submitted to moef, new...
TRANSCRIPT
Updated & Revised Form – I
Submitted to MoEF, New Delhi
for
SRIKALAHASTHI PIPES LIMITED (Formerly Lanco Industries Ltd.)
at Rachagunnari Village of Srikalahasti Mandal, Merlapaka & Chindepalli Village of
Yerpedu Mandal, Chittoor District, Andhra Pradesh
[REQUEST FOR EXTENSION OF VALIDITY & AMENDMENT IN ENVIRONMENTAL
CLEARANCE ISSUED VIDE NO. J-11011/914/2007-IA II (I) dated 25-07-2008]
6-3-652 | Flat # 7-3 | Dhruvatara Apartments | Amrutha Estates | Erramanjil | Somajiguda | Hyderabad- 500082
Prepared by:
Accredited by NABET - QCI ISO 9001: 2008 Certified
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APPENDIX I (See paragraph – 6)
FORM 1
Sr. No
(I) BASIC INFORMATION
1. Name of the project LANCO INDUSTRIES LTD
2. S. No. in the schedule 1 (d) and 3 (a) & (b)
3. Proposed capacity/area/length/tonnage to
be handled/command area/lease
area/number of wells to be drilled
Name of the product Proposed expansion capacity
Pig i ron 3,50,000 TPA Ducti le i ron Spun pipes 2,80,000 TPA Slag cement 3,00,000 TPA Coke oven plant 3,00,000 TPA
Captive power generation 20 MW & 6.0 MW
4. New/Expansion/Modernization The present proposal is to request the Ministry for
Extension of validity of the Environmental
Clearance to complete the unimplemented portion
of the Expansion project & Amendment in
Environmental Clearance.
5. Exis ting capacity/Area etc. Name of the product Existing capacity Pig i ron 1,75,000 TPA Ducti le i ron Spun pipes 1,20,000 TPA Slag cement 90,000 TPA Coke oven plant 1,62,000 TPA Captive power generation 12 MW
& 2.5 MW
Status of the Expansion project
The following are the capacities after expansion for which Environmental clearance was
obtained vide order No. J-11011 / 914 / 2007 – IA II (I) dated 25-07-2008
S.NO. NAME OF THE PRODUCT
EXISTING CAPACITY
PROPOSED EXPANSION
CAPACITY
TOTAL CAPACITY AFTER PROPOSED
EXPANSION 1. Ducti le Iron Pipes 1,20,000 TPA 2,80,000 TPA 4,00,000 TPA
2. Pig Iron 1,75,000 TPA 3,50,000 TPA 5,25,000 TPA
3. LAM Coke 1,62,000 TPA 3,00,000 TPA 4,62,000 TPA
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4. Captive Power
generation
12.0 MW
& 2.5 MW
20.0 MW & 6.0
MW
40.5 MW
5. Slag Cement 90,000TPA 3,00,000 TPA 3,90,000 TPA
The following is the implementation status of the expansion project
S.No. NAME OF THE
PRODUCT
EXISTING CAPACITY
PROPOSED EXPANSION
CAPACITY
TOTAL CAPACITY AFTER
PROPOSED EXPANSION
STATUS OF IMPLEMENTA
TION
1. Ducti le Iron
Pipes
1,20,000 TPA 2,80,000 TPA 4,00,000 TPA 1,05,000 has
been
implemented
2. Pig Iron 1,75,000 TPA 3,50,000 TPA 5,25,000 TPA 1,00,000 TPA
has been
implemented
3. LAM Coke 1,62,000 TPA 3,00,000 TPA 4,62,000 TPA 75,000 has
been
implemented
4. Captive
Power
generation
12.0 MW
& 2.5 MW
20.0 MW & 6.0
MW
40.5 MW Pending
5. Slag Cement 90,000TPA 3,00,000 TPA 3,90,000 TPA Pending
We also would like to bring to your kind notice that, due to improvement in market scenario
for some of our products, we are planning to implement some of the unimplemented units
which could not be taken up during the validity period of Environmental clearance. Our
bankers are also insisting for extension of Environmental Clearance certificate for sanctioning
of loan for those units.
Amendment in Environment clearance
Amendment in treatment system for effluent generated is sought as per Annexure (a)
6. Category of project i.e. ‘A’ or ‘B’. A
7. Does i t attract the general condition? If yes,
please specify.
No
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8. Does i t attract the specific condition? If yes,
please specify.
No
9. Location
Plot/Survey/Khasra No. 274,279/1,281 etc.
Vi l lages Rachagunnaeri, Merlapaka & Chindepalli
Tehs il Srikalahasti & Yerpedu Mandal
District Chittoor
State Andhra Pradesh
10. Nearest ra ilway s tation/airport along with
dis tance in kms.
Railway Station : Rachagunneri - 0.5 Km
Airport : Renigunta (15.0 Kms.)
11. Nearest Town, ci ty, District Headquarters
a long with distance in
Kms
Nearest Town: Srikalahasti (7.3 Kms)
Nearest City: Tirupathi.
