PROPOSAL FOR ENVIRONMENTAL CLEARANCE (PUBLIC … · saurashtra enviro projects pvt. ltd. 347 xiv....

EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S. BILLET/ S.S. BILLETS, MS ROLLED BAR AND COAL BASED CAPTIVE POWER PLANT & WHRB

AT # Survey no. 175/1, Village – Samakhiyali, Tehsil - Bhachau, District – Kutch(Gujarat)

S. No. Product Existing (TPA) Proposed (TPA) Total (TPA) 1. Sponge Iron 2,25,000 1,48,500 3,73,500 2. M.S. Billets 3,36,600 92,400 4,29,000 3. TMT Bars 3,30,000 92,400 4,22,400 4. M S Rolled Bar 5346 1,497 6,843 5. Runner & Raiser 891 No change 891

Power Generation 6. Power Plant (AFBC) 25 MW 10MW 35 MW 7. Power Plant (WHRB) 8MW 8MW 16MW

Area –116.0 Acre Project Cost: -Existing- Rs. 380 Crore.; Proposed Cost - Rs. 216.0 Crore; Total cost- Rs. 596Crore.

Study Period: - December ’2017- January -February’ 2018

PROPOSAL FOR ENVIRONMENTAL CLEARANCE (PUBLIC HEARING)

("A" under category 3(a) of EIA Notification dated 14.09.2006 and its subsequent amendments) Gallantt Metal Limited

Authorized Signatory: - Dinesh Agrawal (Director) #Plot No 123, Ground Floor, Ward 10 BC, Opp. IFFCO Colony Gandhidham,

Kutch-370201 Gujarat, India. Email: - [email protected], [email protected] Phone No. - 02837-283555

ENVIRONMENTAL CONSULTANT ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

Accredited EIA Consultant Organization by NABET, QCI, New Delhi at S. No. 45 (MoEF&CC) List of Accredited EIA Consultant Organizations (as on August 7, 2017).

Validity: -28.05.2018 Corporate Office: -# 92 Heera Nagar - A, Near Shalimar Bagh, Ajmer Road, Jaipur (Raj.). - 302 021

Phone: - 0141-2354997, 2353996, Fax No.: - 0141 – 4026996 Email: - [email protected], Website: - www.enkayenviro.com

PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S. BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT & WHRB

CONTENTS

APPLICANT : GALLANTT METAL LIMITED DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR MAY' 2018 1

Gallantt Metal Limited AT # Survey no. 175/1, Village – Samakhiyali, Tehsil - Bhachau, District – Kutch (Gujarat)

S. No. Contents Page Nos.

1. Executive Summary - English 1 -24

2. Executive Summary - Gujrati 25-51

3. FORM-1 4-31

4. Draft EIA/ EMP REPORT 32-293

SECTION - I Introduction 33-72

SECTION - II Project description 73-96

SECTION - III Description of the Environment 97-156

SECTION - IV Anticipated Environmental Impact & Mitigation Measures 157-198

SECTION -V Analysis of Alternatives 199-200

SECTION -VI Environmental Monitoring Programme 201-213

SECTION - VII Additional Studies 214-244

SECTION - VIII Project Benefits 245-249

SECTION - IX Environmental Cost Benefits Analysis 250- 251

SECTION -X Environmental Management Plan 252- 265

SECTION -XI Summary & Conclusion 266-289

SECTION -XII Disclosure of Consultant Engaged 290-293

5. ANNEXURE 294-

I. COPY OF CONSENT TO OPERATE & AUTHORIZATION 294- 300

II. AMENDMENT IN CONSENT & AUTHORIZATION 301-306

III. CONSENT TO OPERATE FOR ADDITIONAL 8MW CPP 307-308

IV. MAP SHOWING TOPOGRAPHY, SURROUNDING FEATURES 309

V.

UNDERTAKING REGARDING NO LITIGATION PENDING

AGAINST THE PROJECT

310

VI. LAND DOCUMENTS 311-324

VII. LOCATION MAP 325

VIII. MOU FOR FLY ASH DISPOSAL 326-327

IX. SEWAGE TREATMENT PLANT DESIGN & PHOTOGRAPHS 328-340

X. ETP DESIGN & PHOTOGRAPHS 341-343


CONTENTS



XI.

GUJARAT WATER INFRASTRUCTURE LIMITED

AGREEMENT FOR WATER

344

XII. Copy of Manifest form FOR USED OIL and WASTE/ RESIDUES 345-346

XIII.

COPY OF HAZARDOUS WASTE MANIFEST FORM FOR

TRANSPORTATION OF HAZARDOUS WASTE UNDER

HAZARDOUS WASTE (MANAGEMENT, HANDLING AND

TRANSBOUNDARY MOVEMENT) RULES, 2016.

SAURASHTRA ENVIRO PROJECTS PVT. LTD.

347

XIV. COPY OF PREVIOUS ENVIRONMENTAL CLEARANCE 348-354

XV.

COPY OF APPLICATION SUBMIT TO CHIEF WILD LIFE

WARDEN STATING NO NATIONAL PARK, SANCTUARIES,

BIOSPHERE RESERVE, MIGRATORY CORRIDORS OF WILD

LIFE SANCTURY WITHIN 10KM RADIUS FROM PROJECT

BOUNDARY

355

XVI. COPY OF TERMS OF REFERENCE 356-366

XVII.

COMPLIANCE REPORT OF EXISTING ENVIRONMENTAL

CLEARANCE

367-489

XVIII.

COMPLIANCE REPORT OF EXISTING CONSENT TO

OPERATE FOR MANUFACTURING SPONGE IRON, TMT

BARS, MS/SS BILLETS, WASTE HEAT RECOVERY BOILER

(WHRB) AND CAPTIVE POWER PLANT

490-496

XIX. ANALYSIS REPORT OF STACK 497-513

XX. GOOGLE EARTH MAP 514

XXI. LAYOUT SHOWING EXISITNG AS WELL AS PROPOSED UNIT 515

XXII.

PHOTOGRAPHS SHOWING EXISTING AS WELL AS

EXPANSION UNIT

516-521

XXIII.

PHOTOGRAPHS SHOWING EXISTING GREEN BELT/

PLANTATION.

522-524

XXV.

MAP SHOWING SURROUNDING INDUSTRIAL AREA IN 10

KM RADIUS OF THE PROPOSED EXPANSION PROJECT

525

XXVI MAP SHOWING GEOLOGICAL FEATURES AND GEO- 526


CONTENTS



HYDROLOGICAL STATUS OF THE STUDY AREA

XXVII.

MAP SHOWING DRAINAGE OF THE PROJECT UP TO 5.0 KM

OF THE STUDY AREA

527

XXVIII.

APPLICATION SUBMITTED FOR APPROVAL OF

CONSERVATION PLAN FOR PEAFOWL

528

XXIX. MICRO METEOROLOGICAL DATA 529-568

XXX. BASELINE MONITORING REPORT 569-597

XXXI.

PHOTOGRAPHS SHOWING RAIN WATER HARVESTING

STRUCTURE.

598

XXXII. PHOTOGRAPHS SHOWING STACK 599

XXXIII. PHOTOGRAPHS SHOWING BAG FILTER, ESP 600

XXXIV. OCCUPATIONAL HEALTH RECORDS. 601-608

XXXV. ENVIRONMENTAL POLICY. 609

XXXVI. STANDARD OPERATING PROCEDURE 610

XXXVII.

HIERARCHICAL SYSTEM/ ADMINISTRATIVE ORDER OF

COMPANY

611

XXXVIII. NON COMPLIANCE REPORTING PROCEDURE 612

XXXIX. ONLINE STACK MONITORING SYSTEM. 613

XL. SLAG ANALYSIS REPORT 614

XLI. NABET CERTIFICATE 615-618

XLII. TRANPORTAION MAP 619

XLIII UNDER TAKING BY COMPANY 620

XLIV UNDER TAKING BY CONSULTANT 621

************

4

FORM - 1

5

APPENDIX - I

(See Paragraph – 6)

FORM - 1

S.

No.

Basic Information

Item : Details

1. Name of the Project : Proposed expansion project of Gallantt Metal Limited.

2. S. No. in the schedule : As per EIA Notification 14th September’ 2006, and its subsequent

amendments, this project is listed at schedule 3(a) Metallurgical

industries (ferrous & non ferrous) project.

3. Proposed Capacity/ Area/

length/ tonnage to be

handled/ command area/

lease area/ number of

wells to be drilled.

: S.

No.

Product Proposed Capacity After expansion (TPA)

1 Sponge Iron 1,48,500 3,73,500

2 M.S. Billets 92,400 4,29,000

3 TMT Bars 92,400 4,22,400

4 M S Rolled Bar 1,497 6,843

5 Runner & Raiser No change 891 (No change)

Power Generation

6 Power Plant (AFBC) 10MW 35 MW

7 Power Plant (WHRB) 8MW 16MW

Area for expansion 45.22 Acre (Out of 116.0Acre)

4. New/ Expansion/

Modernization.

: Expansion

5. Existing Capacity/ Area

etc.

: S. No. Product Existing Capacity (TPA)

1 Sponge Iron 2,25,000

2 M.S. Billets 3,36,000

3 TMT Bars 3,30,000

4 MS Rolled Bar 5346

5 Runner & Raiser 891

Power Generation

6 Power Plant (AFBC) 25 MW

7 Power Plant (WHRB) 8MW

Area 116.0Acre

� Consent to Operate for Manufacturing of existing products (i.e. Sponge

Iron, M.S. Billets, TMT Bars, MS Rolled Bar, Runner & Raiser) with 8

MW WHRB has been obtained from GSPCB, Gujarat vide letter no. PC/

CCA-KUTCH-341(5)/GPCB ID 17845/349490 dated 21.03.2016. Order

No. AWH/ 76789 dated 29.02.2016 which is valid up to 27.12.2020.

6

Enclosed as Annexure –I

� Amendment in Consent & Authorization has been obtained for

increase product manufacturing capacity vide letter No. PC/CCA-

Kutch-341(5)/GPCB ID17845/364967 dated 01.08.2016 which is

valid for 27.12.2020. Enclosed as Annexure-II.

� Consent to Operate for additional 8MW (Total Capacity- 17+8=25MW)

Captive Power Plant has been obtained from GSPCB, Gujarat vide

letter no. PC/ CCA-KUTCH-351(5)/GPCB ID 17845/412240 dated

11.05.2017 which is valid up to 27.12.2020. Enclosed as Annexure –

III.

6. Category of project i.e. 'A'

or 'B'

: Category –A

7. Does it attract the general

condition? If Yes, please

specify.

: No

8. Does it attract the specific

condition? If Yes, please

specify.

: No

9. Location

Plot/ Survey/ Khasra no. : Khasra No.:- 175/1

Village/ Town : Samakhiyali

Tehsil : Bhachau

District : Kutch

State : Gujarat

10. Nearest Railway Station/

Airport along with

distance in Km.

: Particulars Name Distance, Direction

(From Project Boundary)

Railway Station Samkhaiyali 1.04 Km, SE

Airport Kandla 47.72Km, SW

Source: - All aerial distances are taken with respect to Google Earth.

11. Nearest Town, City,

District Headquarters

along with distance in

Kms.

