitable location at

periodic intervals during construction phase to conform to the stipulated

standards both during day and night time.

8.2.4 Solid /Hazardous Waste Management

The hazardous materials used during the construction may include petrol, diesel,

Welding gas and paints. These materials will be stored and handled according to the KSPCB guidelines.

• Diesel and other fuels will be stored in separate enclosures;

• Wherever possible, hazardous raw materials to be substituted by non- hazardous

materials, e.g. Cleaning solvent can be replaced with film –free biodegradable cleaners. Usage of non chlorinated strippers instead of strippers containing

methylene chloride and substitution of water based paint for oil based ones;

• Separate storage of waste paints, thinners, contaminated rags and brushes will be adopted.

• Vehicle maintenance area to be designed to prevent contamination of ground

water by accidental spillage of oil

8.2.5 Site Security

Adequate security arrangement will be made to ensure that the local inhabitants and the

stray cattle are not exposed to the potentials hazards of construction activities. The proposed site is barricaded with suitable fencing preventing the entry of unauthorized

persons, vehicular movements and stray animals.

8.2.6 Traffic Pattern



Heavy vehicular movement will be restricted to daytime only and adequate parkingfacility will be provided. The speed of all vehicular movements will be controlled

through proper monitoring and by movement of vehicles only in demarcated routes.

8.2.7 Solid Waste Generation

• The solid waste generated during the construction phase is usually Excavated

earth material and Construction debris.

• Excavated earth material will be reused for backfilling between foundations; to

fill up the low-lying areas and whereas, topsoil will be reused forLandscaping/Greenbelt development purpose.

• Construction debris as far as possible will be reused / recycled for back filling / sub base work for roads & pavements and excess will be transported to nearby

authorized disposal sites.8.2.8 Ecological Aspects

• Plantation of dust absorbing trees and shrubs near the dust generating areas.

• Plantation of soil binding plants e.g. grass will be carried out to avoid soilerosion.

• Plantation of noise attenuating species to reduce noise pollution both during the

construction as well as in the operation stage.

• Stabilization of all disturbed slopes before the onset of monsoon to avoid soil erosion.

• Cutting of existing trees/bushes/ other vegetation will be avoided as for as

possible or will be minimized.

• Operation of high noise producing equipment will be avoided during night time to avoid impact on the immediate vicinity of the proposed project site

surroundings.

• Use of best available construction technology to minimize impacts on flora and fauna of the project site area.

8.2.9 Aesthetics

• Existing aesthetics of the site will be tried to maintain by taking appropriate

measures in different activities.

• Existing peaceful environment will be maintained in the vicinity of the project site.

• The excavated material dump will not be permitted to become a major visual

feature of the local landscape. The height of the dump will not exceed the mature tree top level in the area.

8.2.10 Socio-Economic

• Local people from nearby villages will be employed for construction work to the maximum extent possible.

• Proper facilities for domestic water supply and sanitation services will be made

available to the construction workers at the site.

8.2.11 facilities provided for labour force during construction

Facilities provided for workers during the construction phase include the following:



• About 200 construction workers will be employed in the construction site.

• 7 Toilets, 5 Urinals and 5 Bathrooms will be provided for the laborers.

• First Aid facilities will be provided at the site.

• Local Doctor will be assigned for regular health check – up of theconstruction workers

• Arrangement with local hospitals for any emergency measures will be

made for all the laborers working at site

• Safety measures like PPE (Personal Protective Equipments) - Helmets, Safetyshoes, Nose Mask, Goggles, and Safety Belts, etc will be provided for the

construction laborers during construction, depending on the nature of their work.

• About 15 KLD of drinking water will be arranged through private tankers

conforming to IS drinking water quality standards

8.3 Operation stage

8.3.1 Air EnvironmentM/s Shree Ram Electrocast Pvt Ltd. proposes to expand pig iron plant, Captive power

plant and DIP plant, and establish Sinter plant, coke oven plant, slag cement grinding

unit in the existing plant premises which consists of pig Iron plant and Captive Power Plant. Air emissions from the proposed industrial process mainly comprising melting of

various metallic raw materials in the furnace, flue gas from coke ovens, power plant,

and DIP plant and fugitive emission.

The mitigation measures needs to be adopted during the operation stage to control the negative impacts on air environment of the surrounding of the project area given below:

• Air preheater/BF stoves is the main pollution sources from Pig Iron plant. Gas

cleaning plant with venturi Scrubber are provided to control the pollutants in the

Blast furnace (BF) gas before distributon of the gas.

• Anneling furnace, MG treatment and zinc coating unit will be provided with stacks as stipulated by KSPCB norms.

• Magnesium converters and zinc coating units will be provided with Bag filters.

• Sinter plant will be connected to ESP to minimize the impact of air pollution.

• AFBC boiler will also be connected to ESP.

• Reducing emissions from sinter plant by process optimization, including

minimizing stoppages and maintaining consistent operation in terms of strand speed, bed composition (particularly consistent blending of reverts which should not contain oil), bed height, use of additions such as burnt lime; and keeping the

strand, ductwork, ESP and bag filter air tight

• Pollution reduction from coke making relies as much on techniques andoperation does equipment. Prevention of fugitive releases to air and accidental

releases water and land are heavily dependent on maintaining steady operation

of the well trained and motivated operating staff, management who use key

performance parameters in systematic monitoring and fault analysis (e.g.chimney and emissions, coke and flue temperatures and battery pre ssures in the

short battery average temperatures and emissions trends over the medium term)



• The aim should be to see that no fume escapes from any ovens, and associated ductwork, which are closed and carbonising, and requires continuous vigilance. Automated continuous fugitive monitoring is not possible but a view along the

battery top is sufficient. No fumes should be apparent

• Minimising the proportion of fines in the coal feed has been shown to reduce emissions during charging, where these are significant.

• Monitoring of stack emissions and emissions from the dedusting equipments will be carried out regularly to ascertain the performance of the air pollution control

equipments.

• Arrangements are made for periodical monitoring of stack gas and ambient air

quality. The sampling points are located based on meteorological conditions of

the region.• Ladder, port hole, power supply points are provided to the stacks for monitoring

of emissions.

• Water spraying will be adopted at loading and unloading points and storage

yards which will reduce fugitive emissions due to movement of truck.• All the internal roads will be asphalted to reduce the fugitive dust due to truck

movement.

• Green belt cover will be provided. For this, the project has proposed to have

green belt cover to an extent 35% of total area of the land has been demarcated as Green Belt. Already 12000 plants have been planted maintaining the good Flora

& Fauna. Further, we are planned to plant around 5000 plants during the

financial year 2011-2012. Further 15,000 trees are proposed to be planted as a part

of greenbelt development.

• Cabins for shovel and dumpers and dust masks to workmen

• A good house keeping and proper maintenance will be practiced in the industry, which helps in controlling pollution.

• Proper maintenance of air pollution control equipment

• Regular maintenance of vehicles and machinery’s in order to control emissions.8.3.1.1 Air Pollution Control Equipment

The stacks proposed at plant to exhaust the flue gases is estimated based on Central Pollution Control Board formula.

In addition to that, Water sprinkling arrangements will also be done within the site

premises to suppress the dust and fugitive emissions.

Air pollution control equipments used are as follows:

DIP PLANT

Concentrati

onof

pollutants,

mg/ Nm3

Unit Air

Pollutioncontrol(AP

C)

equipment

Chimn

eyheight

x

dia(m)

Exit

gasvelocit

y,

m/sec

Flue

gasTemp0C

Air

pollutants

After APC

1 Anneali ----- 30 x0.6 13.5 Particulate 50



FBC Boiler Capacity- 2 x 54 TPH, 21 MWH

3 Sinter plant

Capacity-300,000 TPA

matter

SO2 15.3

ngFurnace

300-3500C

NO2 12.4

Particulatematter

50

SO2 15.4

2 MgConverter

Bag Filter 30 x0.6 14.5 1500C

NO2 9.4

3 ZincCoating

Bag Filter 30 x 0.5

14.0 400C Particulatematter

50

Concentratio

n of

pollutants,

mg/ Nm3

Unit Air

Pollution

control(AP

C)equipment

Chimney

height x Exit

dia.m

Exit gas

velocity

, m/sec

Flue

gas

Temp 0C

Air

pollutant

s

After APC

Particula

te matter

50

SO2 12.7

1 FBC boile

r

ESP 90 M

x 2.5m

16.0 1800C

NO2 14.2

Concentra

tion of pollutants

, mg/ Nm3

Unit Air

Pollutioncontrol

(APC)equipme

nt

Chimne

y height x Exit

dia. m

Exit gas

velocity,m/sec

Flue gas

Temp 0C

Air

pollutants

After

APC

Particulate

matter

45

SO2 15.7

1 Sinter M/c Head End

Exhaust-

Dedusting

system

ESP 30 M x 1.5

14.0100-

1600C

NO2 13.4

Particulate

matter

45

SO2 13.5

2 Sinter M/c Tail End Exhaust-

Dedusting

system

ESP 30 M x 1.5

14.0 900C

NO2 11.2

3 Fuel Crushing Bag 30 M x 400C Particu 45



4. Coke Oven plant with waste heat recovery boilers (2)

5. Cement PlantCapaciy 100,000 TPA

dedustingsystem

Filter 0.5 latematter

4 Flux crushing

& screening

dedustingsystem

Bag

Filter

30 M x

0.4

6

6

400C Particu

late

matter

50

5 Cold sinter

screeningdedustingsystem

Bag

Filter

30 M x

0.4

6 400C Particu

latematter

50

Unit Air Pollution control(APC)

equipment

Chimneyheight

Exit gas velocity,

m/sec

Fluegas

Temp0C

Airpollutants

Concentrationof pollutants,

mg/ Nm3

Particulate

matter

78

SO2 20

1 Coke

Oven

batteries(2) with waste heat

recovery

boiler

N0.1

- 30 M x

1.5 m

8 1800C

NO2 8

Particulate

matter

78

SO2 20

2 Coke

Oven

batteries

(2) with waste heat

recovery

boiler

No.2

- 30 M x

1.5m

8 1800C

NO2 8

Concentration of

pollutants, mg/

Nm3

Unit Air

Pollution

control(APC)

equipment

Chimney

height x

dia m

Exit gas

velocity,

m/sec

Flue

gas

Temp0C

Air

pollutant

s

After APC

1 Dedusting

unit

Bag Filter 30 M x0.5 6 400C Particula

te matter

50



6. Pig Iron plant at SREPL

*Present pig iron production capacity - 120,000 TPA

**Enhanced capacity- 200,000 TPA

Details of Stack and Gaseous Emissions (on Enhancement of Capacity)

BF gas fired

BoilerMBP/BF stoves Gas flare

ParameterAfter

enhancement**After enhancement** After enhancement**

Stack no. 1 2 3

Stack dia., m 1.24 2.01 0.75

Stack Height, m 30 30 30

Fuel,

B.F.gas,

Nm3/h

F.O., kg/hr

22 000

nil

28,000

NilNil

Emissions

Flue gasTemp. °C 320 -

Velocity of flue

gas15.8m 9.8 -

Pollutants, mg/

Nm3

SPM 50 50 -

SO2 40 40 -

NOx 10 10 -

8.3.1.2 For Fugitive Dust control

Uncontrolled fugitive particulate emissions are associated with material handling

operations. These operations consist of unloading, storing, grinding / crushing and

sizing of coal, and screening, crushing, storing, and unloading of coke. Dry fog type dust suppression system will be installed in the coal preparation unit includingcrushers, screens, etc

Table 8.4: Characteristics of Secondary Fugitive EmissionsSl.