District Head quarter : Tirupathi
12. Vi l lage Panchayats,Zilla Parishad, Municipal
corporation, Local body(complete postal
addresses with telephone nos. to be given)
Village panchayat : Rachagunneri, Merlapka &
Chindepalli
Zilla Parishad : Srikalahasti
Municipal Corporation: Tirupathi
13. Name of the applicant Srikalahasthi Pipes Ltd.
(formerly Lanco Industries Ltd. )
14. Registered Address Rachagunneri (V) & (PO)
Srikalahasti (Mandal),
Chittor District, Andhra Pradesh
15. Address for correspondence:
Name M. R. RAMESH BAPU
Des ignation(owner/partner/CEO) Sr.General Manager (Business Development)
Address Rachagunneri (V) & (PO)
Srikalahasti (Mandal),
Chittor District, Andhra Pradesh
Pin code 517641
E-Mai l [email protected]
Telephone No. 08578-286650-55
Fax No. 08578-286657
16. Details of Al ternative s i tes examined, i f Present proposal is request for extension of
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any. Location these sites should be shown
on a topo sheet
validity of Environmental clearance &
Amendment in Environmental Clearance only.
17. Interlinked Projects No
18. Whether separate appl ication of
interlinked project has been submitted?
Not Applicable
19. If yes , date of submission Not Applicable
20. If no, reason Not Applicable
21. Whether the proposal involves
approval/clearance under; i f yes, details of
the same and their status to be given.
(a) The Forest (conservation)Act,1980
(b) The Wi ldlife (protection)Act,1972
(c) The C.R.Z Noti fication, 1991?
No
22.
Whether there is any a government
order/policy relevant/relating to the s ite?
No
23. Forest land involved(hectares) Nil
24. Whether there is any litigation pending
against the project and/or land in which
the project is propose to be set up?
(a)Name of the court
(b)Case No.
(c) Orders/directions of the court, i f any
and i ts relevance with the proposed
project.
No litigation is pending against the project and /
or land in which the expansion project is propose
to be set up
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(II) ACTIVITY
1. Construction, operation or decommissioning of the Project involving actions, which will cause
physical changes in the locality (topography, land use, changes in water bodies, etc.)
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities /rates, wherever possible) with source of information data
1.1 Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to loca l land use plan)
Yes Present use of land is Industrial. Existing plant is already under operation and part of the expansion project has been implemented and is under operation. Some topographical changes have occurred due to the excavations, construction activities pertaining to the existing and expansion units under implementation. Hence there is no adverse significant impact due to the change in land use pattern due to the expansion project activities.
1.2 Clearance of existing land, vegetation and bui ldings?
No Part of the expansion project was implemented in the vacant area available in the existing plant premises. Unimplemented expansion project activities will be taken up in the vacant area available. However as a part of greenbelt development, 85 acres of Greenbelt (including expansion project) has been developed in the Plant premises.
1.3 Creation of new land uses? Yes Present use of land is already converted for the industrial purpose.
1.4 Pre-construction investigations e.g. bore houses , soi l testing?
No Investigations have been carried out for soil and water in the area where construction of the expansion project is planned
1.5 Construction works?
Yes Construction activities have been completed only part of the expansion project planned. Keeping in view of improvement in market scenario for some of our products, we are planning to take up construction activities pertaining to unimplemented units after obtaining extension of Environmental Clearance.
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All necessary precautions have been taken to prevent dust pollution during construction of existing project and similar practice will be carried out during construction of unimplemented expansion project activities.
1.6 Demol i tion works? No No demolition work is involved for implementing the remaining expansion project activities as it will be taken up in the vacant area available in the site premises
1.7 Temporary s ites used for construction works or hous ing of construction workers?
No Construction workers will be taken from local areas and from other areas. Temporary Labor colony housing will be envisaged for non-local construction workers
1.8 Above ground buildings , s tructures or earthworks including l inear s tructures , cut and fi l l or excavations
Yes Most of the structures in remaining expansion project activities will be above the ground. However excavations are involved for foundations in construction and cut will be used for filling within the site.
1.9 Underground works including mining or tunneling?
No No mining and tunneling is involved in remaining expansion project activities
1.10 Reclamation works? No No reclamation works are envisaged in remaining expansion project activities
1.11 Dredging? No No dredging activity is involved in remaining expansion project activities
1.12 Offshore s tructures ? No No offshore structures are envisaged in remaining expansion project activities
1.13 Production and manufacturing processes?
Yes The detailed process description of all units is attached as Annexure (b).
1.14 Faci l i ties for s torage of goods or materia ls?
Yes Raw materials such as iron ore, coke, Limestone and Dolomite are being stored in open yards. Quartz and Manganese is being stored in closed shed. Fines generated will be stored in silos only. Hence there will not be any adverse impact on environment due to the proposed expansion.
1.15 Faci lities for treatment or disposal of sol id waste or l iquid effluents?
Yes
There will be no effluent generation in the Sinter plant, Cement plant and Annealing furnaces, as closed circuit cooling system will be adopted. The boiler blowdown will be have pH between 9.5 – 10.5. The pH of RO Rejects will be between 5 – 10. These two streams after neutralization will be mixed with cooling tower blowdown in central monitoring basin (CMB). The effluent from
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GCP & from DI pipe division will be treated in a thickener. The treated effluent will be sent to CMB. The concentrated slurry will be dried on sludge drying beds. The filtrate from sludge drying beds will be taken to CMB. Part of the treated effluent from CMB will be utilized for dust suppression and remaining for green belt development. RO reject water from 12 MW CPP is neutralized with blow down cooling tower and boiler in neutralization pit and consumed entire quantity in coke quenching which gets totally evaporated in the process. Also RO reject water from 2.5 MW CPP is neutralized with blow down water of DIP and MBF in Central monitoring basin (CMB) then treated in ETP. Treated effluents entirely consumed in slag granulation, gas cleaning plant, dust suppression etc. which gets totally evaporated. The effluent from the Coke oven plant will be totally recycled. The sanitary wastewater will be treated in STP. Regarding the Solid waste disposal, granulated slag from the Blast furnace will be utilized in the cement plant in the same premises. Slag from Induction Furnace will be utilized in the road construction as sub-base material. Dust from Air pollution control facilities in the steel plant expansion will be utilized in the sinter plant. Hence there will not be any adverse impact on environment due to the proposed expansion project.
