Shri Girija Alloy & Power (I) Pvt. Ltd.
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1 SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT OF Shri Girija Alloy & Power (I) Expansion of Ferro Alloys unit at Submitted to ANDHRA PRADESH POLLUTION CONTROL BOARD 0
2 1.0 PROJECT DESCRIPTION Shri Girija Alloy & Power (I) Shri Girija Alloy & Power (I) is an existing Ferro alloy & Power plant situated at Sy. Numbers 148 P, 149 P, 151, 152 P, 153 P, 162 P, 164, 355 P, 397 P, 400 P, 428 P, Peddapuram Village, Peddapuram Mandal,. Now we propose to enhance the production of existing ferro alloy products and produce other ferro alloy products, noble ferro alloys and calcium aluminate based synthetic slag by proposing 6 x 9 MVA, 8 x 400 Kg Crucibles & 3 x 500 KVA Submerged Electric Arc Furnace. Proposed expansion will be taken up in the existing plant premises of 150 acres only. As per the Ministry of Environment, Forest & Climate Change (MOEF & CC), New Delhi notification, dated 14 th September, 2006 and its subsequent amendments, all Primary metallurgical processing industries are classified under Category A. The Ministry of Environment, Forest & Climate Change, New Delhi has accorded Terms of Reference (TOR) for the proposed expansion project vide letter no. J-11011/679/2009- IA II (I) dated 20 th March, The EIA Report has been prepared by incorporating the TOR stipulated by the Expert Appraisal Committee of MoEF & CC. Pioneer Enviro Laboratories & Consultants Private Limited, Hyderabad, which is accredited by NABET, Quality Council of India, vide certificate No. NABET/ EIA/ 1619/ RA 026, for preparing EIA report for Metallurgical Unit, have prepared Draft Environmental Impact Assessment (EIA) report for the proposed expansion project by incorporating the TOR approved by Ministry of Environment, Forest & Climate Change, New Delhi. The report contains detailed description of the following: Characterization of status of environment with in an area of 10 km radius from the plant site for major environmental components including air, water, noise, soil, flora, fauna and socio-economic environment. Assessment of air emissions, liquid waste and solid waste from the proposed expansion project along with the noise level assessment. Environmental Management Plan comprising of emission control measures proposed to be adopted in the expansion project, solid waste management, Greenbelt development. Post Project Environmental Monitoring & Budget for Environmental Protection Measures. 1
3 2.0 Plant Configuration and Production Capacity S.No The following table furnishes the existing and proposed units along with production capacities Unit Unit 1. Ferro Manganese (High carbon / medium carbon / low carbon) SEAF - 2. Silico Manganese (High carbon / medium carbon / low carbon) 5 X 9 & 1 X 5.4 MVA Existing Proposed Production Capacity Production Production After proposed Unit capacity capacity expansion 1,20,000 TPA 1,56,000 TPA 36,000 TPA (400 TPD) (520 TPD) (120 TPD) (or) 72,000 TPA (240 TPD SEAF - 4 x 9 MVA 85,000 TPA (283 TPD (or) 1,57,000 TPA (523 TPD) 3. Ferro Chrome (High carbon / medium carbon / low carbon) 85,000 TPA (283 TPD) 85,000 TPA (283 TPD) 4. Ferro Silicon (High carbon / medium carbon / low carbon) SEAF 2 x 9 MVA 25,000 TPA (83 TPD) 25,000 TPA (83 TPD) 5. Low carbon Ferro chrome ,600 TPA 3,600 TPA 6. Ferro Molybdenum Crucibles 3,600 TPA 3,600 TPA 7. Ferro Titanium x 400 Kg 3,600 TPA 3,600 TPA 8. Ferro Vanadium ,600 TPA 3,600 TPA 9. Calcium Aluminate based Synthetic slag SEAF 3 x 500 KVA 15,000 TPA (50 TPD) 15,000 TPA (50 TPD) 10. Power generation MW MW 2