: Particulars Name Distance, Direction


Nearest Town Gandhidham 45 Km, SW

Nearest City Gandhidham 45 Km, SW

Nearest District

Headquarter.

Kutch 84.5 Km, NW

7

Source: - All aerial distances are taken with respect to Google Earth.

12. Village Panchayat, Zilla

Parishad, Municipal

Corporation, Local body

(Complete postal address

with telephone no. to be

given)

: Particulars Name Address

Village Panchayat Samkhaiyali Village – Samkhaiyali,

District – Kutch (Gujarat).

Nagar Palika Bhachau Ramwadi, Bhachau, Gujarat -

370140

Municipal Office Bhachau Bhachau, Gujarat

13. Name of the Applicant : Gallantt Metal Limited

14. Registered address : Gallantt Metal Limited

Plot No. 123, Ground Floor, Ward 10 BC, Opposite IFFCO Colony

Gandhidham, Kutch-370201 Gujarat, India.

15. Name : Dinesh Agrawal

Designation (Owner/

Partner / CEO)

: Director ( Power of Attorney )

Address : #Plot No 123, Ground Floor, Ward 10 BC, Opp. IFFCO Colony


Pin Code : 370201

E-mail : [email protected], [email protected]

Telephone no. : 02837-283555

Fax No. : 02836-235787

16. Details of alternative sites

examined, if any. Location

of these sites should be

shown on a Toposheet.

: No alternative site was examined, as the proposed expansion is coming up

within the existing premises. The project area falls on Survey of India

Toposheet No. - 41I/7, 8, 11 & 12.

The map showing location of the project site marked on a toposheet is

enclosed as Annexure – IV.

17. Interlinked projects : No

18. Whether separate

application of interlinked

project has been

submitted?

: No

19. If Yes, date of submission : Not Applicable

20. If no, reason : Not Applicable

21. Whether the proposal

involves approval/

Clearance under:-

: No.

8

If Yes, details of the same

and their status to be

given.

(a) The Forest

(Conservation) Act,

(1980)?

(b) The Wildlife

(Protection) Act,

1972?

(c) The C.R.Z.

Notification, 1991?

22. Whether there is any

Government Order/Policy

relevant/ relating to the

site

: No

23. Forest land involved

(hectares)

: No

24. Whether there is any

litigation pending against

the project and/or land in

which the project is

propose to be set up?

: There is no litigation pending against the project. Undertaking stating the

same is enclosed as Annexure-V.

(a) Name of the Court : Not Applicable

(b) Case No. : Not Applicable

(c) Orders/ directions of

the court, if any and

its relevance with the

proposed project.

: Not Applicable

25. Expected cost of the

project

: Project Cost Amount (In Crores)

Existing 380

Proposed 216

Total 596

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.).

9

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 on land use, land

cover or topography including

increase in intensity of land

use (with respect to local land

use plan)

No Land Use

A certificate has been obtained from Office of Collector, Kutch vide

letter no.- A-3-Land-N.A.-65(B)-C.No.44/2206-07 & N.A.-65(B)-

C.No.44/2009-10 dated 27.04.2007 & 05.11.2009 stating the land is

bonafide for industrial purpose. Enclosed as Annexure – VI This is

an expansion project. Hence, the impact on the physical environment

will be confined within the premises. The construction will be

carried out in an area of 18.5 acre for the proposed expansion i.e.

16% of the total land area 116 Acre. The impact on land use will not

alter significantly.

Land Cover

The soil cover in the area varies from few centimeters to 30cm in the

area. The alluvium cover varies from 0.6m to 1.20m. The regional

soil is poorly fertile. The land cover in the plant area depicts Semi -

arid soil cover supporting perennial plantation.

Topography

The highest and lowest elevation of the project site is 42MSL and

39MSL As, it is an expansion project, the impact on the physical

environment will be confined within the project site. The proposed

production will not cause any change in the topography at the site.

Change in Water Bodies

No natural water bodies exist within the project site.

1.2 Clearance of existing land,

vegetation and buildings?

No No clearance is required.

Vegetation

No such clearance of existing vegetation is required. As a part of

green area development 10.20 Acre area will be for expansion

phase. Local and native species will be planted to enhance the bio-

system.

1.3 Creation of new land uses? No No additional land will be required for proposed expansion. Only

construction activity will be done in future expansion area and will

be 18.5Acre. The land use for future expansion is as stated below:-

10

S.

No.

Land Use Area (Acre) Percentage

(%) Existing Proposed Total

1. Plant Area Office Area, Residential

Colony (All covered area).

40.60 - 40.60 35.0%

2. Paved Area (Road, Corridor, Parking and

Drainage).

2.10 2.10 1.810%

3. Green Belt Area 28.08 28.08 24.20

4. Area for Future expansion 45.22

38.98%

Plant Area, Paved area, Greenbelt -- 28.7 28.7

5. Open area - 16.52 16.52

Total 116.00 - 116 100

Existing Green area is 28.08 Acre which 24.20% and Proposed green area is 10.20Acre. Total Green area wil

be 33% of the total plot area.

1.4 Pre-construction

investigations e.g. bore

houses, soil testing?

No It is an existing project and therefore; no boreholes are required.

1.5 Construction works? No It is an existing project and the construction has already been done

in area of 42.7 Acre (Including residential colony) and proposed to

be increase ground coverage by 16% (18.5Acre) of the total land

area i.e. 116 Acre. The construction activities may have temporal

impact on the nearby receptors but it will not cause any permanent

physical changes to the locality. Temporal impacts will be mitigated

by effective EMP.

1.6 Demolition works? No Demolition works are not envisaged.

1.7 Temporary sites used for

construction works or

housing of construction

workers?

No During construction phase only local people will be employed. Thus,

no temporary sites for construction works or housing of

construction workers will be required.

1.8 Above ground buildings,

structures or earthworks

including linear structures,

cut and fill or excavations

No No cut and fill or excavation is envisaged. The changes in the visual

landscape will be envisaged due to construction 16% of the total

land area. As it is an expansion project, the impact on the physical

environment will be confined within the project site.

1.9 Underground works including

mining or tunneling?

No Not Applicable

11

1.10 Reclamation works? No Not Applicable

1.11 Dredging? No Not Applicable

1.12 Offshore structures? No Not Applicable

1.13 Production and

manufacturing processes?

No The existing production capacity of the plant will increase by Sponge

Iron by 66%, Ms Billets increase by 27.67%, MS Bar by and MS

Rolled increase by 28% with Captive Coal base AFBC Power Plant by

40% and WHRB increase by 100% The impact on physical

environment due to production and manufacturing process will be

confined within the project site (with effective EMP).

1.14 Facilities for storage of goods

or materials?

No No additional storage facility is required for the plant, as the existing

storage facility (Storage area -11482Sq.m.) is sufficient to cater the

additional load.

Proper storage facilities have already been made within the plant

premises.

1.15 Facilities for treatment or

disposal of solid waste or

liquid effluents?

No The existing facility for disposal of solid waste and liquid waste are

as follows:

Particulars Waste Quantity in TPA Treatment/

disposal Type of

Waste

Existing Proposed Total

Solid Waste

(TPD)

Slag 21250 5833 27083 Sold to road

construction

activity.

Total Ash 51400 28077 79477 Sold to brick

manufacturing

unit or used as

binding

material for

land filling.

MOU for fly

ash disposal

and using the

TSDF facility at

Surashtra

Enviro

Projects Pvt.

Ltd. is

enclosed as

Annexure-

VIII.

12

Municipal

Solid Waste

(Kg/ day)

Biodegrad

able

480 145 625 Sent to

Municipal

Council

Bhachau,

Gujarat

Domestic

Waste

water

(KLD)

Domestic

waste

water

105 30 135 Treated in

existing

Sewage

Treatment

Plant (200

KLD).STP

photographs

are enclosed

as Annexure-

IX.

Waste

Water

(KLD)

Industrial

waste

water

(cooling,

boilers,

process,

DM water

rejection)

135.5 73.50 209 Waste water

generated

from cooling

tower, boiler

and process

will be treated

in ETP (200

KLD) and

reused for

green belt at

premises and

dust

suppression

purpose at

premises.

Annexure- X..

The impact due to this is insignificant as the proposed solid waste or

liquid effluent disposal will follow the existing practice.

1.16 Facilities for long term

housing of operational

workers?

No The unit has existing housing facility (224 Nos.) for operational

employees (1250) in an area of 7.2 Acre situated in SE direction

towards from the project site. No additional housing facility is

required.

1.17 New road, rail or sea traffic

during construction or

operation?

No Proposed expansion Project: - During proposed expansion project

additional internal road networks will be developed for internal

connectivity for an area of 0.40 Acre. However, existing unit is well

connected with road and rail transport. The existing infrastructure is

13

sufficient. Thus, this will have insignificant impact on the physical

environment.

1.18 New road, rail, air waterborne

or other transport

infrastructure including new

or altered routes and stations,

ports, airports etc?

No No new road, rail, air waterborne or other transport infrastructure

including new or altered routes and stations, ports, airports etc. will

be required.

1.19 Closure or diversion of

existing transport routes or

infrastructure leading to

changes in traffic movements?

No There will be no closure or diversion of existing transport routes or

infrastructure leading to changes in traffic movements will be

required for proposed expansion project.

1.20 New or diverted transmission

lines or pipelines?

No Not Applicable.

1.21 Impoundment, damming,

culverting, realignment or

other changes to the

hydrology of watercourses

or aquifers?

No There will be no impoundment, damming, culverting, realignment or

other changes to the hydrology of watercourses or aquifers.

1.22 Stream crossings? No Not Applicable.

14

1.23 Abstraction or transfers of

water from ground or surface

waters?

No No abstraction or transfer of water from ground for the proposed

expansion project, as the water demand will met out through canal

from Gujarat Water Infrastructure Limited and the permission has

been obtained from the Office of GWIL, Gandhinagar vide letter no.

GWIL/ Kutch/ Ind. Conn. / 3000 dated 30.12.2010. Enclosed as

Annexure –XI.

The water demand for the industrial process and domestic process

is given below:

S.

No.

Particulars Water Demand (KLD)


1. Industrial

a. Cooling 485 133 618

b. Boiler 428 233 661

c. Process 145 96 241

2. Domestic 215 61 276

3. Plantation/Ot

hers

45 14 59

Total 1318 537 (343 Fresh

+ 194 Recycled)

1855 (1661

fresh + 194

Recycled)

Source: - Water from GWIL water supply system.

1.24 Changes in water bodies or

the land surface affecting

drainage or run-off?

No There is no water body and natural drainage passing through the

project area, as the nearest water body is situated at a distance

Adhoi Nadi - 2.80.km towards North which is a non perennial river.

Hence, there is no impact on water bodies.

1.25 Transport of personnel or

materials for construction,

operation or

decommissioning?

No Construction Phase

During construction phase 110 local people will be employed and

they will use public transport and the construction material and

machinery required will be mobilized from the local area, thus, the

impact due to the same will be temporal.

Operational Phase

The proposed expansion project will require additional man power

of 290 workers. The housing facility (224 nos.) for the employees

(1250Nos.) has been provided. Thus, during operational phase there

will be significant impact to the physical environment due to

additional traffic load.