1.16 Faci l i ties for long term hous ing of operational workers?
No Quarters are provided for Emergency staff and some of Executives. There are about 24 quarters in the township of the existing plant. The township with all infrastructural facilities is situated side of the existing plant.
1.17 New road, ra i l or sea traffic during construction or operation?
Yes During construction phase of part of expansion project additional road/rail traffic has been generated for supply of construction materials and plant equipment. Similarly during construction phase of
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remaining expansion project activities, additional road/rail traffic will be generated for supply of construction materials and plant equipment. During operation of the expansion project, most of the raw materials will be transported by railway wagons. A railway siding is available up to the plant site. Other raw materials in small quantity will be transported by road in covered trucks. The existing roads can handle this minor increase in traffic. Hence there will not be any adverse impact on road traffic/rail traffic/sea traffic due to the remaining expansion project operations.
1.18 New road, rail, air waterborne or othe r transport infrastructure including new or a l tered routes and s tations , ports , a i rports etc?
No A railway siding has already been laid up to the plant from the nearest railway station. No new road / air transport infrastructure is proposed for the expansion project.
1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?
No Not Applicable
1.20 New or diverted transmiss ion l ines or pipel ines?
No Water required for the part of expansion project implemented is being met from Tirupathi Municipal Sewage treatment plant For the remaining expansion project also water required will be met from Tirupathi Municipal Sewage treatment plant An agreement copy with Tirupathi Municipal Corporation for supply of sewage water is enclosed as Annexure – (c)
1.21 Impoundment, damming, culverting, rea l ignment or other changes to the hydrology of watercourses or aquifers?
No No damming, culverting, realignments are envisaged. There will not be any changes to the hydrology of watercourses or aquifers due to the implementation remaining expansion project activities
1.22 Stream cross ings? No Not Applicable 1.23 Abstraction or transfers of water form
ground or surface waters? Yes Water required for the part of expansion
project implemented is being met from Tirupathi Municipal Sewage treatment plant For the remaining expansion project also water required will be met from Tirupathi Municipal Sewage treatment plant An agreement copy with Tirupathi Municipal Corporation for supply of sewage water is enclosed as Annexure – (c)
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1.24 Changes in water bodies or the land surface affecting dra inage or run-off?
No No changes in water bodies, drainage and land surface are anticipated, as the site is more or less flat without many undulations.
1.25 Transport of personnel or materia ls for construction, operation or decommiss ioning?
Yes A few vehicles will be provided for transport of personnel during construction & operation of the remaining expansion project. Construction materials will be transported in contractor’s vehicles. Total no. of vehicles for transport of personnel and materials will be 10 per day during construction. Most of the raw materials will be transported by railway wagons. The existing road is capable of handling the additional vehicular traffic due to the proposed activities.
1.26 Long-term dismantl ing or decommissioning or restoration works?
No Not Applicable
1.27 Ongoing activi ty during decommissioning which could have an impact on the environment?
No Not Applicable
1.28 Influx of people to the area ei ther temporari ly or permanently?
No During construction local people will be involved. During operation of the plant preference will be given to the local people for employment.
1.29 Introduction of a l ien spe cies? No Not applicable 1.30 Loss of native species or genetic
divers i ty?
No Not Applicable
1.31 Any other actions? No Not Applicable
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials
or energy, especially any resources which are non-renewable or in short supply):
S.No. Information/checklist confirmation Yes/No Details thereof (with approximate quantities /rates, wherever possible) with source of information data
2.1 Land especia l ly undevelope d or agricul tura l land (ha)
No 183.85 acres of land is in the possession of the management. The present use of the land is industrial. Out of which 1/3rd of the total area will be developed with greenbelt.
2.2 Water (expected source & competing users ) unit: KLD
Yes Water required for the plant will be met from Tirupathi Municipal Sewage Treatment Plant. Total water requirement for the expansion project is 7750 Cum/day. An agreement copy with Tirupathi Municipal Corporation for supply of sewage water is
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enclosed as Annexure – (c) 2.3 Minera ls (MT) Yes Please refer to Annexure – (d) 2.4 Construction materia l – s tone,
aggregates, sand / soi l (expected source – MT)
Yes All construction materials such as stone, sand, soil are available locally.
2.5 Fores ts and timber (source – MT) No Not Applicable 2.6 Energy including electrici ty and
fuels (source, competing users ) Unit: fuel (MT), energy (MW)
Yes Power generation : Expansion from 14.5 MW to 40.5 MW
2.7 Any other natura l resources (use appropriate s tandard units )
No Not Applicable
3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health. S.No. Information/Checklist confirmation
Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
3.1 Use of substances or materia ls , which are hazardous (as per MSIHC rules ) to human health or the environment (flora, fauna, and water suppl ies )
Yes Zinc dust and Used Oil will be stored and will be disposed as per CPCB / APPCB norms.
