star metallics power english exesummery

8/3/2019 Star Metallics Power English ExeSummery

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GREEN CIRCLE CONSULTANTS (I) PVT. LTD.

REPORT NO.: GC/Bell/2007-08/SMPL_EIA/Jan 078


EHS, Risk & Quality, Consulting Engineers & Trainers

Project Proponent: M/s. Star Metallics & Power Pvt. Ltd: of 13

Project: 32 MW Captive Power Plant





1. BACKGROUND

M/s. Star Metallics and Power Private Limited (SMPPL) is a joint venture

company formed as a Special Purposes Vehicle (SPV) by Euro Industrial

Enterprises Private Limited, India (EIEL) and Emirate Trading Agency (ETA) for

operating existing Ferro Alloy Plant located at Vyasankere, near Hospete,

Karnataka. SMPPL proposes to establish a 32 MW Coal based Captive Power

Plant within the existing premises to meet the power requirement for its ferro

alloy plant.

Euro Industrial Enterprises Private Limited, India (EIEL) had acquired the

established ferro alloy plant having 95 acres of plot area with all its appurtenances

and one 15 MVA submerged arc furnace along with its auxiliary equipments from

Sandur Manganese & Iron Ores Limited (SIMORE).

Emirate Trading Agency (ETA) had purchased two 20 MVA submerged arcfurnaces located in the existing ferro alloy plant at Vyasankere, near Hospete,

Karnataka from Sandur Manganese & Iron Ores Limited (SIMORE). It has

planned to dismantle and relocate one of the 20 MVA furnaces at Bahrain Ferro

Alloys limited, Manama, Bahrain. The other 20 MVA furnace is proposed to be

operated at its current location at Vyasankere along with one 15 MVA furnace

belonging to EIEL.

EIEL and ETA have formed a joint venture company as a Special Purpose vehicle

(SPV) by the name Star Metallics and Power Pvt. Ltd. (SMPPL) for operating

existing ferro alloy plant. SMPPL proposes to install a 32 MW Captive PowerPlant (CPP) within the existing unit premises to meet the power requirement of

existing Ferro alloy plant. Power from public utility grid is being utilized for Ferro

alloy plant and later it will source the power from the proposed 32 MW CPP.

2. NEED OF THE PROJECT

The existing Ferro alloy plant had been stopped since last ten years due to

unavailability of power. The capacity of plant for silicomanganese production

is 44,700 MT per year. Since the state grid power supply is economically

unviable in the long run and every effort to restart the ferro alloy plant using

power from other sources were unsuccessful, it was decided to install a 32MW Captive Power Plant to augment the power requirement. The proposed

32 MW captive power plant is coal based with fluidized bed combustion

technology. Power from the CPP will be used to run ferro alloy plant and the

surplus power will be exported to consumers.

3. PROJECT DETAILS:

3.1 LOCATION OF THE PROJECT:

The ferroalloy complex is situated at Vyasankere, 12 km from Hospet (in Bellary

district) on the National Highway 13 connecting Bangalore with New Delhi on a

95 acre plot. SMPPL’s proposed 32 MW Captive Power Plant will be locatedwithin the existing premises of the ferroalloy plant. Hospete (formerly Hospet) is

located at 15.27° N 76.4° E. It has an average elevation of 480 meters (1574 feet).







3.2 SALIENT FEATURES OF EXISTING PLANT & PROPOSED CPP

Introduction:

Name of the Company : Star Metallics and Power Pvt. Ltd.

Promoters of company : EIEL, India & ETA group, Dubai.Location : Vyasankere, Taluka: Hospete, Bellary

District, Karnataka.

Plot area : 95 acres

Production activity : Ferro alloy Plant (Existing)

32 MW Captive Power Plant (Proposed)

Proposed CPP shall be located within the

existing ferroalloy unit premises to meet

power requirement.

