FOR THE PROPOSED EXPANSION OF FOUNDRY UNIT
ENVIRONMENTAL IMPACT ASSESSMENTFORTHEPROPOSEDEXPANSIONOFFOUNDRYUNIT
ATS.F.NO.211/1A,2A,2B,212/3A,3C&213/1,2A,
KURUDAMPALAYAMVILLAGE,COIMBATORENORTH,COIMBATOREDISTRICT
ExecutiveSummary
ProjectProponent
SAKTHI AUTO ANCILLARY PRIVATE LIMITED No. 211/1, Idigarai Road,
NGGO colony, Coimbatore – 641022
Preparedby
December2016
EIA report for the proposed expansion of foundry unit atKurudampalayam Village, Coimbatore North Taluk, CoimbatoreDistrictbyM/s.SakthiAutoAncillaryPvtLtd
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1.0 BRIEFDESCRIPTIONOFTHEPROJECTM/s. Sakthi Auto Ancillary Private Limited (SAAPL) is part of Sakthi Group, aprestigiousbusinessconglomerateinSouthIndia,isaleadingmanufacturerofGreyIronCastings. The production capacity of the foundry located at KurudampalayamVillage,CoimbatoreNorthTaluk,CoimbatoreDistrictis2400TonsperMonthofGrey&SGIronCastings.NowSAAPLproposedtoincreasethecapacityofitsproductionto5000Tonsper Month by replacing the induction furnaces and upgrading sand plant, mouldingmachines and coremakingmachines. The total cost of proposed expansion project isestimatedasRs.1472.69Lakhs.Asperthe latestEnvironmental ImpactAssessmentNotificationdated14thSeptember2006, theproposedexpansionof foundry (secondarymetallurgy industry) fallsunder‘Category B’ for which Environmental Clearance (EC) from State Level ImpactAssessmentAgency(SEIAA)isnecessary.InlinewithEIANotificationdated14.09.06,aTORmeeting was held for determining Terms of Reference (TOR) on 1st September2016 for the preparation of EIA report for the proposed expansionproject. Based onTOR conditions given by State Environmental Impact Assessment Authority vide itsletterNo.SEIAA/F.No.5573/2016/CBE/3(a)/TOR‐264/2016dated07.09.2016,thisEIAhasbeenprepared.1.1 LandRequirementThetotalareaoftheexistingfoundryis1.327hectaresandthebuiltareaisabout0.604hectares.Theproposedexpansionproposaldoesnotrequireanyadditional landarea.Thelanduseclassificationoftheprojectsiteisindustrialarea.Thelandusebreak‐upoftheexistingandafterexpansionistabulatedbelowinTable‐1.
TABLE‐1:LANDUSEBREAK‐UPOFPROJECTSITE
S.No.
DescriptionBeforeExpansion AfterExpansion
Area(Ha) Percentage(%) Area(Ha) Percentage(%)
1 Built‐uparea 0.604 45.5 0.604 45.5
2 Storagearea 0.015 1.1 0.025 1.9
3 Greenbeltarea 0.35 26.4 0.44 33.2
4 Openarea 0.358 27.0 0.258 19.4
Total 1.327 100 1.327 100
1.2 PowerRequirement
The power requirement will be increased from 4915 KVA to 9000 KVA after theproposed expansionwhichwill be sourced fromTANGEDCO. Tomeet the emergencypowerrequirementduringthegridfailure,adieselgeneratorwithcapacityof1000KVA
EIA report for the proposed expansion of foundry unit atKurudampalayam Village, Coimbatore North Taluk, CoimbatoreDistrictbyM/s.SakthiAutoAncillaryPvtLtd
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is already available. The requirement of the diesel will vary with TANGEDCO powerfailureanditsmaximumrequirementwillnotincreaseitsusageof500lit/day.1.3 RawMaterialsRequirementTherawmaterialsrequiredfortheproductionofcastingsincludingitsquantitybeforeandafterexpansionare tabulated inTable–2which isbeing sourced from the localmarketinandaroundCoimbatore.