3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases)
No
3.3 Affect the welfare of people e.g. by changing l iving conditions?
No Not Applicable
3.4 Vulnerable groups of people who could be affected by the project e.g. hospita l patients , chi ldren, the elderly etc.,
No Not Applicable as the proposed project will create more employment opportunities in the area and thereby a substantial improvement in the socio-economic status.
3.5 Any other causes No State-of-the-art control systems will be installed to bring down the emissions in the exhaust gas to within the stipulated standards of CPCB/APPCB. The treated effluent will be utilized for recycle, dust suppression and for greenbelt development within the premises after ensuring compliance with the CPCB/APPCB standards. All the solid waste generated will be utilized / disposed as per the methods approved by CPCB/APPCB. A thick greenbelt of 85 acres will be developed. There are no hospitals and schools in the vicinity of the plant. Hence there will not be any adverse impact on vulnerable groups due to the proposed project.
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4. Production of solid wastes during construction or operation or decommissioning (MT/month)
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities/rates, where ever possible) with source of information data
4.1 Spoi l, overburden or mine wastes Yes The dug soil during excavation is will be used for filling of low lying areas in the already implemented / yet to be implemented units.
4.2 Municipal waste (domestic and or commercia l wastes)
Yes Small quantities of domestic wastes generated from staff quarters and administrative areas will be disposed off as per MSW norms.
4.3 Hazardous wastes (as per Hazardous Waste Management Rules )
Yes Waste lube oil – 391.5 lit/day Zinc dust – 500 Kg/day
4.4 Other industrial process wastes Yes Please refer to annexure – (e)
4.5 Surplus product No Not Applicable 4.6 Sewage s ludge or other s ludge
from effluent treatment Yes Sludge from STP is being disposed off as per APPCB
norms in environment friendly manner.
4.7 Construction or demol i tion wastes
Yes Construction wastes are will be disposed off as per guidelines.
4.8 Redundant machinery or equipment
No Not Applicable
4.9 Contaminated soi l s or other materia ls
No No contamination of soils or no contaminated materials will be kept in the plant.
4.10 Agricul tura l wastes No Not Applicable
4.11 Other sol id wastes No Not Applicable
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5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities/rates, wherever possible) with source of information data
5.1 Emiss ions from combustion of foss i l fuels from stationary or mobi le sources
Yes The emissions from major concern will be PM, SO2 & NOx, to control these emissions state of art pollution control systems will be installed as per CPCB / APPCB norms.
5.2 Emiss ions from production processes
No Dust emissions from production process are generated, to control these emissions state of art pollution control systems will be installed as per CPCB / APPCB norms.
5.3 Emissions from materials handling including s torage or transport
Yes Dust suppression system will be provided in unloading areas. Dust extraction systems will be provided in coal crushing and screening, etc. Most of the raw materials will be transported through railway wagons. Pucca external & internal roads exist. Raw materials will be stored in yards with water spraying systems. Hence there will not be any adverse impact due to fugitive emissions from the transport and storage of raw materials.
5.4 Emiss ions from construction activi ties including plant and equipment
Yes Some dust emissions will be generated during construction. Dust curtains will be provided all round the work area to prevent the dust emissions. Water spraying will be done to prevent the dust emanation due to vehicular movement.
5.5 Dust or odours from handl ing of materials including construction materia ls , sewage and waste
Yes Not applicable
5.6 Emiss ions from incineration of waste
No Not applicable
5.7 Emissions from burning of waste in open air (e.g. slash materia ls , construction debris )
No All such wastes will be disposed off as per norms.
5.8 Emissions from any other sources No Nil
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6. Generation of Noise and Vibration, and Emissions of Light and Heat:
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities/rates, wherever possible) with source of information data with source of information data
6.1 From operation of equipment e.g. engines , venti lation plant, crushers
Yes The sources of noise generation in the will be DG Sets, Boiler, Compressors, etc All machinery will be manufactured as per OSHA/MOEF guidelines. Noise enclosures will be provided to Turbines. Earplugs will be provided to workers working in the noise prone areas. Ambient noise levels will be in accordance with MOEF notification dated 14-02-2000 i.e. noise levels will be < 75 dBA during daytime and < 70 dBA during nighttime.
6.2 From industria l or s imi lar processes
Yes Nil
6.3 From construction or demoli tion Yes Construction equipment will cause some noise. Ear plugs will be provided to construction workers who work near the noise generating equipment.
6.4 From blasting or pi l ing No No such operations are involved.
6.5 From construction or operational traffic
Yes Vehicles used by construction staff are minimal. The noise levels will be in accordance with MOEF notification dated 14-02-2000.
6.6 From l ighting or cooling systems No Not applicable 6.7 From any other sources No Not applicable
7. Risks of contamination of land or water from releases of pollutants into the ground or into
sewers, surface waters, groundwater, coastal waters or the sea:
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities/rates, wherever possible) with source of information data
7.1 From handl ing, s torage, use or spi llage of hazardous materia ls
Yes Used oil generated from the expansion activities will be stored in covered HDPE drums and will be given to APPCB approved vendors. Good Housekeeping practices are being followed in the existing plant and similar practices will be followed during operation of the expansion project. Hence there will not be any spillage which will affect the environment.
7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of
Yes There will be no effluent generation in the Sinter plant, Cement plant and Annealing furnaces, as closed circuit cooling system will be adopted.