No.

Item Secondary fugitive Emissions Control Strategy

1) Leaking of PipeConnection

Iron Oxide, H2S, CO, NOx,SO2 etc

Weld together

2) Valves Iron Oxide, H2S, CO, NOx,

SO2 etc

Seal-less Design

3) Fans, Compressors Iron Oxide, H2S, SO2, NOx

and other

Closed vent system Dual

mechanical seal

4) Raw material Iron oxide, fine particles of Binding agent in the



preparations additives and auxiliary rawmaterials

water spray dedusting.Plantation around source

7) Casting Fume, lead, SOX, Fluorides

Fume extraction,

water spray

To reduce fugitive emissions of particulate matter during handling of materials, the following prevention and control techniques will be followed:

• Using indoor or covered stockpiles or, when open-air stockpiles are unavoidable,

use of water spray system, dust suppressants, windbreaks, and other stockpile

management techniques;• When transferring volatile liquids, the following techniques should be employed

– subsurface filling via (antisyphon) filling pipes extended to the bottom of the

container, the use of vapour balance lines that transfer the vapour from the

container being filled to the one being emptied, or an enclosed system withextraction to suitable abatement plant.

• Designing a simple, linear layout for material handling operations to reduce the need for multiple transfer points (trucks and tippers)

• Maximizing the use of enclosed silos to store bulk powder;

• Enclose conveyer transfer points with dust-controls;

• Cleaning the return belts in the conveyor belt systems to remove loose dust;

• Implementing routine plant maintenance and good housekeeping to keep small leaks and spills to a minimum;

• Implementation of correct loading and unloading practices.

Action plan to control fugitive dust emissions of particulate matter from different units

are tabulated below:

Table 8.5 Action plan to control fugitive dustFugitive Emission Source Control Technique Control Equipments

Active Storage Piles a) Watering

b) Plantations

- Water Sprinkler on yard

Conveyor & Transfer Points a) Water Sprays

b) Dedusting

- Dust suppression system

Product Handling a) Water sprinkling

b) Dedusting

- Dedusting units

Loading & Unloading a) Windscreens

b) Water Sprays

- Water Sprinkler on yard

Internal Road Transportation a) Water Sprayb) Asphalted/Tar Roadc) Plantation

- Water Sprinkler- Construction of Internalroads

- Plantation at road sides

Road Controlling of vehicle

entering and leavingthe plant

Speed breakers

Signal boardsInstalling of magnifying

glass at junctions



8.3.2 Water PollutionAll water systems inside the plant are closed circuit system and there is no trade effluent

from the process.

8.3.2.1 Water Environment

Water requirement for the proposed project will be met from Tungabhadra River. The

water will be used majorly for cooling purposes. There is no effluent in this process.Therejected water if any will be neutralised and used for gardening. The quantity of canteen

wastewater generated and domestic wastewater generated from toilet and bathrooms

will be treated in the STP of capacity 50 KLD and the treated effluent will be reused for Greenbelt Development.Apart from the proposed treatment schemes, following additional measures will

minimize operational impacts:

• There is no effluent water in this process

• Use of high pressure hoses for area cleaning• House maintenance and floor wash wastewater will be reused after treatment.

• No wastewater will be discharged to any ground water or to the surface water body.

• Storm water drains will be provided to avoid flooding in the proposed project

site area and provision will be made for runoff get diverted to recharge pits with

pre oil and grease trap there by increasing the groundwater table.

• No water will be drawn during lean season. Excess water will be drawn and stored during rainy season and that will be used during lean season.

8.3.2.2 Water Pollution Control and Conservation

Extensive recycling has been adopted in the design of plant water systems. Quality of circulating water will be maintained through dosing of conditioning chemicals forcontrolling corrosion, scale deposit and microbial growth.

The raw water from River will be pumped to reservoir. This water will pass through

filters, softner and demineraliser plants . The treated water will be use for manufacturing process.

Through cascaded reuse of blow down, the water scheme ensures practically zero-

discharge from the industrial water circuits

8.3.2.3 Water pollution control

Water pollution mainly comprises of inorganic solids, oil, grease, etc. in suspension,

solution and emulsion.

The pollutants present in the waste water will be reduced to acceptable levels by

adoption of the following schemes.



• Re-circulating water in the process whereby discharged volume is considerablyreduced

• Close circuit cooling wherever feasible.

• Clarifier and sludge pond for removal of suspended solids

• Neutralization of acidic water by lime

• Removal of oil and grease from the contaminated water by means of oil traps and

skimming devices

No Water is drawn from the river during lean seasons. During rainy season water is drawn and collected in the storage reservoir.

8.3.3 Noise Pollution

All steam outlets like safety valves; ejectors are connected with silencers and all fans are

being insulated with acoustic insulations. The maximum sound in the different areas is maximum 90 decibels, which is in the limit.

8.3.3.1 Noise Environment:

• Personnel working near noisy areas will be provided with adequate personal

protective equipment such as earplugs and earmuffs, use of which will be strictly enforced.

• Sophisticated and low noise generating equipments will be selected.

• Proper mounting of equipments and providing noise insulating enclosures or paddling where practicable.

• The equipments will be maintained at all times to ensure permissible noise levels.

• Appropriate advanced silencers, acoustic barriers; vibration-reducing pads will be provided for all noise generating equipments.

• The sources of continuous noise generating equipment such as compressors,

pumps etc will be designed to have noise level not exceeding 85-90dB(A).

• It would be ensured that there would not be any operator near the noise

generating equipments on continuous basis.

• Boundary walls and dense green belt will be erected to act as acoustic barriers.

• Adequate and appropriate type of green belt would be developed in and around the proposed project site for noise mitigation in the area.

• Shock absorbing techniques will be adopted to reduce noise level.

• Acoustical walls and roofs are provided to buildings where such machineries are installed.

• Proper maintenance of machineries especially oiling and greasing of bearing and gears etc.

• Use of personnel protective to persons working near noise creating locations.

• Plantation of green trees around the factory building and premises to control the

intensity of noise to the surrounding area.

• 35 % land area around the factory is covered with green belt. It includes green belt of 6 to 10 m width around storage yards.



• Trees are planted on either side of the roads with in the factory premise and with in the vicnity around the factory.

• Trees species are selected as per guidelines of CPCB.

8.3.4 Solid Waste

Solid waste generated from different operations of the unit is as shown in the table

below:

Table 8.6 Solid waste generated from different operations after expansion

Pig iron plant

2,00,000 TPA

Iron ore fines (97800 TPA) Coke fines (11000 TPA) B.F.Slag (58000 TPA) GCP dust (6720 TPA) GCP sludge (5430 TPA) P.I. Scrap (15330 TPA)

Used in sinter plant Used in sinter plant Used in cement grinding plant Used in sinter plant Used in sinter plant Sold out

DIP PLANT

200,000TPA

Burnt sand generated in castingsection (5600 TPA)MgO (200 TPA)

ZnO (100 TPA )Slag (1000 TPA)

Stored in the dump yard. Can be used for land fillingSold out to approved vendors.

Sold out to approved reprocessorsUsed for land filling



Sinter plant Sinter fines (6000) TPA

Dust from ESP (5200 TPA)

Circulated back

Circulated back


Nil

Generated Solid waste and Hazardous wastes i.e, disposal mechanism as follows:

• Majority of the solid waste will be recycled back to sinter plant for the production of sinter.

• Where as BF Slag will be used in cement grinding unit.

• Slag from DIP plant will be used for landfilling.

• Domestic Solid waste (Garbage/ Trash/ garden litters) will be stored in Garbage collection pits and disposed to nearby municipality

• Used Oil and scrubbed sludge generated from the industry will be collected and stored in barrels/drums and later disposed to the Karnataka State Pollution

Control Board approved waste oil reprocessors/dealers.

• Any other solid waste generated from the facility will be disposed off by using proper disposal mechanism.

8.3.5 Greenbelt Development



Green belt is an important sink for air pollutants. Trees also absorb noise and byenhancing the green cover, improve the ecology and aesthetics and affect the local

micrometeorology. Trees also have major long-term impacts on soil quality and the

ground water table. By using suitable plant species, green belts can be developed in

strategic zones to provide protection from emitted pollutants and noise.In the proposed plant, green belt will be developed in vacant areas, around office

buildings, around stores, along the side of roads, along the plant’s boundaries and

around the waste dump area. Plant species suitable for green belts should not only be

able to flourish in the area but must also have rapid growth rate, evergreen habit, large crown volume and small / pendulous leaves with smooth surfaces. All these traits are

difficult to get in a single species. Therefore a combination of these is sought while

selecting trees for green belt.

As per provisions 35% of total area of the land has been demarcated as Green Belt.Already 12000 plants have been planted maintaining the good Flora & Fauna. Further,

we are planned to plant around 5000 plants during the financial year 2011-2012.

SRECPL also proposes to plant another 7000 saplings as a part of greenbelt

development. The species selected for greenbelt development will fulfill the following specific requirements of the area:

• Tolerate to specific conditions.

• Will have rapid growth rate.

• They will rich canopy and shielding property.

• Large bio-mass and leaves to provide fodder and fuel.

• Ability to improve wastelands/barren areas.

• As for as possible all be native in nature.

• Greenbelt development plan and tree species proposed is enclosed as Annexure -5

8.3.5.1 Action plan for development of Greenbelt in 35% area

o Greenbelt is defined as the mass plantation of pollution tolerant trees and shrubs

in an area for the purpose of minimizing air pollution by filtering, intercepting and absorbing pollutants in an effective manner for improve of the Environment.

o The proposed project plans to develop and maintain 35% of Greenbelt of the total plot area within its Industrial premises.

o Hence for the same, a standard horticulture practice will be followed whileplanting saplings in pits of dimension 1000mm X 1000mm X 1000mm for

large/big trees and 600mm X 600mm X 600mm for smaller trees and shrubs.

o A three tier system will be followed in order to develop a canopy type greenbelt.

Therefore, the plantation order will follow shrubs, smaller trees and larger trees from inside towards the boundary wall.

o Special care will be taken for planting shrubs or trees along the road side. The

height (1000mm-1500mm for shrubs and 3000mm-5000mm for trees) and the foliage areas will be such that it does not affect the visibility.

o Local native plant species tolerant to local climatic conditions and tree species

that retain foliage longest and attract birds will be preferred for Greenbelt

Development.



o The development of the greenbelt will be in parallel with the constructionactivities of the project and will be maintained effectively during operation phase

of the project too.

o Greenbelt development plan is enclosed as Annexure and Species to be planted is

also enclosed.