1.26 Long-term dismantling or No Restoration works for the project on long-term will be an ongoing

15

decommissioning or

restoration works?

activity, which will not have any impact on physical environment.

1.27 Ongoing activity during

decommissioning which could

have an impact on the

environment?

No Not Applicable

1.28 Influx of people to an area in

either temporarily or

permanently?

No The local people will be provided employment. It is proposed to

employ 290 persons in the expansion phase.

S. No. Category No. of Persons


1. Permanent Staff 355 70 425

2. Skilled Workers 225 60 285

3. Semi-Skilled worker 130 50 180

4. Unskilled worker 250 110 360

Total 960 290 1,250

There is increment of 30.21% employment after proposed

expansion project. This will have minimal impact on coming

permanent of people.

1.29 Introduction of alien species? No No alien species are existing and will not be introduced.

1.30 Loss of native species or

genetic diversity?

No The loss of native species or the genetic diversity in case of

expansion project attracts minimal variation. The area is under

green cover is 24.20% and only 8.8% will be enhanced.

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):-


confirmation.

Yes/

No

Details thereof (with approximate quantities/ rates, wherever


2.1 Land especially undeveloped

or agricultural land (ha).

No The proposed expansion is coming up within existing land area of

116 Acres. No additional land is required for proposed expansion.

16

2.2 Water (expected source &

competing users) unit: KLD.

No For proposed expansion 537KLD (343 Fresh + 194 Recycled) water

will be additional required which will be met out from GWIL,

Ghandinagar.

S.

No.

Particulars Water Demand (KLD)


1. Industrial

a. Cooling 485 133 618

b. Boiler 428 233 661

c. Process 145 96 241

2. Domestic 215 61 276

3. Plantation/Ot

hers

45 14 59

Total 1318 537 (343 Fresh

+ 194

Recycled)

1855 (1661

fresh + 194

Recycled)


2.3 Minerals (MT). No Bricks and stone (locally available in the market) will be required for

plant construction. 18.5 Acre area will be under construction for

proposed expansion out of 116.0 which is only 16% of the total plot

area and will be confined to the project area.

Raw material for production process Coal (4,00,392 and 2,62,665

TPA), Iron ore (5,97,600 TPA) will be procured for the proposed

expansion project

2.4 Construction material – stone,

aggregates, sand/ soil

(expected source – MT).

No For the construction activity Cement, stones, aggregates and sand

will be used, which will be procured from nearby area.

2.5 Forests and timber (source –

MT).

No Not Applicable as fabrication will be done at site.

2.6 Energy including electricity

and fuels (source, competing

users) Unit: fuel (MT), energy

(MW).

No Details as given:-

Phase Demand (MW) Expected Source

Electricity

Existing 33 MWH Captive Power Plant and

remaining will be met

from State Grid as and

when required.

Proposed 18 MWH

Total 51 MWH

Fuel (for machinery operations)– TPA

Fuel Existing Proposed Total

17

Diesel 1.667 - 1.667

CPP & WHRB (MT)

Imported Coal 187617.6 75047 262664.6

Dolochar 58290 38471 96762

Sponge Iron (MT)

Coal 241200 159192 400392

Source: Imported

2.7 Any other natural resources

(use appropriate standard

units)

No No other significant resources other than above are used.

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.


confirmation.

Yes/

No



3.1 Use of substances or

materials, which are

hazardous (as per MSIHC

rules) to human health or the

environment (flora, fauna, and

water supplies).

No As per MSIHC rules, no hazardous chemical or materials will be

used, which affect the human health or the environment.

Only HSD will be store as fuel for machinery at site which is under

flammable chemical.

Fuel Quantity (TPA) Storage (KL)

Existing Proposed Existing Proposed

Diesel 1.667 - 60 -

Total 1.667 60

Safety Measures:-

� Not expose to heat and naked lights, keep containers and valves

closed when not in use.

� Personal Protective equipment: Canister type gas mask. PVC or

Rubber. Goggles giving complete protection to eyes. Eye wash

fountain with safety.

*Source: - Material Safety Data Sheet.

3.2 Changes in occurrence of

disease or affect disease

vectors (e.g. insect or water

borne diseases).

No None

3.3 Affect the welfare of people

e.g. by changing living

No The proposed expansion project will directly/ indirectly develop the

area by providing employment opportunities.

18

conditions?

3.4 Vulnerable groups of people

who could be affected by the

project e.g. hospital patients,

children, the elderly etc.

No Use, storage, transport, handling or production of substances or

materials will not affect vulnerable groups (if Any) as the project

activity is isolated within closed compounded walls.

3.5 Any other causes No Nothing significant.

4. Production of solid wastes during construction or operation or decommissioning (MT/Month)

S.

No.

Information/Checklist

confirmation

Yes/

No



4.1 Spoil, overburden or mine

wastes.

No Not Applicable.

4.2 Municipal waste (domestic

and or commercial wastes)

Yes Approx. 290 people (after expansion) will be employed. Domestic

waste will be generated for expansion phase at project site. The

domestic waste is collected in dustbins, segregated and disposed off

to Municipal Council Sites, Bhachau.

4.3 Hazardous wastes (as per

Hazardous Waste

Management Rules)

No

Authorization for hazardous waste is obtained with CTO is enclosed

as Annexure- II.

Particulars Hazardous Waste Quantity in TPA Treatment/

disposal Type of

Waste


Hazardous

Waste

Used Oil

(5.1)

2.063 1.13 3.19 Used oil is sent to

Hindustan Oil

Industries,

Gandhidham, Gujarat

Enclosed as

Annexure-XII. and

Used Ion exchange

resin is sent to

Saurashtra Enviro

Projects Pvt. Ltd.

Enclosed as

Annexure-XIII.

Used Ion

exchange

resin

(34.2)

0.35 0.19 0.54

Tar

residue

(13.2)

3.6 - 3.6

4.4 Other industrial process

wastes.

Yes Other industrial process waste i.e. slag and fly ash will be generated.

Particulars Waste Quantity in TPA Treatment/ disposal

Type of

Waste


Solid Waste Slag 21250 5833 27083 Sold to road construction activity.

19

(TPD)

Total Ash 51400 28077 79477 Sold to brick manufacturing unit or used as

binding material for land filling. MoU is enclosed

as Annexure-VIII.

4.5 Surplus product. No No surplus product will be generated.

4.6 Sewage sludge or other sludge

from effluent treatment.

Yes The wastewater generated by project activities is being treated in

the existing STP based on moving Bed Biofilm Reactor (MBBR) with

capacity 200 KLD capacities and approx. The solid from the sludge is

200kg generated and utilized as manure for greenbelt development/

plantation within the plant premises. The photographs are enclosed

as Annexure-IX.

4.7 Construction or demolition

wastes.

No There is no considerable C&D waste generated.

4.8 Redundant machinery or

equipment.

No There will no redundant machinery or equipment.

4.9 Contaminated soils or other

materials.

No There will not be any contaminated soils or other materials

4.10 Agricultural wastes. No There will not be any agricultural wastes

4.11 Other solid wastes. No There will be no other solid waste.

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

S.

No.


confirmation

Yes/

No



5.1 Emissions from combustion of

fossil fuels from stationary or

mobile sources.

No Stationary Sources: Stack emission from the Rotary kiln, Induction

furnace, Coal Crusher Stack, Reheating furnace & DG sets are

envisaged for existing and Proposed phase. The details are given

below:-

Mobile Sources: Transportation is the main source in existing and

proposed phase. The Emission details are given below:

Emission Source Emission rate

Line emissions PM10 – 1.31x10-4 g/s/m

PM2.5 – 6 x 10-5 g/s/m

NOx – 1 x 10-3 g/s/m

CO – 3.75 x 10-3 g/s/m

SO2 – 1.25 x 10-4 g/s/m

Emissions from combustion of fossil fuels from mobile sources will

be maintained within the prescribed Environmental Regulatory

Standards.

20

Source Management

Transportation � PUC certified vehicles will be used;

� Plantation will be done at the periphery of

the proposed project and local species will

be planted.

� 33% area is being/will be under green

cover.

Emission from Stack (Existing)

S.

No

.

Parameters Unit

s

Captive

Power

Plant

(25MW

)

Stack-I

Rotary

Kiln No.

1 & 2

Stack-II

Rotary

Kiln No.

3 & 4

Stack-

III

Inductio

n

Furnace

No. 1 & 4

Stack-IV

Inducti

on

Furnace

No. 2 &

3 Stack-

V

Inductio

n

Furnace

No. 5

Stack-VI

Coal

Crushe

r

Stack-

VII

Re-

heating

Furnace

Stack-

VIII

DG Sets

3 nos of

Stack-IX

1 Stack Height M 95 40 35 48 48 48 30 30 12

2 Top

diameter of

flue

M 2 1 1 1 1 1 1 1 0.5

3 Flue gas

velocity

m/se

c

10 10 10 7 7 7 10 8 10

4 Exit Flue gas

temperature

oK 393 393 393 373 373 373 373 423 453

5 Flue gas flow

rate

m3/s

ec

31.41 7.85 7.85 5.5 5.5 5.5 7.85 6.28 1.96

6 Emission rate at stack exit

A

PM10

emission

rate

g/s 1.7 0.81 0.81 0.55 0.55 0.55 0.8 0.25 0.09

B PM2.5

emission

rate

g/s 1.05 0.51 0.51 0.34 0.34 0.34 0.5 0.16 0.06

C NOx g/s 31.05 7.76 7.76 5.15 5.15 5.15 -- -- 1.84

D SO2 g/s 12.2 4.22 4.22 -- -- -- -- -- 0.75

7 APCM ESP ESP ESP Bag

House

Bag

House

Bag

House

Bag

House

Bag

House

--

Stack Emission Details (Proposed Expansion)

S.

No.

Parameters Units Captive Power

Plant (10 MW)

Stack-I

Rotary Kiln No.5

Stack-II

Induction Furnace

No. 6

Stack-III

21

1 Stack Height M 90 48 48

2 Top diameter of

flue

M 2 1 1

3 Flue gas

velocity

m/sec 10 10 7

4 Exit Flue gas

temperature

oK 393 393 373

5 Flue gas flow

rate

m3/sec 31.41 7.85 5.5


A

PM10 emission

rate

g/s 0.8 0.32 0.22

B PM2.5 emission

rate

g/s 0.5 0.2 0.137

C NOx g/s 3.15 3.925 --

D SO2 g/s 3.15 2.4 --

E Mercury (Hg) g/s 0.0009 -- --

7 APCM ESP ESP Bag House

5.2 Emissions from production

processes.

No To control the emission from production process:-

Process Emission from Pollutant Control Measures

Production

Sponge Iron

Manufacturing

Rotary Kiln

PM, SOx,

NOx

Existing:

� Adequate Stack height 35m ESP in Kiln is

installed.

Proposed:

� For Rotary Kiln ESP will be installed.

Power

Generation

from CPP and

WHRB

Boiler PM, SOx,

NOx

Existing:

� Adequate Stack height 95m ESP is installed.

Proposed:-

� ESP and spark Trapper will be used.

Fluidized Bed

Combustion

(CFBC) /

Atmospheric

Fluidized Bed

Combustion

(AFBC) Boiler

PM, SOx,

NOx

Existing:

� Adequate Stack height 95m ESP is installed.