4 1.2 Raw Materials The following will be the raw material requirement for the proposed expansion project: Raw Material Quantity (TPA) Sources Mode of Transport Ferro alloys Manganese Ore 4,41,000 Imported / indigenous from Sea, rail, road Chrome Ore 1,95,500 Karnataka / Orissa / Madhya Pradesh / Sea, rail, road Coke 1,14,320 Imported / Indigenous / Coal 1,59,975 Sea, road Singareni Colleries / imported Charcoal 40,000 Quartz 1,05,250 Rail, road Dolomite 82,000 Rail, road Mill Scales 10,000 Rail, road EC paste 7,815 Rail, road Magnesite 5100 Rail, road Ferro manganese slag 34,000 In plant generation conveyor Noble Ferro alloys Chrome Ore 7,059 Import & Indigenous Orissa Sea, rail, road Aluminimum Telic 5,690 Import -Dubai Sea, Road Flourspar 630 Import China Sea, Road Ferrosilicon 1,525 Captive Ilmenite 3,727 Indigenous - Orissa / Kerala Road Iron Nails 1,680 Indigenous Road lime 784 Indigenous Gujarat Road mill scale 5,690 Indigenous Road Sodium Nitrate 530 Indigenous Gujarat Road rutile 508 Import & Indigenous Orissa / Kerala Sea, Road V 2 O 5 4,000 Import Sea, Road MO 3 (Moly Oxide) 3,600 Import Sea, Road Calcium aluminate based Synthetic slag Hydrated Lime 9,000 Indigenous Rajasthan Road Indigenous - Chhattisgarh / Road Bauxite 4,500 Orissa Aluminium telic 900 Import Sea Aluminium catalyst 600 Indigenous / Gujarat Road 3
5 1.3 Manufacturing Process Ferro alloys Shri Girija Alloy & Power (I) Ferro manganese or silicon-manganese will be produced using manganese ore as main raw material in a sub-merged arc furnace using reducer (Coke) under high voltage. Similarly Ferro silicon will be produced using Quartz as main raw material and Ferro chrome using Chrome ore as raw material. Ferro Chrome Recovery unit The slag generated during Ferro chrome manufacturing will be sent to Ferro chrome recovery unit. Ferro chrome will be recovered through process of crushing, screening and jigging. Noble Ferro alloys Noble Ferro alloys are manufactured through Alumino Thermit Process. Alumino thermic process aims at the production of Ferro Alloys from the oxides of elements by reduction with Aluminum powder using exothermic heat of the reaction for smelting purpose. Calcium Aluminate based Synthetic slag Calcium Aluminate based Synthetic Slag is made of select raw material of Calcium and Aluminium, blended at a proper proportion, ground to powder, pelletized after churning, sintered or melted in kiln. 1.4 Water Requirement Total water requirement after expansion will be 1400 m 3 /day. Water required for the expansion project will be sourced from Samalkot canal. Approval from the Irrigation department for drawing 1400 m 3 /day of water has already been obtained. 4
6 The following is the break-up of the water requirement for proposed expansion project. WATER REQUIREMENT (For Expansion) S.No. Details of water requirement Quantity in (m 3 /day) 1. Make-up water for cooling Domestic Waste Water Generation Total 106 There will be not be any effluent generation from the proposed expansion as closed circuit system will be followed in the Ferro alloy unit. The only source of effluent generation will be sanitary waste water of 8 KLD will be treated in septic tank followed by sub-surface dispersion trench. In the existing plan also zero effluent discharge is being maintained. The following will be the total wastewater & it s break-up. WASTE WATER GENERATION (Expansion) S.No. Source Generation (m 3 /day) 1. Sanitary Wastewater 8 Total Wastewater Characteristics PARAMETER Sanitary waste water ph BOD (mg/l) COD (mg/l) TDS (mg/l) DESCRIPTION OF ENVIRONMENT Base line data has been collected on ambient air quality, water quality, noise levels, flora and fauna and socio economic details of people within 10 km radius of the plant. 5
7 2.1 Ambient air quality Ambient air quality was monitored for PM 2.5, PM 10, SO 2, NOx & CO at 8 stations including plant site during October 2016 to December The following are the concentrations of various parameters at the monitoring stations: Parameter Concentration PM 2.5 : 18.9 to 36.4 g/m 3 PM 10 * : 32.4 to 65.8 g/m 3 SO 2 : 9.8 to 16.3 g/m 3 NO X : 11.7 to 20.4 g/m 3 CO : 360 to 680 g/m Water Quality Surface Water Quality Samalkot canal (5.2 Kms.) is flowing within 10 Km. radius of the plant site. Two nos. of Surface water samples have been collected, one from upstream & other on downstream of Samalkot canal w.r.t the plant site to assess surface water quality. The analysis of samples shows that all the parameters are in accordance with BIS-2296 specifications Ground Water Quality 8 No. of ground water samples from open wells / bore wells have been collected from the nearby villages to assess ground water quality impacts and analyzed for various Physico- Chemical parameters. The analysis of samples shows that all the parameters are in accordance with BIS: specifications. 2.3 Noise Levels Noise levels were measured at 8 locations during day time & Night time. The noise levels at the monitoring stations are ranging from 46 dba to 64.6 dba. 6