EXISTING – Ferro alloy plant:

1 Production plant : Ferro alloy plant

2 Product : Silico manganese (SiMn)

3 Production Capacity : 44,700 MTPA silico manganese

4 Specification of products SiMn

(IS No. 1470-1990) (Si17Mn63)

: Mn: 60-65% Si : 15-20%

C : 1.5-2.0% S : 0.05%, max Fe Balance

P : 0.3% max

5 Raw materials : Manganese ore, metallurgical coke,

limestone, quartz

6 Main production equipment : Submerged Arc Furnace – Open type

(1x15000 KVA, & 1x20000 KVA)

7 Projected operating load of ferro

alloy plant

: 24000 kW

8 Water requirement : 148 m3 /day

PROPOSED – 32 MW Captive Power Plant in existing ferro alloy plant premises

1 Proposed plant : Captive Power Plant

2 Location : Within existing ferro alloy unit premises

3 Capacity of Captive Power Plant : 32 MW

4 No. of boilers : One

5 Capacity of boiler : 140 TPH,

(Type: Fluidized bed Combustion (FBC)

6 Fuel & consumption rate : Indonesian coal, 1,30,000 MTPA

7 Water requirement : 516 m3 /day

8 No. of turbo generators proposed

to be installed

: One

9 Type of turbo generator : Straight condensing machine with Air

Cooled Condenser







4.0 ENVIRONMENTAL IMPACT ASSESSMENT STUDY

Scope of the Study:

The study is conducted with a focus on assessment of Environmental Impacts on

Land, Air, Noise, Water, and Socio-Economic environment and also to plan

mitigative measures to overcome and minimize the negative impact.

Baseline Status:

As part of Environmental Impact Assessment study, baseline environmental

monitoring was carried out for Winter season 2007-08, covering the months of

November 2007 to January 2008.

4.1 DATA SOURCE:

The primary as well as secondary data has been collected on various

environmental attributes. The information on existing environmental condition hasbeen gathered from several sources including:

• Secondary data from IMD & Govt. of Karnataka.

• Site survey and field experiments to gather the information on

Meteorological, Air Environment, Water Environment, Noise

Environment and Ecological Environment were conducted. An area of

10 Kms radius was selected for the study.

Key aspects of prevailing baseline environmental qualities are as follows.

4.2 AIR ENVIRONMENT:

Five ambient air-monitoring stations were selected within the 10 km radius of the

study area, representing the downwind, cross wind and upwind impact scenario of

the project site. Air quality monitoring was done at five locations in the study area

to measure concentrations of Suspended Particulate Matter (SPM), Respirable

Suspended Particulate Matter (RSPM), Oxides of Sulphur (SOx), Oxides of

Nitrogen (NOx) & Carbon Monoxide (CO).

The Ambient Air Quality monitored in the plant area & study area was found to

be well within the limits of NAAQ standards prescribed for Residential, Rural &

Other Areas.

Air Quality in the study area

SL.

NO

POLLUTANTS RANGE OF

AVERAGE

VALUES

NAAQ STANDARDS

1 SPM 129.38 to 162.50 200

2 RPM 49.63 to 78.75 100

3 SO2 8.05 to 14.00 80

4 NOx 24.35 to 31.50 805 CO 147.13 to 239.38 4000

(All the values are in µg/m3)







4.3 NOISE ENVIRONMENT:

Five monitoring locations were selected to asses the noise levels in the study area.

The day time noise levels were in the range of 53 to 62 dBA and night time in the

range of 40 to 65 dBA.

4.4 WATER ENVIRONMENT:

Surface and ground water samples were collected in the stydy area. All the

parameters were found to be within the prescribed limits of IS 10500-1991 except

Total Dissolved Solids in ground water samples.

4.5 LAND ENVIRONMENT:

Soil samples were collected to asses the soil quality in the 10 km study area of

plant site and it revealed soil of medium fertile quality.