8.3.6 Storm Water Management

Shree Ram Electrocast Pvt Ltd is planning to have a system of rainwater harvesting at plant. Rainwater harvesting is primarily dependent on various site characteristics suchas soil properly, catchments characteristics; rainfall characteristic, and ground water

table etc. There are artificial as well as natural rainwater harvesting system.

Construction of rainwater filter bed at centralized place where water from individualunit as well as storm water from open area will be diverted. The rainwater carries

suspended solids as washed out from open area. A filter bed filters the particles thus

prevent them from reaching / contaminating ground water. The first layer of filter bed

will be coarse sand the second layer will be pebbles and third layer will be gravel. The filtrate thus collected from the bottom of filter bed will be piped to recharge bed.

o Storm water gutters will be constructed in the premises.

o Garland channels will be provided to the storage yards.

o Storm water storage capacity will be provided for about 30% of the annual storm water collected from the factory premises.

o The rain water thus collected is used for greenery development in the factory.

o Also, part of storm water thus collected can also be used as a source of water for

the industry.o Storm water drains will be provided within the premises of the industry to avoid

mixing with affluent.

o Storm water drains will be provided on both sides of the roads. Rectangular

drains will be provided based on the quantity of storm water to be conveyed and

depth limitations.o Rainwater harvesting tank of 2 lakh capacity will be constructed.

o 40 recharge pits are provided for the purpose of ground water recharge.

Typical section of recharge pits are shown below:

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

M/

s S

hre

e R

am

Ele

ctro

cast

Pv

t L

td.,

20

9

Fig

ure

8.1

Se

ctio

n R

ech

arg

e p

it

SC

AL

EN

TS

2000

2000

XX

'

DEPTH AS PER SITE CONDITION



8.3.7 Ecological Aspects The following measures are proposed to have minimum impact on ecology of theproject area:

o Continuing greening efforts in and around the project site.o Conservation of existing vegetation and afforestation covering larger areas near

and around existing project area. o The dump yard is treated by a gentle gradient and pitching will be done all

around the earthen heap will be formed into terraces and it will be stabilized by planting grass sets and also by sowing grass seeds.

8.3.8 Aesthetics Aspects o The entire area will be planted with local tree species of aesthetic value, fodder

value, fruit bearing and birds attracting tree species. Hence it would beconverted into a possible park for the nearby villages and project staff forrecreation.

8.3.9 Socio Economic Aspects

Following are the activities conducted and proposed around the premises

• The project is not going to cause significant damage to the existing agricultural situation. Instead, it is likely to provide the farmers with supplementary income.

• The project has very strong positive employment and income effects.• There is a great possibility of industrialization in the vicinity of the proposed

steel plant. This is likely to bring dramatic changes by transforming thisbackward area into an industrially developed one.

• The project has very strong positive impact, which is likely to result in theimprovement of economic situation of Siruguppa

• Overall peoples’ perception on the project is a mix of advantages anddisadvantages. On one hand, they expect job opportunities, market expansion etc. as advantages and on the other hand they are worried about the damage to agriculture.

• As an impact of identification of the project, small-scale industrial economy is likely to flourish in the surrounding area. The small-scale industrial units are expected to get financial supports from the financial institutions and banks. In this way, an overall development may take place in this area.

• The process of development will have maximum impact on the lifestyle of the local people. The project and the consequent peripheral industrial economy will generate income to the local and migrated people which will increase theaggregate demand. This demand will get realized in the market and finally, lead to the market in the locality of the project. Market expansion supported byexpected infrastructural developments like roads, electricity, water supply etc. will result in improving the economic development in the entire region.



8.3.10 Land ManagementThe main intention of land management is to restore the pristine ecological conditions in the region. The major solid wastes generated from the proposed project are reusedback in the sinter plant and BF slag will be utilized in the Cement grinding unit and DIP plant slag will be used for filling low lying areas.. Other solid waste generated will be handed over to KSPCB authorized vendors. General garbage will be disposed off to nearby municipality. Whereas the hazardous waste like Used oil from the D.G Sets will be handed over to the KSPCB authorized reprocessors/dealers.

8.3.11 Traffic Management PlanTable 8.7 Trucks details

Proposed+existing TPA workingdays/

annum

TPD truckcapacity

trucksrequired

Total no of trucks

Limestone 29700 330 90 16 5.625 5Iron ore fines 212400 330 643.63636 16 40.22727273 40

Dolomite 25410 330 77 16 4.8125 5

Quick lime 7260 330 22 30 0.733333333 1

Iron ore 140000 330 424.24242 16 26.51515152 26

limestone 35000 330 106.06061 16 6.628787879 6Dolomite 25000 330 75.757576 16 4.734848485 5

Manganese 3000 330 9.0909091 16 0.568181818 1

Quatrz 11000 330 33.333333 16 2.083333333 2

Clinker 40000 330 121.21212 16 7.575757576 7

Gypsum 2000 330 6.0606061 16 0.378787879

Ferro silicon 1729 330 5.2393939 16 0.327462121

Magnesium 333 330 1.0090909 16 0.063068182Steel Scrap 10000 330 30.30303 16 1.893939394 2

core sand 5717 330 17.324242 16 1.082765152 1


28580 330 86.606061 16 5.412878788 5

Coking coal(dry) 230000 330 696.9697 30 23.23232323 23Coking coal(wet) 248400 330 752.72727 30 25.09090909 25

Non coking coal 125000 330 378.78788 30 12.62626263 13167

PI scrap 15330 330 46.454545 16 2.903409091 3

Burnt Sand 5600 330 16.969697 16 1.060606061 1



MgO 200 330 0.6060606 16 0.037878788

ZnO 100 330 0.3030303 16 0.018939394Slag from DIP 1000 330 3.030303 16 0.189393939

Fly ash/bottom ash

17,500 330 53.030303 16 3.314393939 3

Cement 80000 330 242.42424 16 15.15151515 15


Existing:


PI scrap 9198 330 27.872727 16 1.742045455 2

Burnt Sand 3360 330 10.181818 16 0.636363636 1MgO 120 330 0.3636364 16 0.022727273

ZnO 60 330 0.1818182 16 0.011363636

Slag from DIP 600 330 1.8181818 16 0.113636364Slag from BF 34800 330 105.45455 16 6.590909091 7

32

Iron ore 84000 330 254.54545 16 15.90909091 16Coke 93000 330 281.81818 30 9.393939394 9

Limestone 21000 330 63.636364 16 3.977272727 4

Dolomite 15000 330 45.454545 16 2.840909091 3Manganese 1800 330 5.4545455 16 0.340909091

Quatrz 6600 330 20 16 1.25 1

Ferro silicon 1037 330 3.1424242 16 0.196401515

Magnesium 200 330 0.6060606 16 0.037878788

Steel Scrap 6000 330 18.181818 16 1.136363636 1Core sand 3430 330 10.393939 16 0.649621212

sand for cement coating

17148 330 51.963636 16 3.247727273 3

Cement for coating 12000 330 36.363636 16 2.272727273 239

In Summary

Existing and Proposed

Total raw material Coming in 167 trucks

Total products and solid waste going out in 60 trucks

Existing

Total raw material coming in 39 trucks



Total products and solid going out in 32 trucks

Proposed

expansion

Raw material coming in 128 trucks/day 8trucks/hr

Product and solid waste going out 28 trucks/day

2truck/hr

Total no of trucks/hr is 10Total No of trucks per hour due to expansion is= 10 trucks

Considering the existing scenario as explained in Chapter-III, and traffic due toexpansion is minimum.

8.4 Existing Environmental Management plan8.4.1 Wastewater

i. The effluent generation from the proposed project is nilii. Storm water drains are linked to storm water reservoir.

iii. Re-circulated cooling water collected in the neutralization tank and used forgardening.

8.4.2 Air EnvironmentAir environment is affected by gaseous emissions from boiler, coke ovens, DIP plant and blast furnace air preheater/ stoves in addition to fugitive emissions at different sources. These emissions include SPM, SO2 and NOx. Fugitive emissions are alsogenerated at solid handling locations in the plant. The following measures are adopted to control gaseous emissions and to prevent their adverse impact on the environment.

8.4.3 Stack Emissionsi. Chimney of adequate height are provided to boiler, flare, MBF air

preheater/stoves, coke ovens, sinter plant and diesel generator.ii. Arrangements are made for periodical monitoring of stack gas and ambient air

quality. The sampling points are located based on metrological conditions of the region.

iii. Ladder, porthole, power supply points are provided to the boiler and GCP stacks for monitoring of emissions.

iv. Gas Cleaning Plant and thickeners are operated continuously. Provision are be made for back-up power for this equipment.

v. Water spraying is practiced at loading and unloading points, storage yards and near solid waste dumping yards. Transport of material should be done incovered trucks only.



vi. Green belt cover in the plant should be increased, especially in the direction of winds.

8.4.4 Fugitive Emission• Fugitive emissions within the factory and storage yards are controlled by good

house keeping, water spraying and sprinkling.• Tree plantation in 3 to 5 rows is developed all around raw material and solid

waste storage yards.• All internal roads are properly paved or tarred so as to avoid fugitive emissions.

A tree plantation in 2 to 3 rows is developed on either sides of the roads.• Measures will be taken to maintain all the roads used for transportation of raw

material and finished goods.• Water spraying practice should be continued at loading and unloading points,

storage yards and near solid waste dumping yards.• All the internal roads leading to the sites, should be asphalted to reduce the

fugitive dust due to truck movement.8.4.5 Noise EnvironmentSome units in the plant have noisy operations such as compressors, boiler fans, steamturbine, and D.G. sets. The exposure of workers to the noise of high level will bereduced with appropriate measures. Noise from major equipments will be within 85 dB(A) at 1 m from source and at 1.2 m height. Noise and its adverse impacts will be reduced by incorporating suitable measures in the industry. Acoustic enclosures are provided to the DG sets and air compressors to control the noise.

Safety Measures Against Noise Level

The predominant noise levels will be confined to the work zones in the plant. Noiselevels felt at surrounding villages are not significant as compared to background noise. This will be further attenuated by vegetation. Major noise generating areas are blower house and D.G. set house. Various measures proposed to reduce the noise pollution includes, reduction of noise at source and provision of acoustic lagging for equipment. In some areas where due to technological process, it is not feasible to bring down the noise level within acceptable limits, personnel working in the areas is provided with noise reduction aid such as earmuff and also the duration of exposure of the personnel will be limited as per the norms. Necessary measures as indicated below are taken to reduce the sound intensity below the allowable limits at the source itself in the industry. In general at the locations of turbines, compressors, fans etc, the sound intensitygenerally exceeds the limit. The workers engaged in such locations are provided with earmuffs to have additional safety against noise nuisance.

• Adoption of noise reduction measures the construction of the industry as per the I.S. 3408-1965.

• Specifying the noise standards to the manufacturers of machineries• The use of damping materials for wrapping the work places like MBF platform,

MBP heaters. DG set, etc.