TABLE–2:RAWMATERIALREQUIREMENT
S.No. DescriptionRequirement(Tons/Month)
BeforeExpansion AfterExpansion
1 SteelScraps&Borings 2165 4520
2 Pigiron 250 500
3 FerroSilicon 15 30
4 FerroManganese 10 20
5 FerroSiliconMagnesium 10 20
6 Inoculants 5 10
7 SilicaSand 250 500
8 Bentonite 30 50
9 CoalDust 20 301.4 WaterRequirementThewaterrequirementaftertheproposedexpansionwillbeincreasedfrom18KLDto32 KLD, which is being sourced from the Ashokapuram Village Panchayat. The totalwaterrequirementbeforeandafterexpansionisgiveninTable‐3.
TABLE–3:WATERREQUIREMENT
S.No. CategoryRequirement(KLD)
BeforeExpansion AfterExpansion1 SandMoulding 3.5 7.02 CoolingTowerMakeup 2.5 5.03 Domesticpurposes 12.0 20.0 Total 18.0 32.0
1.5 ManPowerRequirementThemanpowerrequiredfortheexistingfoundryis240No,whichwillbeincreasedto300Noaftertheproposedexpansion.
EIA report for the proposed expansion of foundry unit atKurudampalayam Village, Coimbatore North Taluk, CoimbatoreDistrictbyM/s.SakthiAutoAncillaryPvtLtd
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2.0 DESCRIPTIONOFTHEENVIRONMENT2.1 LocationanddescriptionofthesiteTheterrainofthelandintheplantsiteisplainandnowaterstreamspresentintheplantsitearea.TheenvironmentalsettingoftheproposedplantsiteisgiveninTable‐4.Studyareaof10‐kmradiusaroundtheprojectsiteisshowninFigure‐1.
TABLE–4:ENVIRONMENTALSETTINGIN10‐KMRADIUS
S.No. Particulars Details1 Latitude 09o24’00.20”N2 Longitude 77o36’05.12”E3 ElevationaboveMSL 442m4 Landuse IndustrialUse5 NearestHighway NH67(Coimbatore‐MettupalayamRoad)–
1.3km,W6 NearestRailwayStation CoimbatoreNorth–11.2km,S7 NearestAirPort Coimbatore–20km,SE8 NearestHabitation NGGOColony–0.5km,W9 NearestTown Coimbatore–10km,S10 NearestHarbour Cochin,Kerala–150km,SW11 ReserveForests ThadagamR.F.–5.5km,WNW12 NearestRiver NoyalRiver–8.0km,SSW13 Ecologicallysensitive Nilin10kmradius14 DefenseInstallation Nilin10kmradius15 Historicalplaces Nilin10kmradius16 Socio‐economicfactors NoResettlementandRehabilitationissuesare
involved
EIA report for the proposed expansion of foundry unit atKurudampalayam Village, Coimbatore North Taluk, CoimbatoreDistrictbyM/s.SakthiAutoAncillaryPvtLtd
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FIGURE‐1:STUDYAREAMAP–10‐KMRADIUS2.2 BaselineenvironmentalmonitoringBaseline environmental monitoring studies for the various environmental attributeswerecarriedoutduringJuly2016toSeptember2016coveringthewinterseason.Thedetailsofthebaselinestudyarepresentedasfollows:2.2.1 MeteorologyThe predominantwind direction observed during the study period is SouthWest for22.4%of the total timeand followedbyWestSouthWest for14.7%of the total time.Thecalmconditionswereobservedfor9.22%ofthetotaltime.Themeanmaximumandmean minimum temperatures recorded at site during study period were 28.5oC and20.1oC.Themaximumandminimumrelativehumiditywasobservedtobe74%and23%respectivelyduringthestudyperiod.2.2.2 AirQualityAmbientAirQualityMonitoring(AAQM)stationsweresetupateight locations.Theairsampleswereanalyzedasper standardmethods specifiedbyCentralPollutionControlBoard(CPCB),IS:5184andAmericanPublicHealthAssociation(APHA).