4.6 METEOROLOGICAL DATA

PARAMETERS Value

Max.: Jan to Mar 43 to 440CTemperature

Min : December: 12 to 130C

Predominant Wind direction East

Humidity 96%

Average Rainfall 800 mm to 900 mm

4.7 POWER REQUIREMENT:

Power requirement of ferroalloy industry i.e. 181 million KW is presently

obtained from GESCOM Grid (Until proposed CPP becomes operational).

4.8 ECOLOGY (FLORA/FAUNA):

Assessment of existing environmental status, flora, fauna, demographic, Socio-

economic factors and land use pattern within an area of 10 Kms radius from the

proposed site was done.

i) FLORA IN THE STUDY AREA:

Most of the part has scrubs consisting of species such as Carissa fistula,

Zizyphus oenophilia, Albizzia lebbeck, Acacia catechu and A. latronum. Apart

from these species, trees of Grewia tiliaefolia, Eugenia jombalana and Ficus sp.

are also found in this region.

ii) FAUNA IN THE STUDY AREA:

It includes:

Mammals: Cheetha, Wolf, Jackal, Striped Heyena, Wild bear, jungle Cat,Langoor, Sambar, Spotted deer, squirrel, etc.

Avi Fauna: Crow, Cuckoo, Sparrow, Nightingale, Pigeon, Peacock etc.







Reptiles: The reptiles commonly observed are Pythons Cobra Rat-Snake Green

Snakes, common garden lizard, saw scaled viper chameleon.

4.9 SOCIO ECONOMIC DATA

As per the census the population of the district stood at 16.53 lakhs. Thegeographical area is 8447 sq.km. It has two revenue sub divisions viz., Bellary

Sub-Division and Hospet Sub-Division which have in all seven taluks. The

Bellary Sub- Division has 3 taluks while there are five taluks in Hospet Sub-

Division. There are 27 hoblies, two CMCs one Town Municipality, seven Town

Panchayat 542 Revenue villages, 436 and as/habitations. The rural populations

constitute 70%. The density of population is 196 per sq.km which is much lower

than the State average of 235 per sq.km. However the decimal growth rate for

1981-91 was 26.92 % which is higher than the State growth rate of 21.12 %.

The SC/ST population constitutes 28 % of the total population. The sex-ratio

was 965 which are slightly higher than the state average of 960.

4.10 LITERACY LEVELS: Literacy rate in study area is given below:

LITERACY HOSPETE

Year 1991 Census 2001Census

Literacy % 42.00 60.64

Male Literacy % 51.00 74.95

Female Literacy % 31.00 52.92

The study area (Hospete) experiences a considerably very moderate literacy rateof 60.64% (2001).

5.0 ENVIRONMENTAL IMPACTS AND MANAGEMENT PLAN

The following is the new unit proposed under expansion of the ferro alloy Plant

(a) Coal Based Captive Power Plant of 32 MW.

The proposed coal based captive power plant may influence the environment in

two distinct phases:

a) During construction phase which is temporary and of short term

b) During operation phase which may have long term effects

5.1 Impacts during Construction Phase and control measures

The construction of proposed captive power plant would result in increase of SPM

concentrations due to fugitive dust. Frequent water sprinkling in the vicinity of the

construction sites would be undertaken and will be continued after the completion

of plant construction as there is scope for heavy truck mobility. It will be ensured

that both gasoline and diesel powered vehicles are properly maintained to comply

with exhaust emission requirements.







There will be marginal increase in noise levels during construction phase which is

temporary. Certain activities like welding will be undertaken during night time.

However, this phenomena is temporary in nature.

During construction, provision for infrastructural services including water supply,

sewage, drainage facilities and electrification will be made. The construction site

would be provided with suitable toilet facilities for the workers to allow proper

standards of hygiene and ensure minimum impact on the environment.

SMPPL will optimize the layout design to restrict the cutting of plantation in the

existing plant site.

Any construction activity will benefit the local population in a number of ways.