8 3.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES 3.1 Prediction of impacts on air quality The likely emissions from the proposed project are PM 10, NOx & CO. The predictions of Ground level concentrations have been carried out using Industrial Source Complex (ISC-3) model. Meteorological data such as wind direction, wind speed, max. and min. temperatures collected at the site have been used as input data to run the model. Net Resultant maximum ground level concentrations during operation of expansion project Item PM 10 NO X CO ( g/m 3 ) ( g/m 3 ) ( g/m 3 ) Maximum baseline conc. in the study area Maximum predicted incremental rise in concentration due to emission from proposed expansion project Maximum predicted incremental rise in concentration due to vehicular emissions Net resultant concentrations during operation of the plant National Ambient Air Quality Standards The predicted results show that the net resultant concentration (max. baseline conc. + max. incremental rise in conc.) of PM 10, NOx and CO are well within the National Ambient Air Quality Standards after commissioning of proposed expansion project. Hence there will not be any adverse impact on air environment due to the proposed expansion project. 3.2 Prediction of impacts on noise quality The major sources of noise generation in the proposed expansion project will be DG sets. The ambient noise levels will be within the standards prescribed by MoEF i.e. the noise levels will be less than 75 dba during day time and less than 70 dba during night time acres (inclusive of existing) of extensive greenbelt already developed which helps to further attenuate the noise levels. Hence there will not be any adverse impact due to noise on population in surrounding areas due to the proposed expansion project. 7
9 3.3 Prediction of impacts on Water Environment Water drawl permission already obtained for entire quantity from State Irrigation Department. There will be not be any effluent generation from the proposed expansion as closed circuit system will be followed in the Ferro alloy unit. The only source of effluent generation will be sanitary waste water which will be treated in septic tank followed by sub-surface dispersion. In the existing plant, zero discharge is being maintained and will be continued even after expansion. Hence there will not be any adverse impact on water environment due to the proposed expansion project. 3.4 Prediction of Impacts on Land Environment There will not be any effluent generation from the proposed expansion as closed circuit system will be adopted in the ferro alloy unit. Sanitary waste water generated will be treated in septic tank followed by subsurface dispersion. All the required air pollution control systems will be provided to comply with CPCB / APPCB norms. All solid wastes will be disposed / utilized as per CPCB / APPCB norms Acres (inclusive of existing) of greenbelt has already been developed as per guidelines. Hence there will not be any adverse impact on land environment due to the proposed expansion project. 3.5 Socio - Economic Environment There will be lot of opportunities in employment to local people during construction as well as in operation phase. There will be further upliftment in Socio Economic status of the people in the area. 2.5% of expansion project cost will be allocated for CSR activities. Hence there will be further development of the area due to the proposed expansion project. 8