EIA report for the proposed expansion of foundry unit atKurudampalayam Village, Coimbatore North Taluk, CoimbatoreDistrictbyM/s.SakthiAutoAncillaryPvtLtd
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ThemaximumvalueforPM10wasobservedatThudiyaluras88.7‐µg/m3andminimumvalue forPM10wasobservedatSomayampalayamas28.2‐µg/m3.ThemaximumvalueforPM2.5wasobservedatThudiyaluras41.9‐µg/m3andminimumvalue forPM2.5wasobservedatSomayampalayamas13.7‐µg/m3.ThemaximumvalueforSO2wasobservedat Thudiyalur as 13.1‐µg/m3 andminimum value for SO2 <5.0‐µg/m3was observed atProject Site,Athipalayam,Chinnavedampatty&Somayampalayam.Themaximumvaluefor NO2 was observed at Thudiyalur as 33.9‐µg/m3 and minimum value for NO2 wasobservedatAthipalayamas9.4‐µg/m3.The concentrationsofPM10,PM2.5, SO2andNO2are observed to be well within the standards prescribed by Central Pollution ControlBoard(CPCB)forrural/residentialzone.2.2.3 WaterQualityThe water quality monitoring has been conducted at 8 ground water locationscovering10kmradialdistancewereexaminedforphysico‐chemical,heavymetalsandbacteriologicalparameters.Thewateringeneralisnotfitfordrinkingasmostoftheparameters are above the standards prescribed under IS 10500 drinking waterstandards. The pH value of the collected ground water in the study area variesbetween6.78and7.41andconductivityvariesfrom1210to10740µS/cm.TDSvalueswerefoundtobefrom680to7207mg/L.Thetotalhardnessvariedfrom260‐6340mg/L. The chloride values were found to be in the range 49 mg/L to 2148 mg/L.Metals such as Copper, Lead, Cadmium, Chromium, Arsenic, Selenium, andMercurywereobservedtobebelowdetectionlimitinthegroundwatersamples.2.2.4 SoilQualityEightlocationswithin10‐kmradiusoftheprojectsitewereselectedforsoilsampling.Ateachlocation,soilsampleswerecollectedfromthreedifferentdepthsviz.30cm,60cm and 90 cm below the surface and homogenized. The homogenized sampleswereanalyzedforphysicalandchemicalcharacteristics.Ithasbeenobservedthatthetextureofsoilismostly‘Clay’inthestudyarea.Thecommoncolorofthesoilislightbrown.IthasbeenobservedthatthepHofthesoilqualityrangedfrom7.96to9.01.TheElectricalConductivitywas observed to be in the range of 0.165 to 0.342S/cm.TheNitrogenvaluesrangedbetween23.6to78.1kg/haindicatingthatthesoilhas‘less’quantityofnitrogen.ThePhosphorusvaluesrangeinbetween52.7to208kg/haindicatingthatthesoilishaving‘high’to‘veryhigh’quantityofphosphorous.ThePotassiumvaluesrangein between 171 to 582 kg/ha indicating that the soils in the area have ‘moderate’ to‘high’ quantity of Potassium. Soil organic content varied from 0.84 to 1.54% whichindicatestheverylowleveloforganicmatter.