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discharge)
The boiler blow down will be have pH between 9.5 – 10.5. The pH of RO Rejects will be between 5 – 10. These two streams after neutralization will be mixed with cooling tower blow down in central monitoring basin (CMB). The effluent from GCP & from DI pipe division will be treated in a thickener. The treated effluent will be sent to CMB. The concentrated slurry will be dried on sludge drying beds. The filtrate from sludge drying beds will be taken to CMB. Part of the treated effluent from CMB will be utilized for dust suppression and remaining for green belt development. RO reject water from 12 MW CPP is neutralized with blow down cooling tower and boiler in neutralization pit and consumed entire quantity in coke quenching which gets totally evaporated in the process. Also RO reject water from 2.5 MW CPP is neutralized with blow down water of DIP and MBF in Central monitoring basin (CMB) then treated in ETP. Treated effluents entirely consumed in slag granulation, gas cleaning plant, dust suppression etc. which gets totally evaporated. The effluent from the Coke oven plant will be totally recycled. The sanitary wastewater will be treated in STP. Regarding the Solid waste disposal, granulated slag from the Blast furnace will be utilized in the cement plant in the same premises. Slag from Induction Furnace will be utilized in the road construction as sub-base material. Dust from Air pollution control facilities in the steel plant expansion will be utilized in the sinter plant. Hence there will not be any adverse impact on environment due to the proposed expansion project.
7.3 By depos i tion of pol lutants emitted to a i r into the land or into water
No State-of-the-art Gas cleaning plant will be provided to treat the gases from the proposed Blast Furnace and will be discharged into the atmosphere through a stack of 30 m height. Fume extraction system with bag filters will be provided to treat the gases and the secondary fugitive emissions from the melting sections. Unloading areas will be provided with water
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sprinklers to prevent the fugitive dust. All conveyors will be completely covered with GI sheets. A thick greenbelt of 34 acres will be developed in addition to the existing 51 acres of greenbelt. This greenbelt will be developed as per CPCB guidelines in consultation with DFO. Hence there will not be any deposition of pollutants into the air/land/water.
7.4 From any other sources No Not applicable 7.5 Is there a ri sk of long term bui ld
up of pol lutants in the environment from these sources?
No Not applicable
8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment. S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities/rates, wherever possible) with source of information data
8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances
No Good housekeeping practices are being followed in the existing plant. Similarly good housekeeping practices will be maintained in the expansion project also. Used oil will be stored in covered HDPE drum and will be disposed off to APPCB approved vendors.
8.2 From any other causes No Not applicable 8.3 Could the project be affected by natura l
disasters causing environmental damage (e.g. floods , earthquakes , lands l ides , cloudburst etc)
No Not applicable
9. Factors which should be considered (such as consequential development) which could lead to
environmental effects or the potential for cumulative impacts with other existing or planned activities
in the locality
S. No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities/rates, wherever possible) with source of information data
9.1 Lead to development of supporting uti l i ties , anci l lary development or development s timulated by the project which could
No
No such activities are envisaged.
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have impact on the environment e.g.: • Supporting infrastructure (roads ,
power supply, waste or waste water treatment, etc.)
• hous ing development • extractive industries • supply industries • other
9.2 Lead to after-use of the s i te, which could have an impact on the environment
No Not applicable
9.3 Set a precedent for later developments
Yes With the improvement in the socio-economic status of the people in the area, later developments are expected.
9.4 Have cumulative effects due to proximity to other existing or planned projects with s imi lar effects
No Nil
(III) Environmental Sensitivity
S.No.
Areas
Name/ Identity
Aerial distance (within 15 km.)
Proposed project location boundary
1 Areas protected under international conventions, national or local legis lation for their ecological, landscape, cultural or other related va lue
Yes Sri kalahasthi temple ( 8.5 Kms)
2 Areas which are important or sens i tive for ecologica l reasons - Wetlands , watercourses or other water bodies, coastal zone, biospheres , mountains , forests
Yes Pallam RF, Ramapuram RF, Yerpedu PF
3 Areas used by protected, important or sens i tive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration
Nil Not applicable
4 Inland, coasta l , marine or underground waters
Nil Not applicable
5 State, National boundaries Yes SH – 61 (1 Km)
6 Routes or facilities used by the publ ic for access to recreation or other tourist, pilgrim areas
Nil Not applicable
7 Defense insta l lations Nil Not applicable
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8 Densely populated or bui l t-up area Yes
Srikalahasti (7.3 Kms.)
9 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship, community facilities)
Yes Rachagunneri (1.0 Km.)
10 Areas containing important, high qual i ty or scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)
Yes Swarnamukhi river (4.5 Kms.)
11 Areas a l ready subjected to pol lution or environmental damage. (those where existing legal environmental standards are exceeded)
Nil Not applicable
12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)
Nil Based on the historical data, the site is not likely to prone to earthquakes, floods, etc.
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(IV). PROPOSED TERMS OF REFERENCE FOR EIA STUDIES
NOT APPLICABLE
We request the Honorable Ministry to kindly extend the validity of the Environmental Clearance
& amendment in Environmental Clearance order issued earlier vide order No. J – 11011 / 914 /
2007 – IA II (I) dated 25-07-2008 in order to complete the remaining unimplemented portion of
the project for which Environmental Clearance has been accorded.
“I hereby given undertaking that the data and information given in the appl ication and
enclosures are true to the best of my knowledge and belief and I am aware that i f any part of the
data and information submitted is found to be false or misleading at any s tage, the project wi l l be
rejected and clearance give, i f any to th e project wi l l be revoked at our ri sk and cost.