• Shock absorbing techniques are adopted to reduce noise level at machinery generating high noise.

• Acoustical walls and roofs are provided to buildings where such machineries are installed.

• Proper maintenance of machineries especially oiling and greasing of bearing and gears etc.

• Use of personnel protective to persons working in such locations.• Plantation of green trees around the factory building and premises to control the

intensity of noise to the surrounding area.• Effective equipment maintenance like periodic lubrication, replacement of

bearings and de-dusting will be practiced. • It should be enforced on the workers to use earplugs in high noise areas. Noise

exposure to workers will not be allowed to exceed 80 dB (A) for 8hr shifts. With above noise abatement measures the noise level in the premise will be maintained with the desired limits. Further, noise level will be monitored to confirm the ambient noise level to the standards of industrial area and noise level outside project premise to the standards of residential areas.

8.4.6 Land ManagementThe main intention of land management is to restore the existing ecological conditions in the region. Solid waste storage yard are suitably prepared to avoid seepage ofleachate. Plantations are carried out all around the disposal area to arrest any fugitive emissions.

8.4.7 Green Belt DevelopmentDevelopment of greenbelt in and around industrial activity is an effective was to check pollutants and their dispersion in to surrounding areas. Plants act as natural sink for variety of air pollutants. These can help to reduce the pollutant level in the airenvironment. The degree of pollution attenuation by a green belt depends on its height and width, foliage surface area, density, dry deposition, velocity of pollutants and the average wind speed through the green belt. The main objective of green belt around the factory is:

i. Mitigation of impacts due to fugitive emissionsii. Attenuation of noise levels

iii. Ecological restorationiv. Improvement in aesthetic environment qualityv. Waste water reuse and re-cycling..

vi. Soil erosion preventionKeeping in view of the soil and water quality available in and around the project site and the topography of land, following species are considered for green beltdevelopment.Road side plantation

Avenue plantation include following species



• Albizia lebbeck• Azadirachta indica• Tamarindus indica• Albizia Odoratissima• Leucaena Leucocephala• Mangifera indica• Bamboo• Almond tree• Pongamia pinnata• Acacia nilotica• Ber Plant• Prosophis gulflora

Around various shops

As there will be limited space (in height) due to various overhead pipelines. herefore,small and medium sized species are suggested and they should be planted depending on the vertical height available for plant growth.Small species

• Dodonaea viscosa• Cocoloba uvifera• Cassia auriculata

Medium size species

• Acacia Arabica

Around office and other buildings

Species suggested for plantation around office and other buildings are listed below.• Cassia siamea• Albezzia amera• Albezzia lebbeck• Cassis Javanica• Erythrina indica• Lagrestroemia flosreginea• Peltophorum feruginium• Delonix regia



FIG 8.1 EXISITNG GREENBELT PHOTOGRAPHS



8.5 Conservation of Air, Water and Energy recovery

• Fugitive dust emission control by dry fogging and dust extraction system.• Fugitive emission control at raw materials storage and handling by land based

fume suppression system by sprinkling water.• Fugitive emissions control at Sinter Plant through feed material controls and

enclosures• Extraction of electric power from BF top gas.• Heat recovery in BF stoves.• Arresting fugitive dust emissions in MBF shop.• Reuse/recycling of treated wastewater.

Energy conservation measures: Energy conservation measures at the design stage are

equally important as pollution prevention and control measures, since the energyconsumption has a direct linkage to the emission of carbon dioxide, a green house gas. It is suggested that the energy conservation measures be adopted wherever possible to reduce the specific energy consumption. The incentives offered for energy conservation by the National and international bodies like CDM mechanism should be used toconserve energy.

Energy Saving through Sinter use

Use of sinter in BF burden improves productivity due to increased reactivity because of larger surface area that comes in contact with the upward rising gases. Higher productivity and reduction in coke consumption is linked with sinter use in BF which indirectly reduces CO2 emissions per ton of hot metal in the environment.Further, the contribution of Blast Furnace to CO2 emissions in an integrated steel plant is about 75%. Technologically, there is limited or marginal scope for CO2 reduction measures in the blast furnace. Since, sinter plant enhances BF productivity andreduction in coke rate, the Sinter Plant brings significant benefits for steel plantoperators in reducing CO2 emissions and thus protecting the environment.



Thus the Sinter Plant has significant positive impact on environment.

Conformity to Clean Development Mechanism:The ignition furnace will use blast furnace gas as fuel to ignite the sinter layer to 1100°C. Total requirement of the gas is about 60m3/t of sinter considering the calorific value of the blast furnace gas as 700 kcal/m3.If instead of gas, oil (LDO) were to be used the requirement of the LDO would have been about 2.8 liters per ton of sinter produced considering 9000 kcal available per liter of LDO. With sinter requirement to the tune of 950 t/day, the daily requirement of LDO would have been be 2660 litters, monthly would have been around 80,000 liters and annual would have been 878,000 liters (878 kl).Thus with the use of available blast furnace gas, there is a monthly saving of about 80 kl and yearly saving of about 878 kl (with 330 working days in a year) of LDOconsumption in sinter making leading to huge saving in CO2 release to the atmosphere.

Waste Heat recovery Power PlantHeat from Flue gas from the coke ovens will be recovered to produce 9 MW of power. Otherwise fossil fuels would have been consumed for captive generation or imported from state utilites.

8.6 Budgetary allocation for Environmental Protection Measures (in Rs. Lakhs)

Table 8.8 Capital Cost

Sl.NoEnvironmental pollution control features

Estimated

investmentsRs. Lakhs

1 Air pollution control equipments 12502 Water treatment plant 120

3 Rainwater Harvesting/ recharging 50

4 Greenbelt development 405 D.G Air pollution control measures 2

6 Solid/Hazardous waste management 257 Traffic management 15

Total 1502

Table 8.9 Recurring Cost

Sl.NoEnvironmental pollution control features

Estimated

investmentsRs. Lakhs

1 O & M of Air pollution control equipments 125

2 O & M of Water treatment activities 153 Maintenance of recharge pit 3



4 Green Belt development 10

5 D.G Set Maintenance 16 Solid/ hazardous waste management 5

7 Environmental monitoring 5Total 164

8.7 CREP GUIDELINES

Table 8.10 Compliance to CREP guidelines

CREP GUIDELINES COMPLIANCE

8.0 INTEGRATED IRON & STEEL INDUSTRY1. Coke Oven Plants

- To meet the parameters PLD(% leakingcolors), PLL (% leaking lids), PLO (%leaking off take), of the notified standards under EPA within three years byDecember 2005). Industry will submit time bound action plan and PER Chart along with the Bank Guarantee for theimplementation or the time.

- To rebuild at least 40% of the coke oven batteries in next 10 years (by December2012.).

Adhered accordingly

2. Steel Melting Shop

- Fugitive emissions - To reduce 30% byMarch 2004 and 100% by March 2008(including installation of secondarydedusting facilities).

Not applicable

3. Blast Furnace

* Direct inject of reducing agents ---------- by June 2013.

4. Solid Waste /Hazardous Waste Management

Utilization of Steel/ Melting shop (SMS)/ Blast Furnace (BF) Slag as per the following schedule:* By 2004 - 70%* By 2006 – 80% and* By 2007 – 100 %.Hazardous Wastes

- Charge of tar sludge/ ETP sludge to Coke Oven

100 % blast furnace slag will be utilised in the proposed BF slagcement grinding unit.



by June 2003. - Inventorization of the Hazardous waste as per Hazardous Waste (M& H), Rules, 1989 asamended in 2000 and implementation of theRules by Dec. 2003. ( tar sludge, acid sludge,waste Lubricating oil and type fuel falls in the category of Hazardous waste).

Adhered Accordingly

5. Water Conservation/ Water Pollution

- To reduce specific water consumption to 5 m3/tfor long products and 8 m3/t for flat products by December 2005.- To operate the Co-BP effluent treatment plant efficiently to achieve the notified effluentdischarge standards. – by June 2003.

Existing water consumption1200 KLD (PIG Iron plant-500KLD, DIP Plant- 700 KLD) Proposed plant requirement2215 KLDTotal water requirement afterexpansion = 3415 KLD.

6. Installation of Continuous stacks monitoring system & its calibration in major stacks andsetting up of the online ambient air qualitymonitoring stations by June 2005.

Environmental monitoring will be outsourced to KSPCBapproved Laboratory.

7. To operate the existing pollution controlequipment efficiently and to keep proper record of run hours, failure time and efficiency withimmediate effect. Compliance report in thisregard be submitted to CPCB/SPCB every three months.

Adhered accordingly

8. To implement the recommendations of Life

Cycle Assessment (LCA) study sponsored by

MoEF by December 2003.

Adhered accordingly

9. The industry will initiate the steps to adopt the following clean technologies measures to

improve the performance of industry towards production, energy land environment.

- Energy recovery of top Blast Furnace (BF) gas.

- Use of Tar- free runner linings.- De- dusting of Cast house at tap holes,

runners, skimmers ladle and chargingpoints.

- Suppression of fugitive emissions usingnitrogen gas or other inert gas

- To study the possibility of slag and fly ash transportation back to the abandoned

BF gas will be utilized in power plant

Dedusting facilities will beprovided.

Fugitive dust will besuppressed using watersprinklers.Slag and fly ash will be utilized



mines, to the abandoned mines, to fill up the cavities through empty railwaywagons while they return back to themines and its implementation.

- Processing of the waste containing flux & ferrous wastes through waste recyclingplant.

- To implement rainwater harvesting- Reduction Green House Gases by :

• Reduction in power consumption

• Use of by –products gases forpower generation

- Promotion of Energy Optimisationtechnology including energy/ audit

- To se targets for Resource Conservationsuch as Raw material, energy and water consumption to match InternationalStandards.

- Up- gradation in the monitoring andanalysis facilities for air and waterpollution. Also to impart elaboratetraining to the manpower so that realistic data is obtained in the environmentalmonitoring laboratories.

- To Improve overall house keeping.

in the cement grinding unit

Iron ore fines, coal fines will be utilized back in the sinter plant

Rain water harvesting isproposed.BF gas will be utilized in the power plant and pig iron unit

Adhered accordingly

Adhered accordingly

Monitoring will be carried out as per requirement of KSCB.

Good housekeeping will befollowed



CHAPTER-IX SUMMARY AND CONCLUSION

CHAPTER-1 INTRODUCTIONCompany Profile

Shree Ram Electro Cast Pvt. Ltd., was incorporated on 12th August, 2004 having

registered office 8 Camac Street Shanti Niketan Building 9th Floor Room No. 8 Kolkata-17, West Bengal. Directors of the company are Mr Mukesh Bhandari, Mr. ShaileshBhandari, Mr. Avinash Bhandari and Mr R K Purohit.