EIA report for the proposed expansion of foundry unit atKurudampalayam Village, Coimbatore North Taluk, CoimbatoreDistrictbyM/s.SakthiAutoAncillaryPvtLtd
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2.2.5 NoiseLevelsThenoisemonitoringhasbeenconductedfordeterminationofambientnoiselevelsattenlocationsinthestudyarea.Thedaytimenoiselevelatindustrialzonewasobservedtobe64.3dB(A)whichiswithintheprescribedlimitof75dB(A).Thedaytimenoiselevelatallresidentialzonewasobservedtobe50.9to54.4dB(A)whichiswithintheprescribedlimitof55dB(A).Thedaytimenoiselevelatcommercialzonewasobservedtobe60.1dB(A)whichiswellwithintheprescribedlimitof65dB(A).Thenighttimenoise level at industrial zone was observed to be within the prescribed limit of 70dB(A),whichwas58.1dB(A)atprojectsite.Thenight timenoise levelsatresidentiallocationswerefoundtobe40.4to43.9dB(A)withintheprescribedlimitof45dB(A).The night time noise level at commercial zone was observed to be well within theprescribedlimitof55dB(A)whichisobservedas52.3dB(A).2.2.6 EcologyFieldsurveyconductedduringthestudyperiodrevealedthattotalnumberof36specieshavebeenrecordedofwhichmaximumof24speciesareaccountedfortreesfollowedby12speciesofgrasses&Shrubs.ThadagamReservedforestislocatedat5.5kmWNWoftheprojectsite.Nowildlifesanctuariesornationalparksorbiosphereorhotspotsin10 km radius from the project site area. About 41 species of fauna componentsrecorded/reportedfromstudyareawhicharemainlybelongstomammals,birds,reptiles,amphibians and butterflies. Out of observed faunal components 4 species belongs toSchedule‐II,4speciesbelongstoSchedule‐IIIandrestofspeciesbelongstoSchedule‐IV.3.0 ANTICIPATEDENVIRONMENTALIMPACTS&MITIGATIONMEASURESTheanticipatedenvironmentalimpactsandmitigationmeasuresarepresentedinTable‐5.TABLE–5:ANTICIPATEDENVIRONMENTALIMPACTS&MITIGATIONMEASURES
Discipline PotentialNegativeImpacts
ProbableSource
MitigationMeasures Remarks
ConstructionalImpactWaterQuality
Increaseinsuspendedsolidsduetosoilrun‐offduringheavyprecipitation
Loosesoilatconstructionsite
Duringmonsoonseasonrunofffromconstructionsitewillberoutedtoatemporarysedimentationtankforsettlementofsuspendedsolids.
‐‐‐
AirQuality IncreaseindustandNO2concentration
LevelingactivityandVehicularmovement
Sprinklingofwaterintheconstructionareaandunpavedroads.Propermaintenanceofvehicleswill
Theimpactwillbelow,asthemainapproachroadistarred.
EIA report for the proposed expansion of foundry unit atKurudampalayam Village, Coimbatore North Taluk, CoimbatoreDistrictbyM/s.SakthiAutoAncillaryPvtLtd
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Discipline PotentialNegativeImpacts
ProbableSource
MitigationMeasures Remarks
bedone.Noise Increasein
noiselevelConstructionequipment
Equipmentwillbekeptingoodconditiontokeepthenoiselevelwithin85‐dB(A).
Workerswillbeprovidedwithnecessaryprotectiveequipmente.g.earplug.
TerrestrialEcology
Depressionofplantgrowth
Dustemissionfromconstruction
Landscapingandextensiveplantationwillbedone.
Plantationwillbedoneinconsultationwiththelocalforestdepartment.
OperationalImpactAirQuality Increasein
PM,SO2andNO2levelsinambientair.
Stackemissionsandmaterialhandling
HighefficiencyCassetteFiltertypefumeextractionsystemwillbeinstalledtocontroltheemissionfromproposedinductionfurnaces.DustcollectorsofrequiredsizewillbeprovidedforSandcooler/shotblastingmachine.AdequatestackheightwillbeprovidedasperCPCBguidelinesfortheproperdispersionofgaseouspollutants.Motorableroadsintheplantareawillbepavedtoreducedustemission.Plantationprogramswillbeundertakenaroundtheplantarea.Dustsuppressionmeasureswillbeimplementedmaterialhandlingarea.