Management of M/s SMPPL will give preference to local people through both

direct and indirect employment.

5.2 Impacts during Operation Phase and control measures

5.2.1 Air Environment:

5.2.1.1 WASTE GASES FROM EXISTING FERRO ALLOY PLANT

Smelting Furnace: Hot Submerged Arc Furnace off gas and tap hole

secondary emissions are the main gaseous emission from existing plant. The

gas emissions contain dust particulates, Sulphur dioxide, and oxides of

nitrogen, carbon monoxide and traces of oxides of silica. Hot SAF off gasand tap hole secondary emissions would be cooled to 150-250oC by air

dilution prior to passing to the fume extraction system. The exit gases are

cleaned by dry gas de-dusting system which is already in place .

In the existing bag house fine particulate matter will settle in the settling

chamber. Resultant clean gas is vented out to atmosphere at appropriate

height.

Finished Product Sizing & Preparation:

The cast product is cooled, ground and screened for final bagging. Theseoperations generate fugitive dust. Industry has already provided Dust

Extraction system and bag filter to capture & separate out the fugitive dust.

The clean air is finally vented through a stack .

5.2.1.2 Boiler Emissions from the proposed CPP:

The flue gases from the proposed coal fired boiler of 140 TPH carry pollutants such

as SPM, SO2, NOx . Following measures are provided to control flue gas

emissions:

Boiler of Circulating Fluidised bed combustion type of firing is proposed to

reap the inherent advantages of very low liberation of NOx in the furnace.







The proposed CPP shall use low ash content (1% ash) imported Indonesian

Coal to reduce the generation of SPM and hence the fly ash. The industry

shall provide special high efficiency Electrostatic precipitator at boiler outlet

for extracting the dust pollutant from flue gas for achieving a dust

concentration at the outlet of chimney as low as 100 mg/Nm3.

An adequate chimney of 60 m AGL shall be provided to disperse the flue

gases over a wide area to keep the ambient air quality well within the

permissible limits.

5.2.1.3 DG sets: Two DG sets of adequate capacity shall be used as power

back up. The industry shall operate the same using low sulphur diesel.

Industry shall provide adequate chimneys and necessary noise control

measures for the same.

The dispersion of pollutants in the atmosphere for the proposed CPP is determinedusing Gaussian plume dispersion model. For the present study, this model is used for

the prediction of maximum ground level concentration (GLC).

Predicted ground level concentrations were superimposed on existing ambient air

quality to obtain the overall GLC’s once the CPP becomes operational. It is found

that, there will not be any significant adverse impact on ambient air quality.

5.2.1.4 Fugitive Emissions from Material handling from proposed CPP:

Raw material handling process is one of the main sources of dust generation. Coal

while being drawn from stockyard and ground in hoppers leads to generation of dust.Proper sprinkling & dust extraction shall be adopted to reduce the same.

5.2.2 NOISE ENVIRONMENT

The plant and equipment will be specified and designed with a view to

minimize noise pollution. The major noise producing equipment such as

turbo-generator & DG sets shall be provided with acoustic enclosures.

Pumps, fans, compressors etc., shall be run at speeds less than 1500 rpm.

Equipment shall be statically and dynamically balanced. Safety blow off

valves, discharge pipes, relief valves etc. shall be equipped with silencers.Pipe lines shall be liberally sized for low velocities. Proper encasement of

noise generating sources will be done to control the noise levels below 75 dB(A)

at plant boundary. A scientifically designed thick greenbelt shall be grown.

5.2.3 WATER ENVIRONMENT

The total water consumption of the ferro alloy plant at present is about 136 m3 /day.

With the installation of CPP of 32 MW, the water consumption of the complex shall

increase to 652 (136 + 516 ) m3 /day.







The following table gives the water requirement.