Existing Manufacturing Facilities

Unit Capacity Location

Pig Iron Plant

Captive Power Plant

120,000 TPA

2.5MW

Honarhalli, Hatcholi Post, Sirguppa Talluk, BellaryDistrict, Karnataka

Project profile:

After successful operation of existing steel Plant and power plant at Honarhalli, Post –Hatcholi, Taluk- Siruguppa, Dist.- Bellary and keeping in view growth potential in the steel sectors, the promoters had decided to set up a Ductile Iron Pipe plant of 120,000 TPA as value addition project and obtained the MOEF clearance (vide No J-11011/498/2010-IA-II (I) dated 22nd June 2011). This project is in the implementation phase.Now it is proposed to modernize the Pig Iron Plant to improve the fuel efficiency and capacity from 120,000 TPA to 200,000 TPA and set up the Coke Oven Plant, Expand the Ductile Iron Pipe plant from 120,000 TPA to 200,000 TPA, Sinter Plant, Cementgrinding plant and Captive Power Plant at the existing Site for production ofMetallurgical coke, D.I. Pipe, Sinter, Slag cement and Power. Due to total integration, the proposed project would improve the overall profitability of the project making it financially more viable. The proposed project envisages the followings manufacturing facilities:-

Proposed Project Details

Sl.No Items Particulars

1 Objective of theProject

• Expansion of Pig Iron Plant from 1,20,000 to 2,00,000 TPA

• Coke Oven Plant - 1,60,000 TPA


• Expansion of Ductile Iron Pipe Plant

from 1,20,000 to 2,00,000 TPA

• Sinter Plant– 3,00,000 TPA

• Cement Grinding Plant – 1,00,000TPA



2 Promoters M/s. Shree Ram Electro cast Pvt. Ltd.

3 Investment forExpansion

415 Crores

4 Project location Sy.No.s 80, 81/A3, 95/A1, 95/A3, 96/A1, 96/A3,

97/1, 97/3, 98/A/1A, 98/A/1B, 98/A3, 98/B1, 98/B3, 98/C1,98/C3, 98/D1, 98/D3, 99, 100, 103, 104, 105and 106 of Honnarahalli Village and Sy,

No57/C/1, 57/D/1, 57/A/1A, 57/A/2A,57/A/3A, 57/B/A, 57/A/4A., 77/A, 77/B, 78/Aand 78/B of Halkote Village, Post – Hatcholi,

Taluk- Siruguppa, Dist.- Bellary, Karnataka -583 114

5 Extent of land The land available with SREPL is 114.97 acres.

Proposed additional land to be acquired through KIADB is 25.42 acres.

6 Category ofProject

A

7 Water demandand Source

Existing water consumption 1200 KLD (PIG Iron plant-500 KLD, DIP Plant- 700 KLD)Proposed plant requirement 2215 KLD

Total water requirement after expansion = 3415 KLD.Source: Tungabhadra river. Withdrawalpermission for 4150 KLD for the expansion

seeking from Government. (Order No: CI 57 SPI 2011, Bangalore Dated 25.02.2011.)

8 Power demand 26000 KVA after expansion

Environmental settings around the proposed project site (Within 10 kms radius)

Sl. No Feature Particulars

1. Location Honnarahalli village, Siruguppa taluk, district, Karnataka.

2. Present land use Industrial and agricultural land

3. Altitude above mean MSL 475 m

4. Temp.0C (Range) Max. 31.0 to 41.2 and Min. 10.7 to 20.6



5. Mean Annual humidity & RF

65 % and 645 mm

6. Soil type Black cotton mixed loamy soil

7. Topography Plain terrain sloping towards NW

8. Nearest State Highway S.H.-19(Srirangapatna - Bidar), 8.2 km,

9. Nearest railway station None with in 10 km radius (Adoni-36.4 km in NE direction(S.C. Railway)

10. Nearest airport None with in 10 km radius. Bellary air strip; 63 kms (S) Hyderabad air port is about 227 km in NE.

11. Nearest village Honnarahalli, 1.4 km. in N

12. Nearest town Siruguppa 13.5 km, SW

13. Nearest major city None with in 10 km radius, Bellary, 66.4 km, SW

14. Nearest river Tungabhadra river , 1.8 Km , NW

15. Nearest industry None with in 10 km radius, Siruguppa Sugar 12 km.

16. Sensitive locations No Archeological structures, Historical places, ProtectedForests, Sanctuaries and Biosphere Reserves present within 10 kms from the Industry.



CHAPTER-2 PROJECT DESCRIPTIONMODERNISATION OF PIG IRON PLANT

In oreder to modernize the pig iron plant the following units will be installed:

• Hot blast stoves

• Pulverised coal injection system • Oxygen injection unit

• Steam Injection unit

COKE OVEN PLANT

Shree Ram Electrocast Pvt Ltd plans to set-up a heat recovery type stamp chargedcoking plant to produce about 160,000 tons of gross coke per year and to generate electricity by making use of the waste flue gas from coking plant. The production facilities will contain coal preparation plant, coking plant and coke screening plant and waste heat recovery boilers.

CAPTIVE POWER PLANT

The Waste heat recovery boilers will utilize the latent heat of the flue gas from the coke ovens. AFBC boiler will utilize non coking coal for firing in the boiler. The coalrequirement will be 125,000 TPA or equivalent. The power generation capacity will 30 MW.

DUCTILE IRON PIPE PLANT

Hot metal received from blast furnace is charged along with steel scrap and ferro alloys. Magnesium is added The ductile iron pipes are made using centrifugal casting machineand heat treatment is carried out in annealing furnace. Zinc coating, pressure testing, cement mortar lining and bituminous coating will be carried out.

SINTER PLANT

Sintering is a technology for agglomeration of iron ore fines into useful Blast Furnace burden material. The raw materials used in sinter plant are - Iron ore fines (-10 mm), coke breeze (-3 mm), Lime stone & dolomite fines (-3mm) and other metallurgicalwastes. The proportioned raw materials are mixed and moistened in a mixing drum. The mix is loaded on sinter machine. The top surface of the mix is ignited throughstationary burners at approximately 1200 0C. Sinter is produced as a combined result of locally limited melting, grain boundary diffusion and recrystallisation of iron oxides. On the completion of sintering process, finished sinter cake is crushed and cooled.

Cement grinding unit

The raw materials Clinker and Granulated Slag are stocked in separate hoppers. These are discharged from the hopper with the help of two table feeders to the belt conveyor.



Gypsum is added and all the materials are properly mixed and through a feeder materials are charged into the ball mill for grinding into powder form. The product is packed and sold out.

CHAPTER-3.0 BASELINE ENVIRONMENTAL SCENARIO

Environm

ental

Attributes

No of

LocationsObservations

Meteorolo

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1 Hourly observations for Temperature, Relative

Humidity, Wind direction, wind speed & Rain fall

during 3 month study period

AAQ 8 For all the parameters as per National Ambient Air

Quality Standards, 2009 for 24 hours duration, 2 times

in each week during 12-week study period

Water 9 3 Surface water Locations

6 Ground water locations (including the place near to

the plant site)

Parameters that are analyzed are as per Analysis of

Drinking Water Quality had been carried out

Noise 6 Day and night noise levels once in every location

Soil 05 At 5 locations.

Ecology Flora-Fauna

& Ecosystem

Total study period is 90days. However predicted flora

– fauna also included for non-seasonal plant species

(ephemerals) based on existing secondary data and

field conditions

Land use 10 km radius

study area

Land use data based and satellite imagery data of the

10 km study area.

Socio- Demography Secondary data from the existing literature (Census



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2001)