Date: 28-10-2014 Place : Chittoor
For Srikalahasthi Pipes Limited (formerly LANCO INDUSTRIES LIMITED)
M.R. Ramesh Bapu, Sr.General Manager (Business development)
Rachagunneri (V) & (PO) Srikalahasti (Mandal),
Chittor District, Andhra Pradesh
Annexure-(b)
PROCESS DETAILS
Lanco Industries Ltd. is manufacturing total 4 products namely Pig iron, Slag cement, D.I.
Spun pipes and LAM Coke. Major saleable products are D.I Spun pipes and Slag cement.
Produced LAM Coke is used to produce Pig Iron and Molten Iron is used to produce D.I Spun
pipes.
Manufacturing process of each product as follows:
A) MANUFACTURING PROCESS – PIG IRON:
Pig Iron is manufactured using Korf Technology, Brazil. Pig Iron is made with its state -of-
the-art facilities conforming to national & international standards. The process of
manufacturing of Pig Iron is detailed in this section to give an insight about the world
class manufacturing facilities available at the plant.
Raw material handling system:
Basic raw materials used for production of pig iron are Iron ore, Metallurgical coke,
Limestone, Dolomite, Quartzite and Manganese-ore.
These raw materials are stored / heaped in the respective yards with proper
identification, based on the raw material specification / supplier.
Raw materials are transported from respected yards to ground hopper by means of trucks
or tippers and dumped into the ground hopper, they are sent to respective day bins
through conveyors.
Batching & charging system
Automatic batching & charging system has been envisaged through Honeywell PLC. The
batching will be done automatically as per the burden set by the operation. The burden
will be decided by the operation based on the required quality of the pig iron. The
material, which is weighed, will be sent to the blast furnace via conveyors as per the
recipe. Charging will be done to MBF by means of upper & lower bells.
Preparation of hot blast
There are HT fans installed for generating blast required for blast furnace operation.
Based on the requirement of pressure and flow, the fans will be switched on to operate in
series to maintain the pressure. The cold blast generated from the blower fans is
preheated in Metallic Blast Pre-heaters (MBP) before sending to blast furnace.
There are three MBPs envisaged for pre-heating the cold blast. Based on the process
requirement, MBPs will be started & taken in to service. MBPs will be lighted with oil and
finally used in blast furnace as fuel for firing. The cold blast will be indirectly heated in
MBPs upto required temperature as per process requirement. This hot blast will be sent
to Blast furnace.
Blowing system:
There are 10 tuyers and blowpipes envisaged for blowing hot air in to the furnace. The
hot blast will flow upward in the blast furnace opposite to the direction of movement of
the raw material. The iron ore gets pre-heated, reduction process takes place and iron
start melting at different zones & finally become hot metal. It is collected in the hearth.
The hot metal collected will be tapped from blast furnace at regular intervals. The hot
metal tapped will be collected in ladles and weighed. The weighed ladles will be sent to
spun pipe division through trucks as per the requirement. The excess hot metal will be
converted into pigs through Pig Casting Machine (PCM). The pigs will be collected in
trucks and dumped at pig iron yard with batch identification.
By product / waste generation from mini blast furnace
a. Slag generation
Slag is a bi-product from blast furnace, which is granulated by means of slag granulation
system. A part of the granulated slag is sent to cement plant for making Portland Slag
Cement (PSC). Excess slag is stored at designated storage yard for disposal / sales.
b. Flue gas
The flue gas from MBPs will be used at cement plant for slag drying. Remaining flue gas
will be released to atmosphere.
c. Blast furnace gas
The blast furnace gas coming-out from the furnace is used as fuel for MBPs, Boiler,
Laddle, Spun pipe division annealing furnace. Any excess gas will be let out to
atmosphere through flare stack chimney, after burning the gas using flare ignition system.
d. Flue dust from dust catcher
The flue dust generated will be collected at dust catcher. It is periodically loaded to
trucks and dumped at designated places from where it is used for making sinter in
sintering plant.
e. Captive power plant
2.5 MW BF gas fired captive power plant has been installed to utilize BF gas generated
from the furnace. This will reduce the power cost and also saves the environment from
emission of gas to atmosphere.
f. Effluent treatment plant
ETP has been installed for treatment of wastewater generated from the process and for
reuse at SGP, GCP, sintering plant and PCM cooling.
g. Dispatch
The Pig Iron will be stored at the Pig Iron Yard, which will be dispatched to customers
through trucks / rakes.
B) MANUFACTURING PROCESS SLAG CEMENT
The Main Raw materials required for Slag Cement production are Lime Stone, Coke Fines,
Clay, Slag and Gypsum. Limestone brought from mines in boulder form is crushed to -
20mm size in crusher.
The crushed limestone chips are ground along with Clay, Iron ore and Coke fines in
grinding mills. The resultant product is called ‘Raw Meal’, which is mixed with water and
made into globules in a nodulizer.
These nodules are fired in a vertical shaft kiln at a temperature of 1300 to 1400oC, to get
clinker, which is nothing but Ordinary Portland Cement in unfinished form.
But cement made from above clinker will not have proper setting properties. Hence 2%
Gypsum is added to clinker & ground into a fine powder to make cement.
In our case to make use of the Slag coming from Mini Blast furnace, we are adding slag
with clinker to make slag cement, which is mixed upto 70% depending on the nature of
Slag.