Water Requirement (m3 / day)

UsageExisting Proposed TOTAL

(1) Domestic 36 24 60

(2) Industrial - - -

- Process Nil Nil Nil

- Washing Nil Nil Nil

- Boiler Nil 120 120

- Cooling tower 100 264 364

- Dm plant back wash Nil 108 108

TOTAL 136 516 652

The total wastewater generation from the existing ferroalloy plant is 136 m3 /day.

This is segregated as non process wastewater and domestic sewage. The non

process wastewater (Cooling tower blow down) is neutralized and the residual

chlorine levels are maintained. This treated wastewater is currently used for

gardening & dust suppression in the premises.

The total wastewater generation from the proposed CPP is estimated to be about

260 m3 /day. This also will be segregated as non process wastewater and

domestic sewage to adopt separate treatment schemes.

The following table gives the wastewater generation from the existing

ferroalloy plant and for the proposed CPP.

Effluent Generation (m3 / day)

UsageExisting Proposed TOTAL

(1) Domestic 31 20 51

(2) Industrial Nil Nil Nil

- Process Nil Nil Nil

- Washing Nil Nil Nil

- Boiler blow down Nil 114 114

- Cooling tower blow down 15 40 55

- DM plant discharge Nil 86 86

TOTAL 46 260 306







5.2.3.1 Demineralization plant

Effluents are generated during regeneration of ion exchangers. Alkaly

effluents are generated during the rinsing of anion and mixed bed

exchangers. The effluents from the water treatment plant are led to a

properly sized neutralisation pit having a holding capacity of two

regenerations.

5.2.3.2 Blow down

Blow down from the plant consists of cooling tower blow down and boiler

blow down. The steam blow down will have a pH of 9 .5 – 10.5 at 100oC

temperature. The steam blow down will be cooled and mixed with cooling

tower blow down.

The quality of cooling tower blow down will be as per the standardsprescribed by Pollution Control Board for discharging into inland .

Residual chlorine in cooling tower blow down will be maintained within

acceptable levels.

The treated waste water consisting of cooling tower blow down, boiler

blow down and neutralised effluent will be conforming to the GSR 422 E

onland discharge standards. The treated effluent shall be used for dust

suppression in fuel handling area (12 m3

per day), green belt development

(12 m3

per day) and ash handling system (231 m3

per day). There will be

no discharge of effluent from the plant outside the plant site.

About 51 m3/ day sewage will be generated from various buildings in

the existing and proposed power plant area. The domestic wastewater

generated will be subjected to treatment in Septic tanks followed by soak pits.

No additional land will be acquired for expansion. SMPPL shall optimize the

layout design to restrict the cutting of plantation in the existing plant site.

5.2.4 Solid Waste Generation:

The solid waste generation from the existing ferroalloy plant and proposed

power plant are mainly from the following five areas.

Fines from Raw Material handling

Fines from Product Handling

Dust collected from cleaning of Flue gas from submerged arc

furnace (SAF)

Slag from submerged arc furnace (SAF)

Fly ash & Bed ash from boiler of the proposed CPP







Following table gives the quantities of solid wastes in Tons per annum (TPA)

and their disposal practices adopted/ proposed to be adopted.

Types Of Solid Waste Quantity

(TPA)

Disposal Practices

adopted

/proposed

Fines from Raw Material handling 7800 Collected, packed

in bags & disposed

for commercial

usage

Fines from Product Handling 2240 -do-

Dust collected from cleaning of Flue gas

from submerged arc furnace (SAF)

1700 -do-

Slag from submerged arc furnace (SAF) 31300 Reprocessed &

used forcommercial

purposes

Fly ash from boiler of the proposed CPP 1120 Shall be sold to

Cement Plants

Bed ash from boiler of the proposed CPP 180 Shall be reused

within the plant

5.2.5 HAZARDOUS WASTE MANAGEMENT:

Around 1000 liters per annum of used oil is expected to be generated from usage of DG sets. This shall be sold to authorized recyclers.