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g

tran

sit

Dir

ect,

Neg

ativ

eS

ho

rt-

Ter

mR

ever

sib

leM

ediu

m

Air

En

vir

on

men

t

Op

erat

ion

of

con

stru

ctio

n m

ach

iner

y,

wel

din

g a

ctiv

itie

s an

d

oth

ers

Dir

ect,

Neg

ativ

eS

ho

rt-

Ter

mR

ever

sib

leL

ow

No

ise

En

vir

on

men

tN

ois

e g

ener

atio

n f

rom

u

se o

f m

ach

iner

yD

irec

t,N

egat

ive

Sh

ort

- T

erm

Rev

ersi

ble

Med

ium

Lan

d u

se/

So

il

En

vir

on

men

tS

etti

ng

up

of

Pro

ject

Dir

ect,

Neg

ativ

eL

on

g T

erm

Irre

ver

sib

leL

ow

Eco

log

yL

oss

of

veg

eta

tio

nD

irec

t,N

egat

ive

Sh

ort

-Tem

Rev

ersi

ble

Med

ium

Co

nst

ruct

ion

act

ivit

ies

on

L

and

Hea

lth

Var

iou

s co

nst

ruct

ion

a

ctiv

itie

sD

irec

t,N

egat

ive

Sh

ort

-Tem

Rev

ersi

ble

Lo

w

Air

En

vir

on

men

tO

per

atio

n o

f co

nst

ruct

ion

mac

hin

ery

, M

ov

emen

t o

f V

ehic

les

Dir

ect,

Neg

ativ

eS

ho

rt-

Ter

mR

ever

sib

leH

igh

Lay

ing

of

Ro

ad

s

No

ise

En

vir

on

men

tN

ois

e g

ener

atio

n f

rom

u

se o

f m

ach

iner

y,

Veh

icu

lar

mo

vem

ent

Dir

ect,

Neg

ativ

eS

ho

rt-

Ter

mR

ever

sib

leH

igh

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

M/

s S

hre

e R

am

Ele

ctro

cast

Pv

t L

td.,

23

3

Lan

d u

se/

So

il

En

vir

on

men

tD

evel

op

men

t o

f R

oad

sD

irec

t,N

egat

ive

Lo

ng

Ter

mIr

rev

ersi

ble

Med

ium

Eco

log

yL

oss

of

veg

eta

tio

nD

irec

t,N

egat

ive

Sh

ort

-Ter

mR

ever

sib

leM

ediu

m

Air

En

vir

on

men

tB

urn

ing

of

Fu

els

Dir

ect,

Neg

ativ

eS

ho

rt-T

erm

Rev

ersi

ble

Lo

w

Wat

er E

nv

iro

nm

ent

(Su

rfac

e an

d G

rou

nd

)D

isp

osa

l o

f S

ewa

ge

Dir

ect,

Neg

ativ

eS

ho

rt-T

erm

Rev

ersi

ble

Hig

h

La

nd

/S

oil

En

vir

on

men

tD

isp

osa

l o

f S

ewa

ge

InD

irec

t,N

egat

ive

Sh

ort

-Tem

Rev

ersi

ble

Med

ium

So

cio

-Eco

no

mic

Em

plo

ym

ent

Op

po

rtu

nit

ies,

In

flu

x o

f p

eop

le

InD

irec

t,N

egat

ive

Sh

ort

-Ter

mR

ever

sib

leM

ediu

m

Lab

ou

r C

amp

s

Hea

lth

Dis

po

sal

of

Sew

age/

So

lid

was

tes

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Hig

h

Air

En

vir

on

men

tT

ran

spo

rtat

ion

of

Co

nst

ruct

ion

Mat

eria

lsD

irec

t,N

egat

ive

Sh

ort

–Ter

mR

ever

sib

leM

ediu

mM

ov

emen

t o

f V

eh

icle

sN

ois

e E

nv

iro

nm

ent

Veh

icu

lar

mo

vem

ent

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Lo

w

Co

nst

ruct

ion

Deb

ris

La

nd

/S

oil

En

vir

on

men

tV

ari

ou

s co

nst

ruct

ion

wo

rks

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Lo

w

Ex

cav

ated

Ear

th/

Mu

ckL

an

d/

So

ilE

nv

iro

nm

ent

Fo

un

dat

ion

wo

rks

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Med

ium

Wat

er E

nv

iro

nm

ent

(Su

rfac

e an

d G

rou

nd

)D

om

esti

c ac

tiv

itie

s fr

om

L

ab

ou

r ca

mp

sD

irec

t,N

egat

ive

Sh

ort

-Ter

mR

ever

sib

leH

igh

Aes

thet

ics

Od

ou

r n

uis

ance

InD

irec

t,N

egat

ive

Sh

ort

-Ter

mR

ever

sib

leM

ediu

mD

isp

osa

l o

f S

ewag

e

Hea

lth

Dis

po

sal

of

Sew

ag

eD

irec

t,N

egat

ive

Sh

ort

–Ter

mR

ever

sib

leH

igh

Dis

po

sal

of

So

lid

wa

stes

La

nd

/S

oil

En

vir

on

men

tS

oli

d w

aste

gen

erat

ion

,L

and

co

nta

min

atio

nD

irec

t,N

egat

ive

Sh

ort

–Ter

mR

ever

sib

leM

ediu

m

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

M/

s S

hre

e R

am

Ele

ctro

cast

Pv

t L

td.,

23

4

Aes

thet

ics

Od

ou

r n

uis

ance

InD

irec

t,N

egat

ive

Sh

ort

-Ter

mR

ever

sib

leM

ediu

m

Hea

lth

Deg

rad

atio

n o

f S

oli

d

was

te, a

ttra

ctio

n o

f fl

ies

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Med

ium

Sta

gn

atio

n o

f W

ate

rH

ealt

hM

osq

uit

o b

reed

ing

sit

esD

irec

t,N

egat

ive

Sh

ort

–Ter

mR

ever

sib

leH

igh

Wat

er E

nv

iro

nm

ent

(Su

rfac

e)C

on

stru

ctio

n s

ite

area

sD

irec

t,N

egat

ive

Sh

ort

-Ter

mR

ever

sib

leM

ediu

mS

torm

wat

er

Ru

n-o

ffL

an

d/

So

ilE

nv

iro

nm

ent

Flo

od

ing

Dir

ect,

Neg

ativ

eS

ho

rt–T

erm

Rev

ersi

ble

Hig

h

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

M/

s S

hre

e R

am

Ele

ctro

cast

Pv

t L

td.,

23

5

CH

AR

AC

TE

RIS

TIC

S O

F E

NV

IRO

NM

EN

TA

L I

MP

AC

TS

FR

OM

OP

ER

AT

ION

AL

PH

AS

E

Imp

act

char

acte

rist

ics

Act

ivit

yE

nv

iro

nm

en

tal

Att

rib

ute

sC

ause

Na

ture

Du

rati

on

Rev

ersi

bil

ity

Sig

nif

ica

nce

Air

En

vir

on

men

tO

per

atio

n o

f B

last

fu

rnac

eD

irec

t,N

egat

ive

Lo

ng

-T

erm

Rev

ersi

ble

Hig

hO

per

atio

n o

f P

ig

Iro

n p

lan

tN

ois

eE

nv

iro

nm

ent

Op

erat

ion

of

Bla

st

furn

ace

Dir

ect,

Neg

ativ

eL

on

g-

Ter

mR

ever

sib

leL

ow

Op

era

tio

n o

f co

ke

ov

en p

lan

tA

ir E

nv

iro

nm

ent

Op

era

tio

n o

f co

ke

ov

enD

irec

t,N

egat

ive

Lo

ng

-T

erm

Rev

ersi

ble

Hig

h

Air

En

vir

on

men

tO

per

atio

n o

f an

nea

lin

g f

urn

ace

Dir

ect,

Neg

ativ

eL

on

g-

Ter

mR

ever

sib

leL

ow

Op

erat

ion

of

DIP

p

lan

tN

ois

eE

nv

iro

nm

ent

Op

erat

ion

of

ann

eali

ng

fu

rnac

eD

irec

t,N

egat

ive

Lo

ng

-T

erm

Rev

ersi

ble

Lo

w

Air

En

vir

on

men

tO

per

ati

on

of

bo

iler

Dir

ect,

Neg

ativ

eL

on

g-

Ter

mR

ever

sib

leH

igh

Op

erat

ion

of

Po

wer

p

lan

tN

ois

eE

nv

iro

nm

ent

Op

era

tio

n o

f b

oil

erD

irec

t,N

egat

ive

Lo

ng

-T

erm

Rev

ersi

ble

Lo

w

Op

erat

ion

of

Cem

ent

gri

nd

ing

u

nit

Air

en

vir

on

men

tO

per

atio

n o

f g

rin

din

g

un

itD

irec

tn

eg

ati

ve

Lo

ng

-T

erm

Rev

ersi

ble

Hig

h

Op

erat

ion

of

sin

ter

pla

nt

Air

En

vir

on

men

tS

inte

rin

gD

irec

tn

egat

ive

Lo

ng

-T

erm

Rev

ersi

ble

Hig

h

Air

En

vir

on

men

tO

per

atio

n o

f D

.G S

et

du

rin

g p

ow

er f

ailu

reD

irec

t,N

egat

ive

Lo

ng

-T

erm

Rev

ersi

ble

Lo

wD

.G S

et o

per

ati

on

No

ise

En

vir

on

men

tN

ois

e g

ener

ati

on

D.G

Set

Dir

ect,

Neg

ativ

eL

on

g-

Ter

mR

ever

sib

leL

ow

Aff

ore

stat

ion

/

Gre

en b

elt

dev

elo

pm

ent/

Par

ks

Eco

log

yP

lan

tin

g o

f tr

ees/

Dev

elo

pm

ent

of

Lan

dsc

ape/

Par

ks

Dir

ect,

Po

siti

ve

Lo

ng

-T

erm

Irre

ver

sib

leH

igh

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

M/

s S

hre

e R

am

Ele

ctro

cast

Pv

t L

td.,

23

6

Aes

thet

ics

Pla

nti

ng

of

tree

s/D

evel

op

men

t o

f L

and

scap

e/P

ark

s

Dir

ect,

Po

siti

ve

Lo

ng

-T

erm

Irre

ver

sib

leH

igh

La

nd

/S

oil

En

vir

on

men

t

So

lid

was

te

gen

erat

ion

, Lan

d

con

tam

inat

ion

Dir

ect,

Neg

ativ

eL

on

g–

Ter

mR

ever

sib

leM

ediu

m

Wat

erE

nv

iro

nm

ent

(Su

rfac

e an

d

Gro

un

d)

Lea

chat

e g

ener

atio

n,

Lan

d c

on

tam

inat

ion

Dir

ect,

Neg

ativ

eL

on

g–

Ter

mR

ever

sib

leM

ediu

m

Aes

thet

ics

Od

ou

r n

uis

ance

InD

irec

t,N

egat

ive

Lo

ng

-T

erm

Rev

ersi

ble

Med

ium

So

lid

Wa

ste

gen

era

tio

n

Hea

lth

Deg

rad

atio

n o

f S

oli

d

was

te, a

ttra

ctio

n o

f fl

ies

Dir

ect,

Neg

ativ

eL

on

g–

Ter

mR

ever

sib

leM

ediu

m

D.G

mai

nte

nan

ceL

an

d/

So

ilE

nv

iro

nm

ent

Use

d o

il g

ener

ati

on

Dir

ect,

Neg

ativ

eS

ho

rt–

Ter

mR

ever

sib

leL

ow

Air

En

vir

on

men

tV

ehic

le o

per

ati

on

an

d

fuel

co

mb

ust

ion

Dir

ect,

Neg

ativ

eS

ho

rt-

Ter

mR

ever

sib

leM

ediu

mV

ehic

ula

r tr

affi

cN

ois

eE

nv

iro

nm

ent

No

ise

gen

erat

ion

fro

m

veh

icle

sD

irec

t,N

egat

ive

Sh

ort

-te

rmR

ever

sib

leL

ow

Qu

alit

y o

f L

ife

So

cio

-E

con

om

ic

Em

plo

ym

ent

gen

erat

ion

,Qu

alit

y o

f li

fe,I

n-f

low

of

fun

ds

in t

he

reg

ion

,In

crea

se i

n h

ou

sin

g

acc

om

mo

da

tio

n

InD

irec

t,P

osi

tiv

eL

on

g-

Ter

mIr

rev

ersi

ble

Hig

h

Sto

rm w

ater

Ru

n-o

ffL

and

En

vir

on

men

tF

loo

din

gD

irec

t,N

egat

ive

Lo

ng

term

Rev

ersi

ble

Med

ium



CHAPTER-5.0 ENVIRONMENTAL MONITORING PLAN

Sl.No.

ParticularsMonitoringfrequency

Duration of monitoring

Importantparameters for

monitoring

I Air Quality

1 Ambient Air QualityMonitoring withinpremises

Once in amonth

Grab, 24 hrlysample

PM10, PM 2.5, SO2,NO2.

2 Stack/ChimneyMonitoring

Once in amonth

Grab Temperature,Velocity, SO2, PM,NOx, HC, CO

3 Fugitive emissionsmonitoring

Once in amonth

24 hourly PM 10 and PM 2.5

II Water Quality

1 Ground Water Analysis Once in amonth

Grab As per KSPCBrequirements

III Soil Quality

1 Soil quality analysis Pre monsoonand postmonsoon

Grab Colour, TexturalClass, pH, C,Infiltration rate,Moisture retentioncapacity, Organicmatter, Na,K,P,Pb,Cu,Zn,Cd,Fe

V Noise Quality

• MainGate/Boundary

• Power Plant

• D.G Set Room• Crushing Areas

• Vibrators

• Compressor• Loading and

Unloading

• Others as notices

Once in aMonth

24HrsMonitoring

Noise levels indB(A)

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

M/

s S

hre

e R

am

Ele

ctro

cast

Pv

t L

td.,

23

8

CH

AP

TE

R-6

.0 R

ISK

AS

SE

SS

ME

NT

AN

D D

ISA

ST

ER

MA

NA

GE

ME

NT

PL

AN

Iden

tifi

ed H

azar

ds

SL

NO

NA

ME

OF

TH

E

DE

PA

RT

ME

NT

/SE

CT

ION

TY

PE

OF

HA

ZA

RD

PR

EC

AU

TIO

NS

TA

KE

NM

ITIG

AT

ION

ME

AS

UR

ES

1S

tora

ge

/ s

tore

s•

Fir

eG

oo

d

Ho

use

kee

pin

g

pra

ctic

ew

ill

be

foll

ow

ed

, S

mo

ke

det

ecto

rs w

ill

be

pro

vid

ed

•F

ire

exti

ng

uis

her

s w

ill

be

pro

vid

ed

•F

ire

hy

dra

nt

syst

em s

hal

l b

e in

sta

lled

.•

Fir

st

aid

B

ox

w

ill

be

pro

vid

ed.