Theresultantairqualitywillconfirmtothestipulatedstandards.Particulateemissionfromtheproposedfurnacesstackwillbekeptbelow150mg/Nm3.
Noise Increaseinnoiselevelsintheplantarea.
Equipmentinmainplantandauxiliaries
Equipmentwillbedesignedtoconformtonoiselevelsprescribedbyregulatoryagencies.Providingacousticenclosureassourcecontrol.Provisionofgreenbeltandplantationwouldfurtherhelpinattenuatingnoise.
Employeesworkinginhighnoiseareaswouldbeprovidedearplugsasprotectivedevice.
WaterQuality
Deteriorationofsurfacewaterquality.
Dischargefromdomesticusages.
AdequatecapacityofSewageTreatmentPlantisproposedtoprovidefortreatmentofsewage.
‐‐‐
Solidwaste Burntsand, From Burntsandwillbesent Effortswillbe
EIA report for the proposed expansion of foundry unit atKurudampalayam Village, Coimbatore North Taluk, CoimbatoreDistrictbyM/s.SakthiAutoAncillaryPvtLtd
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Discipline PotentialNegativeImpacts
ProbableSource
MitigationMeasures Remarks
Furnaceslaganddustfromfilter
knockoutsection,furnacesandAPCmeasures
backtothesandmixertousemultipletimes.Thefurnaceslagwillbeusedincementplant/roadlayingmaterial.
madetoutilizethesolidwastetotheextentpossible.
Ecologya.Terrestrial Impacton
plantspeciesEmissionsfromstack
Emissionwillbecontrolledaswellasdispersedthroughappropriatedesign.
Asambientairqualitywillbewithinlimits,noactiveinjurytothevegetationisexpected.
b.Aquatic Impactonaquaticlifeofthewaterbodies
DomesticSewage
Thedomesticwastewaterwillbeprovidedwithadequatetreatmentfacilities(STP)
Asthesewagewaterwillbetreatedproperlynosignificantimpactonaquaticlifeisexpected.
DemographyandSocio‐economics
Strainonexistingamenitieslikehousing,watersourcesandsanitation,medicalandinfrastructurefacilities.
Influxofpeopleofproposedexpansionemployeesaswellascontractor'semployees/labourers.
Mosttheworkersrequirementwillbefulfilledbylocalpeople.Nosignificantimpactisenvisaged
Overallsocio‐economicstatusoftheareaisexpectedtoimprove.
4.0 ENVIRONMENTALMONITORINGPROGRAM
Environmentalmonitoringwillbe conductedon regularbasisbySAAPL toassess thepollution level in the surrounding area. A comprehensive monitoring program issuggestedinTable–6.
TABLE–6:MONITORINGSCHEDULEFORENVIRONMENTALPARAMETERS
S.No.
Component Parameter NoofLocations
Frequency/
Duration
1 AmbientAirQuality
PM10,PM2.5,SO2,NO2,CO,Pb,As,Ni,NH3,O3,C2H6&BAP.
4 Onceinamonth
2 FugitiveEmission
PM10,PM2.5,SO2,NO2&CO 4 Onceinamonth
EIA report for the proposed expansion of foundry unit atKurudampalayam Village, Coimbatore North Taluk, CoimbatoreDistrictbyM/s.SakthiAutoAncillaryPvtLtd
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S.No.