Proposed:

� Existing Stack will be utilized.

� Power plant ESP and spark Trapper will be used.

22

TMT Bar

Manufacturing

Reheating

furnace

PM, SOx,

NOx

Existing:

� Adequate Stack height 30m is installed.

� Gas cooler + Bag filter is installed

Proposed: No reheating furnace is proposed.

M.S. Billet

Manufacturing

Induction

Furnace

PM, SOx,

NOx

Existing:

� Adequate Stack height 48m is installed.

� Gas cooler + Bag filter + Spark Trapper +Pop Pet

Dampers is installed.

Proposed: No reheating furnace is proposed.

All adequate measures will be strictly followed to keep the pollution level well within the limits.

5.3 Emissions from materials

handling including storage or

transport

No Fugitive emission from the Storage and transport is:

Particular Emission from Pollutant Control Measures

Storage

Construction Phase Raw Material Loading,

Unloading

Dust

Water Sprinkling at dust prone area

Operational Phase Raw Material loading,

unloading, transfer point

and storage device.

Dust

Transportation

Construction Phase Trucks movement, Heavy

earth moving machinery,

Installation of Machinery

Dust, SOx,

NOx

� Water Sprinkling at dust prone area

� To avoid the tail-pipe emissions and

exhaust gas, new and PUC certified

vehicles will be used.

Operational Phase � Coal Crusher House

� Raw material feed area

� Product separation

area

� Bagging area

Dust � Water Sprinkling, Stack height 30m

with Bag house is installed at Coal

Crusher House

5.4 Emissions from construction

activities including plant and

equipment

No The construction work will be for structure foundation and

equipment erection in the area of 18.10 Acre which is only 15% of

the total land area. The emission from the construction activity with

equipment erection will be mainly PM, SOx, NOx; The emission is as

under activity:-

Particulars Emission Mitigation Measure

Raw material PM10, SOx, NOx Materials Sourced Locally

23

Transport

Equipment

Transport

PM10, SOx, NOx Improved Site Logistics & Crane

Sizing

Construction

workers

PM10, SOx, NOx Worker Carpooling

Welding and

Bolting

PM10, SOx, NOx Electrical Welder in place of

Diesel Welder

5.5 Dust or odors from handling

of materials including

construction materials,

sewage and waste.

No Construction: - Dust will be generated during the construction of

plant and heavy earth moving machineries. However, water

sprinkling will be done to reduce the impact.

The odor generated due to treatment of waste water will be confined

to the project only.

5.6 Emissions from incineration

of waste

No There will be no incineration of waste.

5.7 Emissions from burning of

waste in open air (e.g. slash

materials, construction

debris).

No There is no burning of waste in open air.

5.8 Emissions from any other

sources

No No other source is significant.

6. Generation of Noise and Vibration, and Emissions of Light and Heat.

S.

No.


confirmation

Yes/

No


possible) with source of information data with source of

information data.

24

6.1 From operation of equipment

e.g. engines, ventilation plant,

crushers

Yes Existing Phase: The main noise generating sources in the existing

plant is compressors house, material handling, process plant, D.G.

set and transportation vehicles etc.

Proposed Phase: Capacity enhance of Boiler, Crusher house

capacity, Induction furnace will be in expansion phase which will be

cause of Noise and vibration generation source.

Mitigation Measures:- The noise transmitted outside the plant

boundary is low as most of the noise generating equipments is in

closed structures with acoustic enclosure. However, the following

measures is being/will be adopted to control the noise:-

� Proper and regular maintenance of machinery.

� PPE’s is being/will be provided.

� Periodical medical checkup is being /will be conducted.

� Measures will be taken to contain noise levels up to 85dB (A).

� An area of about 38.28 Acre. (33%) will be under greenbelt,

which will help to contain the emission within the lease area.

6.2 From industrial or similar

processes.

Yes There is additional source of noise generation due to steel melting

shop, mould removal process, fettling operation, rolling mill are the

rollers of the different mills, blowers, compressors and standby DG

set. Following measures will be taken to reduce the noise:-

� Proper maintenance and lubrication of plant machineries.

� Vibrations are being / will be monitored and will be controlled

appropriately.

� Installation of barriers between noise source and receiver can

attenuate the noise levels.

� PPE’s is being / will be provided to all the workers.

� Noise levels generated is being / will be maintained to comply

with the Factories Act & Rules and will not exceed 75 dB(A) at 1m

distance.

� Implementation of green belt (33%) within the premises of plant

will help to absorb the noise.

� Proper lubrication and housekeeping is being/ will be usually

done to avoid excessive noise generation.

6.3 From construction and

demolition

No There will be noise generated from stationary equipment such as

pumps, generators, compressors, etc. These types of equipment

25

operate at a constant noise level under normal operation and are

classified as non-impact equipment.

6.4 From blasting or piling No Not Applicable.

6.5 From construction or

operational traffic.

No Noise generated during operational traffic i.e. due to operation of

machineries and equipments, vehicular traffic and material

transportation within the project site. Further due to natural

attenuation effects, by proper green belt development, design/

maintenance of machines, etc., the impact on noise levels will be

minimal. Measures are taken to contain noise levels up to 85 dB (A).

6.6 From lighting or cooling

systems.

No Not Applicable.

6.7 From any other sources No No other sources are significant.

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.


confirmation

Yes/

No

Details there of (with approximate quantities/rates, wherever


7.1 From handling, storage, use or

spillage of hazardous

materials.

No The risks of contamination of land or water from releases of

pollutants during handling, storage, use and spillage of pollutants.

Details are as given below:-

S. No Fuel Quantity (TPA) Storage capacity (KL)


1. HSD 1667 - 60 -

Total 1667

Safety Measures:-

� Not expose to heat and naked lights, keep containers and valves

closed when not in use.

� Personal Protective equipment: Canister type gas mask. PVC or

Rubber. Goggles giving complete protection to eyes. Eye wash

fountain with safety.

*Source: - Material Safety Data Sheet.

7.2 From discharge of sewage or

other effluents to water or the

land (expected mode and

place of discharge).

No Waste water generated will be mainly from cooling and boiler blow

down and treated in ETP and further reused for green belt

development and dust suppression purpose. Domestic wastewater

will be generated from the plant, which will be treated in existing

STP and treated water will be used in greenbelt development.

26

7.3 By deposition of pollutants

emitted to air into the land or

into water.

No The ground level concentrations will be computed for 24-hr average.

The maximum GLC’s falling within the project area for the given

meteorological and topographical conditions is calculated.

Pollutant Maximum Incremental

Concentration (µµµµg/m3)

Direction

PM10 2.2 SSW

PM2.5 1.4 SSW

NOx 13.5 SSW

SO2 9.2 SSW

Hg 0.001 SSW

Isopleths showing Ground Level Concentration shown on Google

map has been given in Section-IV, Sub- Section – 4.3.3.5 of the Draft

EIA/EMP report.

7.4 From any other sources. No There will not be any other sources, which will contaminate land

and water resources.

7.5 Is there a risk of long term

build up of pollutants in the

environment from these

sources?

No Risk of long term build up pollutants in the environment will be

nullified by effective EMP. Periodic monitoring is done for the air,

water and soil in the unit premises and surrounding areas.

8. Risk of accidents during construction or operation of the Project, which could affect human health

or the environment.

S.

No.


confirmation.

Yes/

No



8.1 From explosions, spillages,

fires etc from storage,

handling, use or production of

hazardous substances.

No There will be no hazardous substance or chemical generated used in

the proposed expansion project. Risk of Fire cannot be averted. Due

care will be taken to avoid such accident.

S. No Fuel Quantity (TPA) Storage capacity (KL)


1. HSD 1667 - 60 -

Total 1667 60

All precautionary measures are adopted:

Risk of accidents Measures

27

Explosions &

Fire, Heat stress,

Burning

� Fire detection alarm is/will be installed.

� ABC type fire extinguishers of different

capacity are / will be installed at various

places to avoid any fire hazard.

� Periodic condition assessments in addition to

routine inspection, testing, and maintenance

will be done.

� Access to these areas is / will be limited only

to those having official business in the area.

Proximity of the public to transformers will

be restricted

� Knowledge of alarm system is / will be given

to every employee.

� However, to meet out the minor incidences

and accidents First Aid measures are / will

be provided at site.

� Pollution abatement measures are / will be

installed to avoid any kind of risk and

contamination.

� All employees are/ will be made aware of the

safety and health hazards, which can occur in

the industry.

� Personal Protective Equipment (Spats, Boots,

Gloves, and Helmets with face-shield or

Goggles) is/will be provided.

� Health surveillance is/will be conducted as

per Factory Act.

8.2 From any other causes. No None

8.3 Could the project be affected

by natural disasters causing

environmental damage (e.g.

floods, earthquakes,

landslides, cloudburst etc)?

No As per the 2002 Bureau of Indian Standards (BIS) seismic zone map

of India, the region is categorized as “Severe” Zone-IV.

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.


confirmation.

Yes/

No



28

9.1 Lead to development of

supporting cities, ancillary

development or development

stimulated by the project

which could have impact on

the environment e.g.:

• Supporting infrastructure

(roads, power supply,

waste or waste water

treatment, etc.)

• housing development

• extractive industries

• supply industries

• other

No None

9.2 Lead to after use of the site,

which could have an impact

on environment

No With effective EMP at project site , no impact will be significant

9.3 Set a precedent for later

developments

No Nothing significant.

9.4 Have cumulative effects due

to proximity to other existing

or planned projects with

similar effects

No The cumulative effect on environment cannot be ruled. However,

adequate control measures will be implemented for expansion.

Environmental Sensitivity (within 15 km radius). Toposheet showing Environmental Sensitivity is enclosed as

Annexure –IV.

S.

No.

Areas Name/

Identity

Details thereof (with approximate quantities/rates,

wherever possible) with source of information data.

1 Areas protected under

international conventions,

national or local legislation for

their ecological, landscape,

cultural or other related value.

None None

2 Areas which are important or

sensitive for ecological reasons -

Wetlands, watercourses or other

water bodies, coastal zone,

S. No. Particulars Distance (Km) Direction


Water Bodies

29

biospheres, mountains, forests. 1. Kara Vokra 7.60 WSW

2. Gupt Nadi 4.50 SW

3. Amliyara Nadi 8.15 S

4. Vango Nadi 10.45 SE

5. Khari River 9.82 E

6. Pipla Talav 6.06 E

7. Babudi Nadi 13.50 E

8. Adhoi Nadi 2.80 N

9. Gorasar Talav 4.50 SSE

Forests

1. R.F. Near Gamdau Village 11.50 NNE

*Source: All distances are taken with respect to Google Earth.

3 Areas used by protected,

important or sensitive species

of flora or fauna for breeding,

nesting, foraging, resting, over

wintering, migration.