2P

rod

uct

ion

•B

last

Fu

rnac

e A

rea

•S

inte

r P

lan

t ar

ea

•P

ow

er P

lan

t A

rea

•D

IP p

lan

t ar

ea

•C

emen

t g

rin

din

g u

nit

•C

ok

e o

ven

•C

arb

on

Mo

no

xid

ele

ak

ag

e.

•E

xp

losi

on

.

•F

ire.

Go

od

Ho

use

kee

pin

g p

ract

ice

is

foll

ow

ed.

On

lin

e C

O

mo

nit

ors

shal

l b

e p

rov

ided

. B

y f

oll

ow

ing

st

and

ard

o

per

atin

g

pro

ced

ure

sfo

r ea

ch a

ctiv

ity

.

•F

ire

exti

ng

uis

her

s /

F

ire

hy

dra

nt

wil

l b

e p

rov

ided

•P

rop

er

trai

nin

g

to

the

con

cern

ed

thro

ug

h

mo

ckd

rill

s et

c.

•F

irst

ai

d

bo

xes

&

p

lan

tm

edic

al u

nit

are

pro

vid

ed.

•E

vac

uat

e th

e p

lace

.3

Qu

alit

y C

on

tro

l•

Fir

eG

oo

d V

enti

lati

on

ex

hau

st s

hal

l b

e p

rov

ided

.F

ire

exti

ng

uis

her

s w

ill

be

pro

vid

ed,

suit

able

clo

thin

g l

ike

Mas

k, C

aps

are

pro

vid

ed.

Fir

st A

id f

acil

ity

.

4F

inis

hed

Go

od

s•

Mo

vin

gm

ach

ine

Par

ts.

•P

hy

sica

lac

cid

ents

Em

erg

ency

Sto

p d

evic

es s

hal

l b

e p

rov

ided

.A

pp

ly

Sta

nd

ard

O

per

atin

gP

roce

du

res.

Co

nd

uct

ing

reg

ula

r m

ock

dri

ll

Med

ical

un

it, F

irst

aid

fac

ilit

y.

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

M/

s S

hre

e R

am

Ele

ctro

cast

Pv

t L

td.,

23

9

Iden

tifi

ed O

ccu

pat

ion

al H

eal

th H

azar

ds

Ty

pe

of

Ha

za

rdA

reas

Pre

ven

tiv

e /

Mit

igati

on

measu

res

Du

stR

aw m

ater

ial

han

dli

ng

&

sto

rag

e y

ard

Wil

l b

e tr

ansp

ort

ed i

n t

he

tru

cks

wit

h t

arp

ual

in c

ov

ers.

En

vis

aged

to

in

stal

l a

tru

ck t

iple

r. W

ater

sp

rin

kle

rs i

n t

he

yar

d.

Co

ver

ed c

on

vey

or

bel

ts f

or

RM

fe

edin

g

to

RM

HS

b

un

ker

s as

wel

l to

B

F.

Pn

eum

atic

co

nv

eyo

r fo

r d

ust

han

dli

ng

fr

om

D

ry

GC

P

to

Sin

ter.

P

rov

idin

g

per

son

nel

p

rote

ctiv

eeq

uip

men

ts

lik

e re

spir

ato

rs,

cap

s,

apro

ns.

D

evel

op

men

t o

f g

reen

ary

al

lar

ou

nd

th

e y

ard

. Dev

elo

pin

g R

oad

s, a

shp

hal

tin

g e

tc.

No

ise

Blo

wer

ho

use

,

ID

fan

h

ou

se,

Tu

rbin

e h

all,

A

irco

mp

ress

or

ho

use

, DG

&P

um

p h

ou

ses.

Sel

ecti

on

o

f eq

uip

men

ts

con

firm

ing

to

st

and

ard

s.

i.e.

<

90

dB

A

at

1 m

trd

ista

nce

. A

ll t

hes

e ar

eas

shal

l b

e u

nm

ann

ed d

ue

to h

igh

lev

el a

uto

mat

ion

. S

uit

able

Ear

mu

ffs

wil

l p

rov

ided

to

th

e w

ork

ers

du

rin

g i

nsp

ecti

on

s.G

reen

bel

t co

rrid

or

wil

l b

e d

evel

op

ed a

lon

g t

he

per

iph

ery

of

the

pla

nt.

Ex

trem

e H

eat

Cas

t h

ou

se,

Pig

C

asti

ng

Mac

hin

e,

Sin

teri

ng

pla

tfo

rm, S

team

pip

ing

Pro

vid

ing

pro

per

PP

E l

ike

leg

gau

rds

wit

h s

ho

es,

Fac

e sh

eild

, le

ath

er h

and

g

lou

se,

Lea

ther

A

pro

ns,

h

elm

ets

etc.

T

her

mal

in

sula

tio

n

for

stea

m

lin

e.P

rov

idin

g f

ans,

per

son

nel

co

oli

ng

dev

ices

, wat

er s

ho

wer

s et

c.B

F G

as -

CO

BF

To

p,

Sto

ve,

GC

P,

Cas

t h

ou

se,

Sin

ter

pla

t fo

rm,

Bo

iler

.

On

lin

e g

as d

ete

cto

r sy

stem

s sh

all

be

inst

alle

d i

n a

dd

itio

n t

o p

ort

able

CO

mo

nit

ors

. O2 m

ask

s &

kit

s sh

all

be

pro

vid

ed.

No

ise

Blo

wer

ho

use

,

ID

fan

h

ou

se,

Tu

rbin

e h

all,

A

irco

mp

ress

or

ho

use

, DG

&P

um

p h

ou

ses.

Sel

ecti

on

o

f eq

uip

men

ts

con

firm

ing

to

st

and

ard

s.

i.e.

<

90

dB

A

at

1 m

trd

ista

nce

. A

ll t

hes

e ar

eas

shal

l b

e u

nm

ann

ed d

ue

to h

igh

lev

el a

uto

mat

ion

. S

uit

able

Ear

mu

ffs

wil

l p

rov

ided

to

th

e w

ork

ers

du

rin

g i

nsp

ecti

on

s.G

reen

bel

t co

rrid

or

wil

l b

e d

evel

op

ed a

lon

g t

he

per

iph

ery

of

the

pla

nt.

Pre

lim

inar

y H

azar

d A

nal

ysi

s fo

r P

roce

ss a

nd

Sto

rag

e A

reas

Eq

uip

me

nt

Pro

cess

Po

ten

tial

Haz

ard

Pro

vis

ion

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

M/

s S

hre

e R

am

Ele

ctro

cast

Pv

t L

td.,

24

0

BF

Red

uct

ion

of

Iro

n O

reE

xp

losi

on

, Gas

lea

kag

e –

air

po

llu

tio

nG

as l

eak

age

det

ecti

on

sy

stem

, Str

ict

foll

ow

up

of

Std

Op

erat

ing

Pra

ctic

es

Blo

wer

Ho

use

Gen

erat

ion

of

bla

stN

ois

eP

rop

er s

elec

tio

n o

f m

ach

iner

y.

Rem

ote

co

ntr

oll

ed.

Sto

ve

sP

re h

eati

ng

of

bla

stG

as l

eak

age,

Fir

e &

Ex

plo

sio

nS

afet

y i

nte

r-lo

ckin

g, g

as d

etec

tors

.

RM

HS

Raw

mat

eria

l h

and

lin

g

& t

ran

spo

rtat

ion

Du

stC

lose

d s

yst

em, d

ust

ex

trac

tio

n s

yst

em

/ d

ry f

og

du

st s

up

pre

ssio

n s

yst

em.

GC

P–

Dry

ty

pe

Cle

anin

g o

f B

F g

asD

ust

& G

as l

eak

age

Pn

eum

atic

co

nv

eyo

r, G

as d

etec

tor

syst

em

Pu

mp

Ho

use

Wat

er p

um

pin

gN

ois

eR

emo

te c

on

tro

l sy

stem

. Pro

per

se

lect

ion

of

m/

c.

Co

mp

ress

or

Ho

use

Gen

erat

ion

of

com

pre

ssed

air

.U

sag

e o

f co

mp

ress

ed a

ir f

or

hu

man

bo

dy

cle

anin

gC

reat

ion

of

awar

enes

s &

tra

inin

g.

Pig

cast

ing

mach

ine

Pig

gin

gH

igh

am

bie

nt

tem

per

atu

re,

Sp

urt

ing

of

HM

.

Iso

lati

on

, bar

rica

din

g, e

ng

g c

on

tro

ls.

Std

op

erat

ing

pra

ctic

es.

Sin

ter

Pla

nt

Cru

shin

g &

Sin

teri

ng

Ex

cess

hea

tIs

ola

tio

n &

un

man

ned

op

erat

ion

Du

ctil

e i

ron

pip

e p

lan

tH

igh

am

bie

nt

tem

per

atu

reIs

ola

tio

n, b

arri

cad

ing

, en

gg

co

ntr

ols

. S

td o

per

atin

g p

ract

ices

.

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

M/

s S

hre

e R

am

Ele

ctro

cast

Pv

t L

td.,

24

1

Co

ke

ov

en

pla

nt

Co

ke

man

ufa

ctu

re f

rom

co

al

Hig

h

amb

ien

t te

mp

erat

ure

,sp

illa

ge

of

ho

t co

ke,

mo

vem

ent

of

mac

hin

es.

Iso

lati

on

, bar

rica

din

g, e

ng

g c

on

tro

ls.

Std

op

erat

ing

pra

ctic

es

Po

we

r P

lan

tP

ow

er g

ener

atio

nE

xp

losi

on

, ele

ctri

c sh

ock

s.

Ste

am l

eak

age.

Saf

ety

in

ter

lock

ing

, gas

lea

kag

e d

etec

tor

syst

em, E

lect

rica

l sa

fety

g

adg

ets

& t

rain

ing

. In

sula

tio

n.

Ce

me

nt

gri

nd

ing

Cru

shin

g a

nd

gri

nd

ing

u

nit

Mo

vem

ent

of

mac

hin

erie

s S

afet

y i

nte

r lo

ckin

g

Sw

itch

Yard

Rec

eiv

ing

SS

fo

r v

olt

age

step

do

wn

Fir

e, e

lect

ric

sho

ckA

ll e

lect

rica

l fi

ttin

gs

and

cab

le a

re

pro

vid

ed a

s p

er t

he

spec

ifie

d

stan

dar

ds.

Bar

rica

din

g. R

estr

icte

d e

ntr

y.

Pro

tect

ion

sys.

Ear

thin

g. S

mo

ke

det

ecto

rs.