5.2.6 THERMAL POLLUTION:

Heat constitutes a form of pollution if it is above acceptable levels. Therefore

control measures shall be adopted to minimise thermal pollution. All

equipment and pipelines whose surface temperature is 500C and above will

be provided with thermal insulation.

The plant building shall be designed for adequate air circulation through natural

ventilation. In addition, air conditioning systems will be provided for specificareas. Man coolers will be installed at hot work spots.

5.2.7 WORK ZONE POLLUTION:

The work zone pollution would be mostly due to fugitive dusts, heat and

noise. The work zone noise would be mostly emanating from the rotary

equipment and machinery like fans, blowers, compressors and pumps. The

fugitive dust emission in open area would be controlled by Dust Extraction

and Dust Suppression systems.

As far as possible, natural draft ventilation would be enabled in the shop. All the

process vessels would be lined with adequately thick refractory bricks to contain the

surface heat emission and in some cases they would be indirectly cooled by water. In







addition to this, there would be provision for forced draft cooling and ventilation of

closed environment in the work zone.

Proper equipment design for control of noise at source, adopting proper

protective appliances and administrative control for rotation of manpower in

noisy areas would prevent exposure of workmen to high noise levels.

5.2.8 Occupational Safety & Health Management

Plant safety measures would form an integral part of the environmental

management plan of the proposed plant. Workers safety would be given

highest priority so as to avoid any form of personal injury or lost-time

accident. In-built safety features of the plant and machinery would help to

avoid hazardous events causing damage to the life and property.

SMPPL has provided all necessary provisions under Factory Act. In addition aSafety committee will be formed and manned by equal participants from

Management and Workers.

Safety shoes, helmet & uniform are issued to each worker. Other safety

equipments will be used according to the nature of job involved

SMPPL has established its own well equipped occupational health center headed

by experienced Doctors with a team of Nurses, /Compounders .

5.2.9 SOCIAL IMPACTS:

Population displacement is main culprit during the establishment of a thermal

power plant due to large area requirement. The proposed project shall be located

in the existing ferro alloy plant premises in an area of 25 acres (Existing area is 95

acres). Hence, there shall not be additional requirement of land. There shall be no

displacement of the population by the proposed project. The land transformation

shall be marginal.

5.3 Social Welfare

SMPPL shall employ an additional manpower of 45 people in the proposed CPP.plant. A total of about 100 persons will be given indirect employment during

construction and installation of the new unit. Preference will be given to the local

people.

This expansion project would aid in the overall social and economic development

of the region.







SMPPL has also constructed a full-fledged colony consisting of houses for the

benefit of employees. Most of the employees shall be from the local area. Hence,

the influence of influx on environment is insignificant. It is anticipated that the

project would bring following benefits to the people of the surrounding villages

Generation of employment and improved standard of living.

Establishment of small and medium scale engineering ancillaries,

agro - based industries with cascading employment opportunities.

Superior communication and transport facilities etc.

5.4 GREEN BELT DEVELOPMENT:

More than 2200 trees (more tha 40 years old) are present all around in theexisting premises. The industry shall increase the green belt as per KSPCB

guidelines.

5.5 POST PROJECT MONITORING PLAN

As a part of the Environmental Management Plan (EMP), monitoring of air and

water quality shall be carried out. SMPPL will upgrade its quality control

laboratory and also avail third party services for monitoring of environmental

parameters as per KSPCB/CPCB guidelines.

Budgetary Provisions For Environmental Monitoring Plan

Sl. No Item Cost in Rs. Lakhs

1 Electrostatic Precipitator 130

2 Air Cooled Condenser

(Decrease of water consumption for cooling)

1500

3 Cost of Chimney 60

4 Water Pollution Control 10

5 Green Belt 156 Laboratory for Monitoring 20

7 Recurring 180

Project Proponent: M/s Star Metallics & Power Pvt Ltd: of 13

star metallics power english exesummery

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