1. R.F. Near Gamdau Village 11.50 NNE


4 Inland, coastal, marine or

underground waters

Gulf of Kutch 40.0Km, SW direction

5 State, National boundaries None within 15 Km radius.

6 Routes or facilities used by the

public for accessto recreation or

other tourist, pilgrim areas



1. NH-8A 750 m S

2. NH-15 2.90 E

3. SH-42 13.62 W


7 Defense installations None within 15 Km radius.

8 Densely populated or built-up

area

Samakhaiyali 1.04 km SE 10,402

30

9 Areas occupied by sensitive

man-made land uses (hospitals,

schools, places of worship,

community facilities)


Social Structures Distance and Direction

(From Project

Boundary)

Nearest organized marketplaces for the

locals

1.06 SE

Medical Facility

Govt. Primary Health Centre , Samakhiyali 1.68 SE

Govt. Primary Health Centre , Vondh 10.42 W

Govt. Primary Health Centre , Gharana 4.61 NE

Govt. Primary Health Centre , Aadhoi 8.43 NNE

Pvt. Hospital , Bachahu 16.54 W

Vagad Welfare Hospital, Bachau 16.36 W

Govt. Primary Health Centre , Amliyara 7.85 SSW

Schools

Shri Bodh Kumar Prathmik Pathshala , Vondh 1.30 S

Shri Bodh Kanya Prathmik Pathshala , Vondh 270 m N

Govt. Uchh Prathmik Pathshala Samakhiyali 1.89 SE

Govt. Uchh Madhyamik Vidhyalya Lakhpat 5.30 NNW

Govt. Uchh Prathmik Pathshala Laliyana 7.25 SE

Govt. Uchh Prathmik Pathshala Gharana 4.45 NE

Others

Police Station Samakhiyali 1.64 SE

10 Areas containing important, high

quality or scarce resources

(ground water resources,

surface resources, forestry,

agriculture, fisheries, tourism,

minerals)

None Bhachau Taluka falls in 107.98 % over exploited

category in terms of Ground water Resources.

*Source Ground Water Brochure of Kutch District.

11 Areas already subjected to

pollution or environmental

damage. (those where existing

legal environmental standards

are exceeded)

None There is no area already subjected to pollution or

environmental damage within 15 km radius of the plant

site.

12 Areas susceptible to natural

hazard which could cause the

project to present

None As per the 2002 Bureau of Indian Standards (BIS)

seismic zone map of India, categorized under “Severe”

Zone-IV.

31

environmental problems

(earthquakes, subsidence,

landslides, erosion, flooding or

extreme or adverse climatic

conditions)

“I hereby give undertaking that the data and information given in the application and enclosure are

true to the best of my knowledge and belief and I am aware that if any part of the data and

information submitted is found to be false or misleading at any stage, the project will be rejected

and clearance given, if any to the project will be revoked at our risk and cost.”

Date: - 15.05.2018 Signature and Name of Applicant

Place: - Gandhidham Authorized Signatory

*********************

PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S. BILLET/ S.S.

BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT & WHRB

APPLICANT : GALLANTT METAL LIMITED

DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

MAY' 2018 32

EIA / EMP REPORT

PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.

BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &

WHRB

SECTION – I – INTRODUCTION




MAY' 2018 33

INDEX

SECTION - I

1.1 PREAMBLE............................................................................................................................ ……34

1.2 REGULATORY COMPLIANCES ................................................................................................ 35

1.3 IDENTIFICATION OF PROJECT PROPONENT .................................................................... 36

1.4 ENVIRONMENTAL CLEARANCE ............................................................................................ 37

1.5 TERMS OF REFERENCE ............................................................................................................ 38

1.6 POST- ENVIRONMENTAL CLEARANCE MONITORING ................................................... 72

1.7 GENERIC STRUCTURE OF ENVIRONMENTAL IMPACT ASSESSMENT DOCUMENT72

*****************



WHRB





MAY' 2018 34

1.0 INTRODUCTION

1.1 PREAMBLE

Environmental Impact Assessment (EIA) is the management tool to ensure the sustainable

development and it is a process, used to identify the environmental, social and economic

impacts of a lease prior to decision-making. It is a decision making tool, which guides the

decision makers in taking appropriate decisions for existing mine. EIA systematically examines

both beneficial and adverse consequences of the existing mine and ensure that these impacts

are taken into account during the project execution and expansion.

The existing project is categorized under category 3(a) - A category under schedule 3(a)

Metallurgical industries (ferrous & nonferrous) of EIA Gazette Notification dated

14thSeptember, 2006 and its subsequent amendment.

Gallantt Metal Limited (GML) is a large scale existing industrial unit which is situated at Survey

No. 175/1, Village - Samkhaiyali, Tehsil- Bhachau, District - Kutch, Gujarat.

Gallantt Metal Ltd. was accorded Environmental Clearance expansion in existing manufacturing

of products vide letter no. J-11011/52/2013-IA II(I) Dated 19.05.2016 from MoEF&CC.

Enclosed as Annexure-XIV.

Now Gallantt Metal Limited proposes to expansion in production capacity. The proposed

expansion is categorized A" under schedule 3(a)Metallurgical industries (ferrous &

nonferrous) Sponge iron manufacturing ≥ 200TPD of Gazette Notification dated 14thSeptember,

2006 and its subsequent amendment.

The proposed expansion is capacity are as stated under:--

S.

No.

Product Existing

(TPA)

Proposed

(TPA)

Total After

Expansion (TPA)

1. Sponge Iron 2,25,000 1,48,500 3,73,500

2. M.S. Billets 3,36,600 92,400 4,29,000

3. TMT Bars 3,30,000 92,400 4,22,400

4 M S Rolled Bar 5346 1,497 6,843

5 Runner & Raiser 891 No change 891

Power Generation

6 Power Plant

(AFBC/CFBC)

25 MW 10MW 35 MW

7. Power Plant (WHRB) 8MW 8MW 16MW



WHRB





MAY' 2018 35

The proposed expansion is coming up in 45.22 Acre area within existing plant i.e. 116.0 Acres

(4,73,325Sq.m). No additional land is required for the proposed expansion. The expected

capital investment for the proposed expansion is Rs. 216.0 Crore and the total project cost will

be 596.0 Crore.

Site History:

This is an expansion project of Gallantt Metal ltd. situated n Survey o 175/1, Village

Samyakhali, Tehsil – Bhachau, District – Kutch. The site history is given below:-

� Certificate of Incorporated of Gallantt Metal Limited was made on February 07, 2005, under

the Companies Act, 1956 with Cin No- U27 7O9 WBZU)SPLC 107553 under Dy. Registrar of

Companies, West Bengal.

� All statutory approval has obtained from time to time with concerned departments.

� The unit has developed Green area in existing plant is 28.08Acre which is 24.20% of the

total area i.e. 116 Acre.

� Gallantt Metal Limited has developed roads at inside and outside the premises, parking

area, Monitoring facility, DM Plant, Residential colony, Petty shop, Canteen for workers,

Shelter for workers, Drinking water facility at plant site.

1.2 REGULATORY COMPLIANCES

� A certificate has been obtained from Office of Collector, Kutch vide letter no.- A-3-Land-

N.A.-65(B)-C.No.44/2206-07 & N.A.-65(B)-C.No.44/2009-10 dated 27.04.2007 &

05.11.2009 stating the land is bonafide for industrial purpose. Enclosed as Annexure –

VI.

� Environmental Clearance was granted by MoEF&CC, New Delhi for the existing capacity

of manufacturing Sponge Iron, TMT Bars, M.S. Billet/ S.S. Billets, Coal based Captive

Power Plant and WHRB vide letter no.-J-11011/52/2013-IA II(I) dated 19.05.2016.

Enclosed as Annexure – XIV.

� Consent to Operate for Manufacturing of existing products (i.e. Sponge Iron, M.S. Billets,

TMT Bars, MS Rolled Bar, Runner & Raiser) with 8 MW WHRB has been obtained from

GSPCB, Gujarat vide letter no. PC/ CCA-KUTCH-341(5)/GPCB ID 17845/349490 dated

21.03.2016. Order No. AWH/ 76789 dated 29.02.2016 which is valid up to 27.12.2020.

Enclosed as Annexure – I.



WHRB





MAY' 2018 36

� Consent to Operate for additional 8MW (Total Capacity- 17+8=25MW) Captive Power

Plant has been obtained from GSPCB, Gujarat vide letter no. PC/ CCA-KUTCH-

351(5)/GPCB ID 17845/412240 dated 11.05.2017 which is valid up to 27.12.2020.

Enclosed as Annexure – II.

� The permission for water supply from GWIL to the tune of 1.755 MLD has been obtained

vide letter no. GWIL/Kutch/Ind. Connect./3000 dated 31.12.2010. Enclosed as

Annexure – IX.

� Used oil and Waste/ residues containing oil has been sent to Hindustan Oil Industries,

Gandhidham, Gujarat. Copy of Manifest form is enclosed as Annexure- XII.

� Ion Exchange resin (used) is sent to Surasthtra Enviro Projects Pvt. Ltd. Bharuch. Copy

of Manifest form is enclosed as Annexure-XIII.

� There is no National Parks, Sanctuaries, Biosphere Reserves, Wildlife Corridors, Tiger /

Elephant Reserves / (existing as well as proposed) within 10km radius from the study

area. A copy of submitted letter is enclosed as Annexure –XV.

� Terms of Reference have been issued from Ministry of Environment, Forests & Climate

Change, New Delhi vide letter no. J-11011/ 52/ 2013 – IA.II (I) dated 19.12.2017.

Enclosed as Annexure – XVI.

� There is no litigation pending against the Project/ Project Proponent in the court of law

as of date to the best of our knowledge. A undertaking stating the same is enclosed as

Annexure- V.

1.3 IDENTIFICATION OF PROJECT PROPONENT

Gallantt Metal Limited is company incorporated by two patron companies; namely M/s.

Govind Mills Limited based at Gorakhpur (Uttar Pradesh; India) and M/s. Ganesh Laxmi

Processors Pvt. Ltd. based at Surat (Gujarat; India). At present, M/s. Govind Mills Limited is

involved in running Flour Mills, Induction Furnaces and Re-rolling Mills in and around

Gorakhpur.

Gallantt Metal Ltd has set up an integrated steel plant near to Bhachau in Gujarat for

manufacture of Sponge iron, Steel billets, M.S Bars, Runner riser, MS Rolled Bars and captive

power plant

Gallantt Metal Limited (GML) is a large scale industrial unit which is located at Survey No.

175/1, Village- Samkhaiyali, Tehsil-. Bhachau, District- Kutch (Gujarat). The company

manufactures sponge iron, TMT Bars, M.S. Billets/S.S. Billets and having Captive power plants



WHRB





MAY' 2018 37

Now GML has decided to expand its sponge iron, TMT Bars, M.S. Billet/ S.S. Billets and captive

power plant capacity within existing premises of industries.

Name and address

of the Applicant

Gallantt Metal Limited (GML)

Dinesh Agrawal (Director)

Address: Gallantt Metal Limited

Plot No 123, Ground Floor, Ward 10 BC, Opp. IFFCO

Colony Gandhidham, Kutch-370201 Gujarat, India.