Sw

itch

Yar

d c

on

tro

l

roo

m--

--F

ire

in c

able

gal

leri

es a

nd

sw

itch



CHAPTER-7.0 PROJECT BENEFITS

The benefits from the project, listed as follows:

• Increase in direct and indirect employment opportunities• Zero discharge of water

• The proposed green belt development program will increase biomass andbiodiversity and leads to sustainable environment

• The proposed green belt will not give opportunities for suitable habitat toanimals but also attracts avifauna

• The existing infrastructure will be utilized as far as possible, and thereforedisturbance ecosystem balance is negligible due to infrastructure facilities

• The industry spend money for their social activities for the benefit of the nearly living people with in 10 km radius

• CSR activities proposedCSR Activities conducted and proposed around factory premises

Programme Conducted Proposed Time frame

Health Conducted medicalcamp at Honnarahalli Village

Construction of ladies toilet inKudadarahal Village

Before April 2013

Free medical checkup camp atKudadarahal and Hatchollivillages

Twice in a month. Started from

Jan,2012

Up gradation of toilets and washrooms in the Govt Schools

December 2013

Education Distribution of notebooks to schoolchildren (each child 7 note books) ofKudadarahal villages

• Higher educationprogramme: Sponsership to meritorious and underprevillaged students forDiploma Courses at theprivate & Govt.polytechnics.

• Opportunity foremployment uponcompletion of course

Started from academic year

2011.

Workshop wasconducted to farmerson scientific irrigation, soil management and economic feasibility of crops by agriculturalscientists



Welfare Electrification:Distribution ofstreetlights toKudadadarahal,Sridharagadda andNagalapura Villages

Training on vocational courses intailoring, candle making, bookbinding, etc., for economicupliftment of poor woman.

During financial year 2012

Provided temporaryshelters and food toflood affectedpopulation ofHonnarahalli,chikballary,shridharagaddavillages (about 65families still dwellingin our premises)

Distribution of tricycle tophysically handicapped persons in Kudadarahal and HatcholliVillages.

Before December 2012

Upgradation of MDR road fromSiruguppa junction to Hatcholliwith state PWD under PPP scheme

On or before 2015

Concreting of village internal roads in Kududarahal, Honnarahalli and Hatchcholli grampanchayaths

On or before 2015

Shelter to traffic police Jan- Feb 2012

Traffic signage/ control boards Jan- Feb 2012Providing safe drinking water,scientifically.

During financial year 2012

Infrastructural welfare

Distribution of saplings topanchayaths & schools.

Before March 2012

Sports Distribution of sports kits and materials toschools atKudadarahal Village

Conduct of Inter School Athleticmeet with sports materials.

September 2012

The budget for CSR activities will be 5% of the project cost to be spent over 5 years period.



CHAPTER-8.0 ENVIRONMENTAL MANAGEMENT PLAN

M/s Shree Ram electrocast Pvt Limited will develop the following managementactivities for the Environmental Management Programme which will meet all statutory requirements and help to improve environmental quality.In order to improve the aesthetic look of the area and enhance the land use as well as to compensate for any loss in ecology during construction, adequate plantationprogrammes around the project site have been planned and will be adopted.Development of green belt will include plantation of trees along boundary of the factory, roads, raw material yard and other available spaces. Over 35% of total area of factory will be covered under green cover.A detailed monitoring for different environmental parameters will be carried out as per direction of Karnataka State Pollution Control Board. An environmental management group would be established to implement themanagement plan.

AIR ENVIRONMENT

The mitigation measures needs to be adopted during the operation stage to control the negative impacts on air environment surrounding the project area are given below:

• Gas cleaning plant for BF gas is provided to supply clean gas to consuming units. Viz BF stoves , power plant boiler and sinter pant

• Annealing furnace, MG treatment and zinc coating unit will be provided with stacks as stipulated by KSPCB norms.

• Magnesium converters and zinc coating units will be provided with Bag filters.

• Sinter plant will be connected to ESP to minimize the impact of air pollution.• AFBC boiler will also be connected to ESP.

• Reducing VOC emissions from sinter plant by process optimization, including minimizing stoppages and maintaining consistent operation in terms of strand speed, bed composition (particularly consistent blending of reverts whichshould not contain oil), bed height, use of additions such as burnt lime; and keeping the strand, ductwork, ESP and bag filter air tight

• Pollution reduction from coke making relies as much on techniques andoperation.

• By stamp charging the emission during charging can be minimized.• Water spraying will be adopted at loading and unloading points and storage

yards which will reduce fugitive emissions due to movement of truck.

• All the internal roads will be asphalted to reduce the fugitive dust due to truck movement.

• Green belt cover will be provided. For this, the project has proposed to have green belt cover to an extent 35% of total area of the land has been demarcated as Green Belt. Already 12000 plants have been planted maintaining the good Flora & Fauna. Further, we are planned to plant around 5000 plants during the



financial year 2011-2012. Further 15,000 trees are proposed to be planted as a part of greenbelt development.

CONTROL OF FUGITIVE EMISSIONS AT VARIOUS AUXILIARY FACILITIESINSIDE THE PLANT

CONTROL OF PRIMARY AND SECONDARY EMISSIONS FROM SINTER PLANT

The source of dust emissions will be at the transfer points of the raw materials, which will be contained by the installation of Agglomerative Dust Suppression (ADS) system.The emissions from the sintering process, where combustion take place, will be routedthrough Electrostatic Precipitator, ultimately to be released into the atmosphere through stack.

CONTROL OF FUGITIVE EMISSIONS AT VARIOUS AUXILIARY FACILITIESINSIDE THE PLANT

There will be Dust Suppression Systems/ Foggy Dust Arresters to control fugitiveemissions at various facilities inside the plant

WATER POLLUTIONThe plant will be designed as a zero discharge plant as far as the process effluents are concerned. The water will be recirculated through required cooling and treatment. In cases were contamination will take place during cooling, a treatment plant will beinstalled inside the plant. After treatment, the supernatant water will be sent back to the plant. No plant effluent will be discharged outside the plant premises.

• There is no effluent water in this process• Use of high pressure hoses for area cleaning

• House maintenance and floor wash wastewater will be reused after treatment.

• No wastewater will be discharged to any ground water or to the surface water body.

• Storm water drains will be provided to avoid flooding in the proposed project site area and provision will be made for runoff get diverted to recharge pits with pre oil and grease trap there by increasing the groundwater table.

• No water will be drawn during lean season. Excess water will be drawn and stored during rainy season and that will be used during lean season.

NOISE ENVIRONMENT

• Proper mounting of equipments and providing noise insulating enclosures or paddling where practicable.

• The equipments will be maintained at all times to ensure permissible noiselevels.

• Appropriate advanced silencers, acoustic barriers; vibration-reducing pads will be provided for all noise generating equipments.



• Boundary walls and dense green belt will be erected to act as acoustic barriers.

• Adequate and appropriate type of green belt would be developed in and around the proposed project site for noise mitigation in the area.

• Use of personnel protective to persons working near noise creating locations.

• Plantation of green trees around the factory building and premises to control the intensity of noise to the surrounding area.

• 35 % land area around the factory is covered with green belt. It includes green belt of 6 to 10 m width around storage yards.

SOLID WASTE Solid waste generated from different operations of the unit is as shown in the table below:

Solid waste generated from different operations (after expansion)

Pig iron plant Iron ore fines (97800 TPA)

Coke fines (11000 TPA) B.F.Slag (58000 TPA) GCP dust (6720 TPA) GCP sludge (5430 TPA)

P.I. Scrap (15330 TPA)

Used in sinter plant

Used in sinter plant Used in cement grinding plant Used in sinter plant Used in sinter plant

Sold out

DIP PLANT200,000TPA

Burnt sand generated in casting

section (5600 TPA)MgO (200 TPA)ZnO (100 TPA )Slag (1000 TPA)

Stored in the dump yard. Can be

used for land fillingSold out to approved vendors. Sold out to approved reprocessorsUsed for land filling



Sinter plant Sinter fines (6000) TPA ESP dust (5200 TPA)

Circulated backCirculated back


Nil

GREENBELT DEVELOPMENT

• Greenbelt is defined as the mass plantation of pollution tolerant trees and shrubs in an area for the purpose of minimizing air pollution by filtering, intercepting and absorbing pollutants in an effective manner for improve of the Environment.

• The proposed project plans to develop and maintain 35% of Greenbelt of the totalplot area within its Industrial premises.



STORM WATER MANAGEMENT

• Storm water drains will be provided within the premises of the industry to avoid mixing with affluent.

• Storm water drains will be provided on both sides of the roads. Rectangular drains will be provided based on the quantity of storm water to be conveyed and depth limitations.

• 40 recharge pits are provided for the purpose of ground water recharge.

ECOLOGICAL ASPECTS• Continuing greening efforts in and around the project site.

• Conservation of existing vegetation and afforestation covering larger areas near and around existing project area.

AESTHETICS ASPECTS

• The entire area will be planted with local tree species of aesthetic value, fodder value, fruit bearing and birds attracting tree species. Hence it would beconverted into a possible park for the nearby villages and project staff forrecreation.

Dra

ft E

nv

iro

nm

en

tal

Imp

act

Ass

ess

me

nt

Re

po

rt

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s S

hre

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INB

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on

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llu

tio

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ini

Bla

st

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rnac

e(M

BF

)W

aste

g

ases

m

ain

lyco

nsi

stin

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of

carb

on

dio

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d

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en,

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re d

ust

, co

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fin

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and

ash

.

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fro

m t

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furn

ace

top

wil

l fi

rst

ente

r a

du

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her

wh

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f th

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arse

par

ticl

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ill

sett

le.

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e g

as i

s th

en r

ecei

ved

in

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rato

r w

her

e it

wil

l p

ass

thro

ug

h w

oo

den

baf

fles

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w

et t

yp

e g

as c

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ing

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in

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last

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in t

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as w

ill

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f 5

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clea

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g

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d i

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wh

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in u

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ill

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in

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and

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e h

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stac

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ill

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in

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mo

sph

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Re

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M/

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pre

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vis

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r d

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aste

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Aft

er t

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men

t g

as s

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l co

nta

in

less

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an 1

00 m

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f p

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. Th

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d

ust

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l b

e re

cycl

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r P

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, F

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, SP

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CHAPTER-XDISCLOSURE OF CONSULTANTS ENGAGED WITH RESPECT THE

PROJECT

Sl No Name of the Consultant Name of the organization and complete address and phone no

Consultants services to the project

1 Dr. Ravi Kiran ANDShivanand Dambal

PRAGATHI LABS AND

CONSULTANTS PVT.

LTD.

PLOT NO.8, TARBUND X

ROAD, SECUNDERABAD-9

Environmental Health & Safety Consultants Pvt.Ltd.,No.13/2, 1st Main Road,Near Fire Station, Industrial Town,RAJAJINAGARBangalore – 560 010.Tele: 080-23012100.Fax: 080 23012111

EnvironmentalConsultants

2 George Thomas Process Consultant,

Bangalore

Process Consultant

3 Anantha Rama GIS ConsultantBangalore

GIS Consultant

4 Aparna Mahesh NaksheArchitects, & Interior Landscape consultants# 23, I A Main , Mico Layout , BTM II StageBangalore 560 076 Email : [email protected]

Landscape Consultant

draft environmental impact assessment report ram eia report.pdf · draft environmental impact...

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