Component Parameter NoofLocations
Frequency/
Duration
3 StackEmissionMonitoring
PM,SO2,NO2,CO &HC 6 Onceinamonth
4 SourceNoise InstantaneousNoiselevelindB(A)
6 Onceinamonth
5 AmbientNoiseQuality
Ambientnoiselevel(Leq,LDay&LNight)
4 Onceinamonth
6 GroundwaterQuality
ParametersspecifiedunderIS:10500,1991
2 Oncein3months
7 SoilQuality Parameterforsoilquality:pH,texture,EC,OrganicMatter,N,P,K,Na,Ca&Mg
2 Onceinayear
5.0 ADDITIONALSTUDIES Apreliminaryriskassessmentstudy,disastermanagementplan&occupationalhealth& safety has been carried out for the proposed expansion project and associatedfacilitieslikeHSDstorageandthebroadconclusionsareasfollows: There will be no significant community impacts or environmental damage
consequences;andThe hazardous event scenarios and risks in general at this facility can be adequatelymanagedtoacceptablelevelsbyperformingtherecommendedsafetystudiesaspartofdetailed design, applying recommended control strategies and implementing a SafetyManagementSystem.6.0 PROJECTBENEFITS
The basic requirement of the community needs will be strengthened by extendinghealthcare,educational facilities to thecommunity,strengtheningofexistingroads inthearea.SAAPLwill initiate theaboveamenitieseitherbyprovidingorby improvingthe facilities in the area, which will help in uplifting the living standards of localcommunities. Medical facilities will be augmented in dispensaries located near thefoundry area. These medical facilities would also be available to local people in thesurroundingincaseofemergencies.Theproposedexpansionfoundryprojectwillresultinimprovingthesocialinfrastructureinfollowingmanner: Generationofemploymentandimprovedstandardofliving; Establishmentofsmallscaleancillary&supplyindustries; Increasedrevenuetothestatebywayofroyalty,taxesandduties; Improvedcommunicationandtransportfacilitiesetc.
EIA report for the proposed expansion of foundry unit atKurudampalayam Village, Coimbatore North Taluk, CoimbatoreDistrictbyM/s.SakthiAutoAncillaryPvtLtd
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Thetotalmanpowerrequiredfortheproposedexpansionprojectduringtheoperationphaseisabout60personswhichwouldbemainlysourcedfromlocalcommunityinandaroundthe foundryand fewtechnicalpersonswillbeemployed fromoutsidearea. Inadditiontotheabove,indirectemploymentopportunitiesshallariseafterexpansionofthefoundry.7.0 EMP‐ADMINISTRATIVEASPECTSA permanent organizational set up will be formed to ensure the effectiveimplementationofmitigationmeasuresandtoconductenvironmentalmonitoring.ThemajordutiesandresponsibilitiesofEnvironmentalManagementCellwillbeasfollows: Toimplementtheenvironmentalmanagementplan; Toensureregularoperationandmaintenanceofpollutioncontroldevices; Toassureregulatorycompliancewithallrelevantrulesandregulations; TominimizeenvironmentalimpactsofoperationsbystrictadherencetotheEMP; Toinitiateenvironmentalmonitoringasperapprovedschedule; Review and interpretation of monitored results and corrective measures in case
monitoredresultsareabovethespecifiedlimit; Toreportthenon‐compliances/violationsoftheenvironmentalnormstotheboard
directorsofthecompany.Normalactivitiesof theEMPcellwillbesupervisedbySeniorGeneralManagerof theunitwhowillreporttotheUnitHeadoftheproposedproject.Environmentalengineer&techniciansarereporttheissuestotheSGMtomakethepossiblepreventiveactions.
8.0CONCLUSIONSTheproposedexpansionoffoundryprojectwillhavecertainlevelofmarginalimpactson the localenvironment.However,developmentof thisprojecthascertainbeneficialimpact/effects in termsofprovidingtheemploymentopportunitiesthat thesamewillcreate during the course of its setting up as well as during operational phase of theproject.Thus,itcanbeconcludedthatwiththejudiciousandproperimplementationofthepollutioncontrolandmitigationmeasures, theproposedexpansionprojectwillbebeneficialtothesocietyandwillhelpreducethedemand–supplygapofGreyIron&SGIron Castings and will contribute to the economic development of the region inparticularandcountryingeneral.