Telephone No. No. –02837-283555

Email:- [email protected], [email protected]

1.4 ENVIRONMENTAL CLEARANCE

As per the Gazette Notification dated 14th September, 2006 and its subsequent amendment on

dated 01.12.09 and 04.04.2011, the project is classified under 3 (a). Thus, the project is “A”

category project. The Environmental Clearance process for the proposed expansion project will

comprise of three stages. These stages in sequential order are:-

1. Scoping;

2. Public consultation;

3. Appraisal

The flow chart depicting these stages to obtain the prior Environmental Clearance for the

existing project is as given below:-



WHRB





MAY' 2018 38

1.5 TERMS OF REFERENCE

The application for the Terms of Reference of the proposed expansion project for

manufacturing of Sponge Iron, TMT Bars, M.S. Billet/ S.S. Billets , MS Rolled Bar and Captive

Power Plant & WHRB of M/s Gallant Metal Limited has made online application vide

proposal no. IA/CG/IND/67974/2017 dated 10th November at MoEF&CC, New Delhi and

Project Concept

Form 1, Pre-feasibility Project Report with Proposed TOR to MoEF&CC (EAC)

Scoping by EAC (Site visit by sub group of EAC, if necessary)

TOR approved by EAC EC - rejected by MoEF&CC on recommendation of EAC

Draft EIA Report to SPCB

by Project Proponent

Public Consultation process by SPCB

Summary EIA and Form 1 –

display on the Website by SPCB

Proceedings of Public Consultation

Appraisal and Recommendation by EAC

Display on MoEF&CCWebsite

Display at Panchayat, ZP, DM/DC/

Dy. Com & on the SPCB website

To Proponent for Submission of Final EIA

Report/Supplementary Report to Draft EIA

Approval by MoEF&CC

Rejected Approved Display on MoEF&CCWebsite& Project Proponent Website

Post EC

Monitoring

Submission of half yearly Compliance

Report to MoEF&CC/ RO-MoEF&CC

Display of Compliance Report

on MoEF&CCWebsite



WHRB





MAY' 2018 39

the same after consideration in the 26th Meeting of the Expert Appraisal Committee on

Industry- I held on dated 12.12.2017 was accorded approval vide letter no. J-11011/ 52/

2013 – IA.II (I) dated 19.12.2017. (Annexure - XVI). The point wise compliance of the TOR

is as under:-

Table 1.1: TOR Compliance

TOR

Ref.

TOR Detail Implementation / Plan

1. Executive Summary Executive Summary has been given in Section – IX of Draft EIA/

EMP report.

2. Introduction

Details of the EIA Consultant

including NABET

Accreditation.

Enkay Enviro Services Pvt. Ltd. , Jaipur

Accredited EIA Consultant Organization by NABET, QCI, New

Delhi at S. No. 44 (MoEF&CC) List of Accredited EIA Consultant

Organizations (as on April 5, 2018).

Validity: -28.05.2018.

Information about Project

Proponent

Gallantt Metal Limited (GML)

Dinesh Agrawal (Director)

Address: Gallantt Metal Limited

Plot No 123, Ground Floor, Ward 10 BC, Opp. IFFCO Colony


Telephone No. No. –02837-283555

Email:- [email protected], [email protected]

Importance and benefits of the

project.

Importance: - The need for the expansion is due to the rising

infrastructural demand from the existing unit and to keep its

continuous supply, owing to the growth in the region.

� In order to meet the in house demand of raw material for

billets and TMT bars and also to meet the market requirement

in timely manner the proposed expansion project is

undertaken.

� Huge demand in construction sector.

Benefits:-

The proposed expansion project aims to fill the demand – supply

gap through optimum allocation and production of natural

resources required to meet the demand effectively.



WHRB





MAY' 2018 40

3. Project Description

i. Cost of project and time of

completion.

Project Cost: - Existing – Rs. 380.0 Crore; Proposed:- Rs. 216.0

Crore; Total:- Rs. 596.0Crore

Time of Completion: -3 Years after start of installation.

ii. Products with capacities for

the proposed project.

S.

No.

Product Proposed

Capacity

After expansion

(TPA)

1 Sponge Iron 1,48,500 3,73,500

2 M.S. Billets 92,400 4,29,000

3 TMT Bars 92,400 4,22,400

4 M S Rolled Bar 1,497 6,843

5 Runner & Raiser No change 891 (No change)

Power Generation

6 Power Plant (AFBC) 10MW 35 MW

7 Power Plant (WHRB) 8MW 16MW

iii. If expansion project, details of

existing products with

capacities and whether

adequate land is available for

expansion, reference of earlier

EC if any.

The existing products detail are given below:

The proposed expansion is coming up within the existing plant

premises for an area of 116 Acre. The expansion area is

earmarked for future expansion in the total existing plant and

will be utilized for the proposed expansion. The detail is given

below:

Product Existing (TPA)

Sponge Iron 2,25,000

M.S. Billets 3,36,600

TMT Bars 3,30,000

M S Rolled Bar 5346

Runner & Raiser 891

Power Generation

Power Plant (AFBC/CFBC) 25 MW

Power Plant (WHRB) 8MW

Area In Acre

Total Land 116.0



WHRB





MAY' 2018 41

Environmental Clearance has been granted by MoEF&CC, New

Delhi for the existing capacity of manufacturing Sponge Iron,

TMT Bars, M.S. Billet/ S.S. Billets, Coal based Captive Power Plant

and WHRB vide letter no.-J-11011/52/2013-IA II(I) dated

19.05.2016. Enclosed as Annexure – XIV.

Land For future expansion (within

existing land area)

45.22

iv. List of raw materials required

and their source along with

mode of transportation.

List of raw materials required and their source along with mode

of transportation has been given in Section – II, Sub-Section –

2.6.1 of Draft EIA/ EMP Report.

v. Other chemicals and materials

required with quantities and

storage capacities.

Other chemicals and materials required with quantities and

storage capacities is given below:

S. No. Fuel Existing Proposed Total

1. HSD Quantity 1667 TPA Nil 1667 TPA

Storage capacity 60 KL - 60 KL

vi. Details of emission, effluents,

hazardous waste generation

and their management.

Emission Major emissions from the proposed expansion

project are of PM, SO2, and NOx.

Management: Management is as follows:

Sponge Iron:

� During the manufacturing process exhaust

gases generated from rotary kiln will be

directed to Waste Heat Recovery Boiler

(WHRB) for heat recovery. After that the

exhaust gases will be routing through ESP to

reduce the particulate matter in the exhaust

gases to less than 50 mg/Nm3.

� After treated in ESP gases will be release

through a combined stack of 42 m height for

effective dispersion and dilution of

emissions into the atmosphere.

� Dust extraction system with Bag filters is

being / will be provided at all material



WHRB





MAY' 2018 42

transfer points, raw material storage area,

etc. to control fugitive dust emission. All the

material handling systems will be connected

with de- dusting system at all discharge

points and feed points wherever the

possibility of dust generation.

� Water sprinklers are being/will be provided

for dust suppression during unloading of

raw materials.

� All conveyors is /will be covered with GI

(Galvanized iron)sheets.

� Major raw materials will be stored in

covered sheds.

Induction Furnace:

� The Fugitive emissions from the Induction

furnaces will be routed through side draft

hood and will be directed a fume extraction

system comprising of bag house and then

release through a common stack of 30 m

height.

� The outlet dust emission will be kept less

than 50 mg/Nm3. The dust will be

pneumatically carried to covered storage

bins.

AFBC /CFBC

� The flue gases generated from boiler will be

treated in ESP (Efficiency 99.9 %) to reduce

the particulate matter emission to keep less

than 50 mg/Nm3 and will be emit through an

existing stack of 80.0m.

Effluent Domestic waste water (135 KLD) generated

from plant and colony will be treated in existing

STP (Activated Sludge Process) with 200 KLD



WHRB





MAY' 2018 43

capacities and treated water will be utilized in

greenbelt development/plantation.

ETP waste water: Waste water (209 KLD)

generated from cooling tower, boiler and

process will be treated in ETP (250 KLD) and

reused for green belt and dust suppression

purpose.

Hazardous

Waste

The manufacturing process does not involve any

hazardous waste generation.

� Used oil, used ion exchange resin and tar

residue are generated and stored at separate

designated storage areas and maintained as

per Hazardous and Other Wastes

(Management and Transboundary

Movement) Rules, 2016. The Hazardous

waste generated at site being sent to

Hindustan oil, Industries, Gandhidham and

the same practice will be adopted for

proposed expansion project. The

Authorization has been obtained with

Consent to Operate for existing quantity vide

letter no. AWH/ 76789 dated 29.02.2016

which is valid up to 27.12.2020. Enclosed as

Annexure – II.

Particulars Hazardous Waste Quantity in TPA Treatment/

disposal Type of

Waste


Hazardous

Waste

Used

Oil(5.1)

2.063 1.13 3.19 Used oil is sent

to Hindustan

Oil Industries,

Gandhidham,

Gujarat and

Used Ion

exchange resin

is sent to

Saurashtra

Enviro Projects

Pvt. Ltd.

Used Ion

exchange

resin

(34.2)

0.35 0.19 0.54

Tar

residue

(13.2)

3.6 - 3.6



WHRB





MAY' 2018 44

vii. Requirement of water, power,

with source of supply, status of

approval, water balance

diagram, man-power

requirement (regular and

contract).

Requirement of Water: The daily water requirement for the

existing plant is 1318 KLD and proposed water demand is

537KLD (343Fresh +194 Recycled). Total Water demand after

expansion is 1855KLD (1661 fresh +194Recycled). The break up

is given below:

Man Power: The existing and proposed man power is given

below:

S. Category No. of Persons Remarks

S. No. Particulars Water Demand (KLD)


1. Domestic 215 61 276

2. Industrial

a. Cooling 485 133 618

b. Boiler 428 233 661

c. Process 145 96 241

3. Plantation/

Others

45 14 59

Total 1318 537(343

Fresh +194

Recycled)

1855(1661 fresh

+194

Recycled)

Source: - GWIL water supply system

Approval: The permission for water supply from GWIL to the

tune of 1.755 MLD has been obtained vide letter no.

GWIL/Kutch/Ind. Connect./3000 dated 31.12.2010. Enclosed as

Annexure – XI.

Water Balance diagram has been given in Section – II,

Sub-Section-2.5.2 of Draft EIA/ EMP Report.

Power Demand: The existing and proposed power demand

is given below:

S. No. Particulars Power Demand (KW)


1. Power 33MWH 18MWH 51MWH

Source: - Existing & proposed CPP and remaining will be met from

State grid as and when required.



WHRB





MAY' 2018 45

No. Existing Proposed Total

1. Permanent Staff 355 70 425 Local People

will be given

employment. 2. Skilled Workers 225 60 285

3. Semi-Skilled

worker

130 50 180


Total 960 290 1,250

viii. The Project Proponent shall

furnish the requisite

documents from the

competent authority in

support of drawl of ground

water and surface water and

supply of electricity.

Ground Water withdrawal: No ground water withdrawal is

envisaged for the proposed expansion project.

Surface Water Supply: The permission for water supply from

GWIL (Gujarat Water Infrastructure Limited) to the tune of 1.755

MLD has been obtained vide letter no. GWIL/Kutch/Ind.

Connect./3000 dated 31.12.2010 which is sufficient for existing

and proposed water demand. Enclosed as Annexure – XII.

Supply of electricity:

Existing & proposed AFBC/CFBC and remaining will be met from

State grid as and when required.

ix. Process description along with

major equipments and

machineries, process flow

sheet (quantitative) from raw

material to products to be

provided.