The Cement manufacturing process is semi dry process. Raw meal is prepared by grinding
and mixing in the pre-worked proportions of main raw material (Lime Stone) with the
additives (Iron Ore, Coke fines, Clay, etc.) Then the raw meal is burnt at a high
temperature attained in the initial ignition system in a vertical shaft kiln result in
penultimate end product called clinker. Clinker after cooling, along with slag and gypsum
are fed into the cement mill and are ground to fineness to produce the finishe d product
i.e. Portland Slag Cement (PSC).
C) MANUFACTURING PROCESS OF D.I SPUN PIPES
Pre- analyzed liquid metal from Blast Furnace is taken into Induction Furnace. The metal
is superheated to a temperature of about 15200C and adjusted for chemical composition
by addition of steel scrap and Ferro Silicon. The adjusted metal is taken into converter for
treatment to convert into SG Iron. The metal is analyzed for chemical composition before
and after the treatment of conversion with the help of spectrometer. The treated metal
from converter is transferred to spinning machines through ladles. The metal is kept
poured to unlined water-cooled metallic moulds through a runner. The mould is kept at
slightly inclined position and rotated at high speed. The uniform flow of metal and
uniform travel of the mould is ensured through flow control valves to achieve the
uniformity in thickness. Due to the centrifugal force, the metal is held against the mould
wall and the solidification of metal takes place due to water-cooling of the mould. The
pipe cast through above process known as delavud process is heat-treated in furnace.
The pipes are heated to a temperature of 9200C to 970
0C and soaked at this temperature
for a period of 20 to 25 minutes. Then the pipes are cooled to a temperature of 700 to
7500C in 8 to 10 minutes time inside the furnace and held at the above temperature for a
period of 12 to 15 minutes before final cooling. Samples are collected for mechanical
testing of physical properties and microstructure. After heat treatment the pipes are
finished by cleaning the socket configuration and inside surface of the pipes with grinders
by using abrasive grinding wheels before testing them with recommended hydrostatic test
pressure. The tested pipes are inspected and sent for coating/lining as per the customer’s
requirement.
1. External coating of Metallic Zinc, Cement mortar lining of internal surface without
seal-coat, and finishing layer of bitumen paint over metallic Zinc coating on
external surface.
2. External coating of bitumen paint and internal coating of Cement mortar lining
without seal-coat.
3. External and internal coating of bituminous paint.
Coatings:
a. Pipes are coated externally with metallic Zinc by spraying process. Before
coating of zinc, the external surface of the pipe is cleaned with wire brush
manually if required, to ensure good surface.
b. Cement mortar lining inside the pipes is done by centrifugal spinning
process. Before lining the inside surface of the pipes, it is cleaned with
barrel grinders using abrasive grinding wheels. Sand quality is ensured and
controlled by screening of sand and analyzing with sieve shaker on regular
basis. The thickness of cement coating is measured with the help of coat
meter.
c. Finishing layer of Bitumen paint over metallic zinc coating is applied on pipe
surface by spraying process. The coating of thickness is measured with a
thickness gauge (coat meter).
After coating/lining the pipes as per customer’s requirement / choice are marked and
sent to dispatch yard for stacking/ dispatch.
D) MANUFACTURING PROCESS OF LOW ASH METALLURGICAL COKE (LAMC) & CAPTIVE POWER GENERATION PROCESS (NON-RECOVERY COKE OVEN PLANT) The Low ash metallurgical (LAM) Coke making process is basically carbonization of coal to
higher temperature around 11000C in an Oxygen deficient atmosphere, which aids
concentration of carbon. There are two types of manufacturing process available viz.
byproduct (Recovery) and non-recovery types.
Lanco has opted for non-recovery (Heat Recovery) type method for various advantages
over the by product (Recovery) type coke oven as listed below.
a. Less investment cost as no byproduct related equipments and related auxiliaries
are required.
b. Low operation and maintenance cost.
c. Low conversion cost.
d. High coke yield.
e. Any oven in a battery can be isolated and cooled down to repair at any time
without affecting the life of the oven.
f. No effluent generation, only emissions of burnt i.e clean flue gas resulting to
minimal environmental impact.
g. Oven of non-recovery type is being operated under negative pressure, no fugitive
emissions through the doors and hence no pollution problems.
h. Extensive flue path system ensures complete combustion of all hydrocarbons,
resulting in clean stack discharges into the atmosphere.
The individual ovens are rectangular cross sections and horizontally positioned. A row of
such ovens is called battery.
Lanco Industries Limited is having two batteries, battery I & battery II, Each battery
consist of 34 ovens and each battery is connected to separate stack or emissions are sent
to each boiler of captive power plant. After passing through the boiler, the emissions are
discharged into atmosphere through a common stack of both the boilers.
The imported coal (coking coal) is powdered, charged into the oven from top through
charging ports using a changing car, which moves, on top of the oven to feed coal into the
oven. The charging car receives powdered coal from bunkers stock. The bunkers are filled
with powered coal through a belt conveyor from the ground stock of pulverized coal; the
charged coal in the oven is leveled and compacted by the leveler cum pusher, which will
improve the cycle. The other facility also provided for charging i.e. the powdered coal
also compacted in a machine and formed cake then it is charged in to the oven from the
front door as stamp charging. These both options are used for charging of coal into the
ovens. As gases are evolved, they are combusted. Thus the entire coal charges get
carbonized thoroughly by combustion inside the oven. Then by opening the side doors
after cycle time (app.36 hours) oven temperatures are monitored from time to time to
determine now coke is ready. With the help of lever cum pusher the ready hot coke is
pushed into the quenching car, and then it is quenched with water. The lumps are stored
and fed to coke cutter to sizing.