10 4.0 ENVIRONMENTAL MONITORING PROGRAMME In the existing plant online stack monitoring has been provided. Ambient Air Quality, Sack monitoring & effluent analysis will be carried out regularly as per CPCB norms and the analysis reports will be submitted to Ministry of Environment & Forest, Chennai & APPCB regularly. Online stack monitoring facility will be provided o furnace stacks. 5.0 ADDITIONAL STUDIES No Rehabilitation and Resettlement is involved in the proposed project. Hence no R & R study has been carried out. 6.0 PROJECT BENEFITS With the establishment of the proposed expansion project employment potential will increase. Land prices in the area will further increase. The economic status of the people in the area will improve due to the proposed expansion project. CSR activities will be taken up as per norms. Periodic medical checkups will be carried out. Top priority will be given to locals in employment. 7.0 ENVIRONMENT MANAGEMENT PLAN 7.1 Air Environment The following are air emission control systems proposed in the proposed expansion project: S.No. Source Control Equipment Maximum Particulate emission at the outlet Submerged Electric Arc Fume extraction & cleaning 1. Furnace (6 x 9 MVA) system With bagfilters 50 mg/nm Crucibles (8 x 400 Kg) Submerged Electric Arc Furnace (3 x 500 KVA) Fume extraction & cleaning system With bagfilters Fume extraction & cleaning system With bagfilters 50 mg/nm 3 50 mg/nm 3 The following air pollution control systems/ measures are proposed in the Plant: All conveyors will be completely covered with G.I. sheets to control fugitive dust. 9
11 All bins will be totally packed and covered so that there will not be any chance for dust leakage. All the dust prone points material handling systems will be connected with de-dusting system with bag filters. All discharge points and feed points, wherever the possibility of dust generation is there a de-dusting suction point will be provided to collect the dust. Raw material unloading areas will be provided with dust suppression system Greenbelt developed will help in attenuating air emissions further 7.2 Water Environment There will be not be any effluent generation from the proposed expansion as closed circuit system will be followed in the Ferro alloy unit. The only source of effluent generation will be sanitary waste water which will be treated in septic tank followed by sub-surface dispersion. 7.3 Noise Environment The major sources of noise generation in the proposed project will be DG sets. Acoustic enclosure will be provided to the DG set. All the machinery will be manufactured in accordance with MoEF&CC norms on Noise levels. The employees working near the noise generating sources will be provided with earplugs. The extensive greenbelt developed within the plant premises will help in attenuating the noise levels further. 7.4 Land Environment There will be not be any effluent generation from the proposed expansion as closed circuit system will be followed in the Ferro alloy unit. The only source of effluent generation will be sanitary waste water which will be treated in septic tank followed by sub-surface dispersion. All the required Air emission control systems will be installed and operated to comply with MOEF&CC / CPCB / APPCB norms. Solid wastes will be disposed off as per norms. Extensive greenbelt has been developed in the plant premises. Hence there will not be any impact on land environment due to the proposed expansion project. 10
12 Solid waste generation and disposal S.No Waste / By product Quantity (TPA) Method of disposal 1. Ferro Manganese slag 96,000 Will be used in manufacture of Silico manganese as it contains high MnO Silico Manganese slag 1,02,000 Will be utilized in road construction / land filled 3. 1,02,000 Will be utilized in road construction / land Ferro Chrome slag filled 4. 10,000 Will be utilized in road construction / land Ferro Silicon slag filled 5. Low carbon Ferro chrome slag 6,426 Once the product is manufactured, TCLP test will be conducted for the slag and will be used 6. Ferro Molybdenum slag 3, Ferro Titanium slag 3, Ferro Vanadium slag 3,960 for landfill / as per outcome of TCLP test sent to TSDF. 7.5 Greenbelt Development Greenbelt of 50.0 acres (inclusive of existing) has already been developed in the site premises. Capital cost for environment protection for the proposed expansion project will be Rs Crores. ********* 11
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