Process description along with major equipments and

machineries, process flow sheet (quantitative) from raw material

to products has been given in Section – II, Sub-Section – 2.6.3 and

2.9.2 of Draft EIA/ EMP Report.

x. Hazard Identification and

details of proposed safety

systems.

The hazards and their proposed safety measures are given

below:-



WHRB





MAY' 2018 46

Project Phase Hazard Identified Safety Systems/ Measures:-

Existing and

proposed expansion

phase

Material hazards:

� Furnace Oil (FO), High Speed Diesel

(HSD)/ Light Diesel Oil (LDO)

� Risk associated with coal handling plant

– dust explosion;

� Coal storage in open yard;

� Coal handling plant;

� Boilers/ Steam Turbine Generator

Building;

Process hazards

� During handling of hazardous materials

or processes resulting in Heat, fire,

explosion, etc.

Electrical hazards:

� Electrocution, high voltage levels, short

circuit, etc

� On-Site/ Off- Site Emergency Plan.

� Exposure Controls and Personal Protection;

� Personnel Protective Equipments;

� Other Safety Measures:-

• Safety training to the workers is given.

• PPE is provided to the workers.

• The maintenance and cleaning of bag filters

is carried out regularly.

• The dust removal efficiency of bag filters is

check regularly.

• Work place environment monitoring is

carried out regularly and records are

maintained. Good housekeeping is

implemented in the plant.

• First aid box is provided.

• The industry is providing adequate lighting

facility inside the plant premises.

Hazard identification and details of proposed safety systems has been given in Section-VI, Sub-Section – 6.2.3

of Draft EIA/EMP Report.

xi. Expansion/ Modernization proposals:-

a. Copy of all the Environmental

Clearance(s) including

amendments thereto obtained

for the project from MoEF/

SEIAA shall be attached as

Annexure. A certified copy of

the latest Monitoring Report of

the Regional Office of the

Ministry of Environment and

Forests as per circular dated

30th May, 2012 on the status of

compliance of conditions

stipulated in all the existing

Environmental Clearances

including amendments shall be

Environmental Clearance has been granted by MoEF&CC, New

Delhi for the existing capacity of manufacturing Sponge Iron,

TMT Bars, M.S. Billet/ S.S. Billets, Coal based Captive Power Plant

and WHRB vide letter no.-J-11011/52/2013-IA II(I) dated

19.05.2016. Copy of all the Environmental Clearance(s)Enclosed

as Annexure – XIV.

S.

No

Particular Letter no Granted

on

1. Environmental

Clearance for 12MW

Coal based power

plant

J-13011/37/2007-IA II(I) 28..09.2007

2. Expansion for Steel

Plant by installation

of Sponge Iron

J-13011/37/2007-IA II(I) 8 .06. 2009



WHRB





MAY' 2018 47

provided. In addition, status of

compliance of Consent to

operate for the ongoing/

existing operation of the

project from SPCB shall be

attached with the EIA-EMP

Report.

The compliance report of existing Environmental Clearance has

been submitted to Regional Office, MOEF&CC Bhopal for

certification. Acknowledgment copy submitted is enclosed

Annexure – XVII.

The compliance report of existing Consent to Operate for

manufacturing Sponge Iron, TMT Bars, MS/SS Billets, Waste Heat

Recovery Boiler (WHRB) and Captive Power Plant has been

submitted to Gujarat Pollution Control Board. Enclosed as

Annexure – XVIII.

The monitoring of stack (source emission) has been carried out

on 29.11.2017 The analysis report is enclosed as Annexure- XIX.

Copy of all the Consent to Operate obtained for the existing plant

from GPCB, Gujarat has been enclosed as Annexure -II & III &

details are given below:

Plant, Captive

Power Plant

3. Expansion of

Sponge Iron, Steel

billets TMT bar and

Captive Power Plant

J-11011/52/2013-IA II(I) 19.05.2016

S. No. Consent & Authorization

Letter No.

Issued on Valid up to Production Capacity

1. PC/CCA-Kutch-341(3)GPCB

ID:17845/99847

16.12.2011 27.12.2015 Sponge Iron -9375MT/Month

M.S. Billets -14850 MT/Month

TMT Bars -14330.25 MT/Month

M S Rolled Bar-445.50 MT/Month

Runner & Raiser-74.25 MT/Month

Power Plant (AFBC/CFBC) –12MW

Power Plant (WHRB) -6MW


ID:17845/106250

02.02.2012 27.12.2015 Power Generation – 12.0MW to 17.0MW


ID:17845/204290

10.01.2014 16.12.2015 Sponge Iron -14625.0 MT/Month



ID:17845/349490

29.02.2016 27.12.2016 Sponge Iron -14625MT/Month

M.S. Billets -14850MT/Month



WHRB





MAY' 2018 48

TMT Bars -14330.25 MT/Month






ID:17845/364967

27.07.2016 27.12.2020 Sponge Iron -18,750MT/Month

M.S. Billets -28,050 MT/Month

TMT Bars -27,500MT/Month






ID:17845/412240

11.05.2017 27.12.2020 Sponge Iron -18,750T/Month

M.S. Billets -21,450 T/Month

TMT Bars -20,915 T/Month

M S Rolled Bar-445.50 T/Month

Runner & Raiser-74.25 T/Month



b. In case the existing project has

not obtained Environmental

Clearance, reasons for not

taking EC under the provisions

of the EIA Notification 1994

and/ or EIA Notification 2006

shall be provided. Copies of

Consent to Establish/ No

Objection Certificate and

Consent to Operate (in case of

units operating prior to EIA

Notification 2006, CTE and

CTO of FY 2005-2006)

obtained from the SPCB shall

be submitted. Further,

compliance report to the

conditions of consent from the

The existing project has been accorded Environmental Clearance

granted by MoEF&CC, New Delhi for the existing capacity of

manufacturing Sponge Iron, TMT Bars, M.S. Billet/ S.S. Billets,

Coal based Captive Power Plant and WHRB vide letter no.-J-

11011/52/2013-IA II(I) dated 19.05.2016. Enclosed as

Annexure – XIV.

.



WHRB





MAY' 2018 49

SPCB shall be submitted.

4. Site details

i. Location of the project site

covering Village, Taluka/

Tehsil, District and State.

Justification for selecting the

site, whether other sites were

considered.

Location: Khasra No.:- 175/1 Village- Samyakhali, Tehsil –

Bhachau, District – Kutch (Gujarat.).

Justification for selecting the Site: -

No additional site was identified as it is expansion project is

within the same premises. No additional land is required for the

proposed expansion.

ii. A Toposheet of the study area

of radius of 10 Km and site

location on 1:50,000/ 1:25,000

scale on an A3/ A2 sheet.

(Including all eco-sensitive

areas and environmentally

sensitive places).

A toposheet of the study area of radius of 10 Km and site location

on 1:50,000 on an A3 sheet including all eco-sensitive area is

enclosed as Annexure – IV.

iii. Co-ordinates (Lat-Long) of all

four corners of the site.

The co-ordinates (Latitude - Longitude) of all four corners of the

sites has been given below:-

N E

Latitude 23°19’4.47” N Latitude 23°19’2.33” N

Longitude 70°29’10.21” E Longitude 70°29’10.21” E

S W



iv. Google Map - Earth

downloaded of the project site.

Google Map – Earth downloaded of the project site has been

enclosed as Annexure – XX.

v. Layout maps indicating

existing unit as well as

proposed unit indicating

storage area, plant area,

greenbelt area, utilities etc. if

located within an Industrial

area/ Estate/ Complex, layout

of Industrial Area indicating

Layout map showing existing unit as well as proposed unit

showing storage area, plant area, greenbelt area etc. have been

enclosed as Annexure – XXI.

A certificate has been obtained from Office of Collector, Kutch

vide letter no.- A-3-Land-N.A.-65(B)-C.No.44/2206-07 & N.A.-

65(B)-C.No.44/2009-10 dated 27.04.2007 & 05.11.2009 stating

the land is bonafide for industrial purpose.Enclosed as Annexure

– VI.



WHRB





MAY' 2018 50

location of unit within the

Industrial Area/ Estate.

vi. Photographs of the proposed

and existing (if applicable)

plant site. If existing, show

photographs of plantation/

green belt, in particular.

Photographs showing existing and proposed plant site have been

enclosed as Annexure – XXII.

Photographs showing existing plantation/ green belt have been

enclosed as Annexure – XXIII.

vii. Land use break – up of total

land of the project site

(identified and acquired),

Government/ private –

agriculture, forest, wasteland,

water bodies, settlements, etc.

shall be included (not required

for industrial area).

This is an expansion project which is coming up within existing

premises and no additional land is required for the proposed

expansion. The land use break-up of total land area has been

given below:-

S.

No.



1. Plant Area Office Area,

Residential Colony (All

covered area).

40.60 - 40.60 35.0%

2. Paved Area (Road, Corridor,

Parking and Drainage).

2.10 2.10 1.810%

3. Green Belt Area 28.08 28.08 24.20

4. Area for Future expansion 45.22

38.98%

Plant Area, Paved area,

Greenbelt

-- 28.7 28.7

5. Open area - 16.52 16.52

Total 116.00 - 116 100

The land use of the study area showing Government/ private – agriculture, forest, wasteland, water bodies,

settlements etc. has been enclosed as Annexure – XXIV.



WHRB





MAY' 2018 51

viii. A list of major industries with name

and type within study area (10 Km

radius) shall be incorporated. Land

use details of the study area.

List of industry with Name lies in 10 Km radius is given

below:

*Source: All distance are taken in respect to Google Earth

Map showing surrounding industries on Google Earth

within 10 km radius is enclosed as Annexure- XXV.

A Land use detail of the study area has been given in Section

– III, Sub-section – 3.4.3 of Draft EIA/ EMP Report. The

same has been enclosed as Annexure – XXIV.

S.

No.

Name of Industries Type Distance &

Direction

1. Electrotherm (India) Ltd. Steel &

Power

835m, WSW

2. A.S.R Multimetals Pvt Ltd Steel &

Power

1.6 Km, WSW

ix. Geological features and Geo-

hydrological status of the study area

shall be included.

The map showing Geological features and Geo-hydrological

status of the study area has been enclosed as Annexure –

XXVI.

x. Details of drainage of the project up

to 5Km radius of the study area. If

the site is within 1 km radius of any

major river, peak and lean season

river discharge as well as flood

occurrence frequency based on peak

rainfall data of the past 30 years.

Details of Flood level of the project

site and maximum flood level of the

river shall also be provided (Mega

green field projects).

The map showing drainage of the project up to 5.0 Km of

the study area has been enclosed as Annexure – XXVII.

No major river/ dam are situated at a distance of 1.0Km

from the existing site.

xi. Status of acquisition of land. If

acquisition is not complete, stage of

the acquisition process and expected

time of complete possession of the

land.

There is no acquisition of land.

xii. R & R details in respect of land in Not Applicable. There is no acquisition of land.



WHRB





MAY' 2018 52

line with State Government Policy.

5. Forest and Wildlife related issues (If applicable).

i. Permission and approval for the use

of forest and (Forestry Clearance), if

any, and recommendations of the

State Forest Department (If

applicable).