Combustion and temperature can be controlled to achieve required coke quality for the
steel industry while assuring clean exhaust gas.
The primary air for combustion is introduced into the chamber through several ports
located above the charge level in both the side doors. Partially combusted gas exits at the
top chamber through down corner passages in the oven wall and enters the sole flue path
thereby heating sole of the oven.
Since the air is drawn into the oven at upper end and off gases is combusted within the
oven chamber itself, the oven has been provided with long flue path thus burning of all
the exhaust gases from oven which contain various volatile organics etc. The fully
combusted waste flue gases containing mostly CO 2 and Nox go through the chimney and
that’s how it meets the pollution control requirements.
As the exhaust gases from oven battery are collected into common tunnel and exit
through a 37.25 m height chimney c reates natural draft inside the oven and there will be
no fugitive emissions/leaks through doors etc. of ovens.
For power generation, the hot exhaust gas is diverted into waste heat recovery boilers
without letting into atmosphere through battery chimneys. The hot gas heats up the water
and convert into steam were it generates 12 MW power, then cooled gas is discharged into
atmosphere through a common chimney of the height 55 m.
The new oven design ensures excellent thermal efficiency. Anyone oven can be shut down
for any fault without affecting the production. The emission of smoke from the chimney is
without any harmful gas. The harmful gasses that are generated in the process are reused
as combustible material and the gasses are totally burnt within the oven battery itself,
hence free from pollution and discharged into atmosphere through 37.25 m height stack
when captive power plant if not working. Process flow for coking coal to LAM coke
manufacturing and power generation process is shown in Fig.1 and Fig.2.
The water used as quenching and cooling agent is collected in the canals surrounding the
ovens and the same is sent to settling tank and the clear overflow from settling tank is
collected into a clear water tank and reused. The required quantity of water is
replenished to compensate the evaporation losses.
The settled particles in the settling tank are reclaimed and this has large demand in mini
cement plants and briquetting plants.
Annexure – (d)
RAW MATERIAL REQUIREMENT
RAW MATERIAL
QUANTITY (TPA)
SOURCE METHOD OF
TRANSPORTATION EXISTING EXPANSION TOTAL
DUCTILE IRON PIPE DIVISION
Molten metal 127,925 2,97,500 4,25,425 In plant generation EOT crane
Scrap 13,244 30,800 44,044 Open market Covered trucks / rail
Ferro silicon 2,007 4,667 6,674 Open market Covered trucks / rail
Cement 12,642 29,400 42,042 In plant generation Cement transfer poucher
Sand 15,010 34,908 49,918 Open markets Covered trucks
Silica sand 903 2,100 3,003 Open market Covered trucks
Bitumen paint 662 1,540 2,202 Open market Covered trucks
Zinc 662 1,540 2,202 Open market Covered trucks
Magnesium 146 339 485 Open market Covered trucks
LDO/LVFO 520 1,040 1,560 Open market Oil tankers
PIG IRON DIVISION
Sinter 2,27,500 4,55,000 6,82,500 In plant generation Conveyor
Coke 78,834 1,57,500 2,36,334 In plant generation Conveyor
Coal fines 17,667 35,000 52,667 Imported & Indigenous Rail / Covered truck
Lump ore 63,500 1,05,000 1,68,500 Hospet / Bellary
Karnataka
Railway rakes & Covered
trucks
NON RECOVERY COKE OVEN
Imported coking
coal 2,48,400 4,60,000 7,08,400 Australia
Through sea ways followed by
rakes & trucks
CEMENT DIVISON
Lime stone 104,400 348,000 4,52,400 Kadapa Covered trucks/Rail
Clay 6,207 20,690 26,897 Kadapa Covered trucks
Coal 4,655 15,518 20,173 Imported & Indigenous Covered trucks / rail
Coke breeze 4,654 15,518 20,172 In plant generation Conveyors
BF slag 25,430 1,22,500 1,47,930 In plant regeneration Conveyors
Gypsum 3,103 10,345 13,448 Open market Covered trucks
Annexure – (e)
SOLID WASTE GENERATION
S.NO SOLID WASTE EXISTING
(TPD)
EXPANSION
(TPD)
TOTAL AFTER
EXPANSION (TPD)
METHOD OF DISPOSAL
DI PIPE DIVISION
1. Furnace waste
(CI / DI scrap) 60.0 140.0 200.0
Sold to the authorized
dealers
2. Burnt core sand 2.6 6.0 8.6
Reclaiming low lying areas
in industry premises
3. Waste sand
cement slurry 4.0 12.0 16.0
Reclaiming low lying areas
in industry premises
4. Slag 2.0 5.5 7.5 Used for road laying
5. Zinc residue 0.07 0.15 0.22
Sold to the authorized
dealers
6. Mg converter waste
0.02 0.05 0.07 Used in Sinter plant
SINTER PLANT 1. Sinter return -- 460 460 Used in Sinter plant
PIG IRON 1. By product
(Slag)
140.0 350.0 490.0 Used to produce slag
cement
2. Sludge 10.0 20.0 30.0 Reclaiming low lying areas
in industry premises
3. Dust from
settling chamber
23.5 47.0 70.5 Used in sinter plant to
produce sinter