Not Applicable.

ii. Land use map based on High

Resolution Satellite Imagery (GPS) of

the proposed site delineating the

forestland (in case of projects

involving forest land more than 40

Ha.).

No forest land is involved in the proposed expansion

project.

Land use map based on High Resolution Satellite Imagery

(GPS) of the proposed expansion has been enclosed as

Annexure –XXIV.

iii. Status of application submitted for

obtaining the Stage – I Forestry

Clearance along with latest status

shall be submitted.

No forest land is involved in the proposed expansion

project. Hence, it is not applicable.

iv. The projects to be located within 10

Km of the National Park, Sanctuaries,

Biosphere Reserves, Migratory

Corridors of Wild animals, the

Project proponent shall submit the

map duly authenticated by Chief

Wildlife Warden showing these

features vis-à-vis the project

location and the recommendations

or comments of the Chief Wildlife

Warden – thereon.

There are no National Park, Sanctuaries, Biosphere

Reserves, and Migratory Corridors of Wild animals within

10 Km radius from the proposed expansion site.

A letter for map authentication has been submitted to Chief

Wild Life Warden, Kutch dated 24.04.2018 stating that

there are no National Park, Sanctuaries, Biosphere

Reserves, Migratory Corridors of Wild animals will be

obtained and incorporated in Final EIA/EMP Report.

v. Wildlife Conservation Plan duly

authenticated by the Chief Wildlife

Warden of the State Government for

conservation of Schedule I fauna, if

any exists in the study area.

Schedule – I i.e. Peafowl and Painted Stork have been

reported in the buffer zone during the study period. The

application for authentication of Conservation Plan of

Indian Pea – Fowl (Pavo cristatus) & Painted Stork has been

submitted to the Office of Deputy Conservator of Forest



WHRB





MAY' 2018 53

(Wildlife) Kutch, A copy of application submitted is

enclosed as Annexure – XXVIII.

vi. Copy of application submitted for

clearance under the Wildlife

(Protection) Act, 1972, to the

Standing Committee of the National

Board for Wildlife.

Not Applicable.

6. Environmental Status

i. Determination of atmospheric

inversion level at the project site and

Site-Specific Micro Meteorological

data using Temperature, Relative

Humidity, Hourly Wind Speed and

Direction and Rainfall.

Site - Specific Micro Meteorological data (Temperature,

Relative Humidity, Hourly Wind Speed and Direction,

Rainfall) were collected during winter season (December

2017 to February 2018) has been enclosed as Annexure-

XXIX.

ii. AAQ data (except Monsoon) at 8

locations for PM10, PM2.5, SO2, NOX,

CO and other parameters relevant to

the project shall be collected. The

monitoring stations shall be based

CPCB guidelines and take into

account the pre-dominant wind

direction, population zone and

sensitive receptors including

reserved forests.

� One – season data i.e. Winter (December’ 2017, January

and February’ 2018) has been generated & collected.

� AAQ data includes PM10, PM2.5, NOX, SO2, CO and other

parameters relevant to the project were generated.

� The monitoring stations were selected taking into

account the dominant wind direction, population zone

and sensitive receptors etc.

� The monitoring station selected is as described under:-

S. No. Name of Location Distance (Km) Direction Remarks

1. Project Site - - -

2. Samakhiali 2.24 km SE Nearest habitation

towards Downwind

3. Near to gorasar talav 4.96 Km SSE Downwind

4. Ramapar 5.06 Km SW Upwind & Crosswind

5. Gharana 4.74 Km NE Downwind

6. Vipasar 6.52 Km WNW Upwind



WHRB





MAY' 2018 54

7. Vondh R.S. 5.09 Km WSW upwind

8. Lakhpat 5.04km NNE downwind

iii. Raw data of all AAQ measurement

for 12 weeks of all stations as per

frequency given in the NAAQM

Notification of Nov. 2009 along with

Min., Max., Average and 98% values

for each of the AAQ parameters from

data of all AAQ stations should be

provided as an annexure to the EIA

Report.

The raw data of all AAQ measurement for 12 weeks of eight

stations as per frequency given in the NAAQM Notification

of November 2009 has been given in Section – III, Sub-

Section –3.6.3, Table No. – 3.12 of Draft EIA/ EMP report.

The Baseline monitoring report has been enclosed as

Annexure – XXX.

iv. Surface water quality of nearby

River (60m upstream and

downstream) and other surface

drains at eight locations as per

CPCB/ MoEF&CC guidelines.

Seven surface water samples were collected as grab

samples and were analyzed for various parameters as per

CPCB/ MoEF&CC guidelines. The analysis has been given in

Section – III, Sub-Section – 3.5.1, Table No. – 3.5 and 3.6 of

Draft EIA/ EMP report.

The same has been enclosed as Annexure – XXX.

v. Whether the site falls near to

polluted stretch of river identified by

the CPCB/ MoEF&CC.

The proposed expansion project does not falls near to

polluted stretch of river identified by the CPCB/ MoEF&CC,

New Delhi.

vi. Ground water monitoring minimum

at 8 locations shall be included.

Eight locations of ground water samples have been

collected and analyzed for various parameters as per CPCB/

MoEF&CC guidelines. The analysis has been given in Section

– III, Sub-Section – 3.5.1, Table No. – 3.5 and 3.6 of Draft

EIA/ EMP report.


vii. Noise levels monitoring at 8

locations within the study area.

Noise level monitoring was carried out at eight locations

within the study area during winter season (December’

2017 to January- February’2018) as per CPCB/ MoEF&CC

guidelines. The analysis has been given in Section – III, Sub-

Section – 3.7.1, Table No. – 3.15 of Draft EIA/ EMP report.

The same has been enclosed as Annexure XXX.



WHRB





MAY' 2018 55

viii. Soil characteristics as per CPCB

Guidelines.

Soil sampling was collected and analyzed for eight locations

within the study area during winter season (December’

2017 to February’2018). The analysis has been given in

Section – III, Sub-Section – 3.4.4, Table No. – 3.4 of Draft

EIA/ EMP report.


ix. Traffic study of the area, type of

vehicles, frequency of vehicles for

transportation of materials,

additional traffic due to proposed

project, parking arrangement etc.

Types of Vehicles : Trucks, Tippers

Frequency of vehicles for

transportation of material

: Daily

Additional traffic due to

proposed project

: 50 - 100/ day in operation

phase based on plant

running.

25 max per day in

construction phase.

Parking arrangement : Available

x. Details description of flora and fauna

(terrestrial and aquatic) existing in

the study area shall be given with

special reference to rare, endemic

and endangered species. If Schedule

– I fauna are found within the study

area, a Wildlife Conservation Plan

shall be prepared and furnished.

The study of flora and fauna (terrestrial and aquatic)

existing in the study area has been given in Section- III, Sub-

Section -3.8 of Draft EIA/ EMP report.

Core Zone Buffer Zone

Flora

Grass - 6 Species Grass –10 Species

Herb– 8 Species Herbs - 33 Species

Shrubs - 10 Species Shrubs - 13 Species

Tree - 22 Species Tree - 27 Species

Fauna

Amphibian – 0 Species Amphibian - 1Species

Reptiles - 2Species Reptiles –5 Species

Avifauna - 13 Species

Butterflies -4 Species

Avifauna – 34Species

Butterflies - 9Species

Mammals - 3 Species Mammals -9 Species

One schedule I specie reported i.e. Indian Peafowl & Painted

Stork in the buffer zone.

� The application for authentication of Conservation Plan



WHRB





MAY' 2018 56

of Indian Pea – Fowl (Pavo cristatus) & Painted Stork

has been submitted to the Office of Deputy Conservator

of Forest (Wildlife), Kutch. The copy of receipt is

enclosed as Annexure – XXVIII.

xi. Socio-Economic status of the study

area.

Socio-Economic status of the study area has been given in

Section- III, Sub-Section – 3.9 of Draft EIA/ EMP report.

7. Impact Assessment and Environment Management Plan.

i. Assessment of ground level

concentration of pollutants from the

stack emission based on Site-Specific

meteorological features. In case the

project is located on a hilly terrain,

the AQIP Modelling shall be done

using inputs of the specific terrain

characteristics for determining the

potential impacts of the projects on

the AAQ. Cumulative impact of all

sources of emissions (including

transportation) on the AAQ of the

area shall be well assessed. Details of

the model used and the input data

used for modeling shall also be

provided. The air quality contours

shall be plotted on a location map

showing the location of project site,

habitation nearby, sensitive

receptors, if any.

In order to predict the incremental particulate emissions,

AERMOD Version 7.1.0 model was used to predict changes

in air quality i.e., maximum ground level concentration

(GLC’s) of PM10, PM2.5, NOX and CO due to the expansion

project activity. The inputs required for the model is:-

� Hourly meteorological data

� Source data

� Receptor data

� Programme control parameters.

The GLC’s were predicted for the scenario, with EMP (80%

of pollution control) in the project.

Maximum ground level concentrations of particulate

matter due to project activities are.

Pollutant Maximum Incremental

Concentration (µµµµg/m3)

Direction

PM10 2.2 SSW

PM2.5 1.4 SSW

NOx 13.5 SSW

SOx 9.2 SSW

Hg 0.001 SSW

Isopleths showing Ground Level Concentration shown on

Google map has been given in Section-IV, Sub- Section –

4.3.3.2 of the Draft EIA/EMP report.

ii. Water Quality Modeling – in case,

the effluent is proposed to be

The unit will be maintained ZLD after expansion. Thus,

there will be nill discharge .



WHRB





MAY' 2018 57

discharged in to the local drain, then

Water Quality Modeling should be

conducted for the drain water taking

into consideration the upstream and

downstream quality of water of the

drain.

Domestic waste water (135 KLD) generated from plant

and colony will be treated in existing STP (Activated Sludge

Process) with 200 KLD capacities and treated water will be

utilized in greenbelt development/plantation.

ETP waste water: Waste water (209 KLD) generated from

cooling tower, boiler and process will be treated in ETP and

reused for green belt and dust suppression purpose.

iii. Impact of the transport of the raw

materials and end products on the

surrounding environment shall be

assessed and provided. In this

regard, options for transport of raw

materials and finished products and

wastes (large quantities) by rail or

rail- cum road transport or conveyor

– cum-rail transport shall be

examined.

� There will be no major impact of the transport of the

raw materials and end products on the surrounding

environment due to proposed expansion project as

proper mitigation measures will be adopted.

� Major raw material i.e. manufacturing of TMT Bars and

same for proposed expansion which process does not

include any hazardous/ fugitive materials as raw

materials.

� Imported Coal will be transported by road.

� The impact of the transport of the raw material and end

products on the surrounding environment has been

assessed as a Line Source Emissions. The Ground level

concentrations are computed for 24-hr average. The

incremental ground level concentrations for various

pollutants are given below:-

Emission Source Emission rate

Line emissions PM 10 – 1.31x10 -4 g/s/m

PM 2.5 – 6 x 10 -5 g/s/m

NOx – 1 x 10 -3 g/s/m

CO – 3.75 x 10 -3 g/s/m

SO2 – 1.25 x 10 -4 g/s/m

iv. A note on treatment of wastewater

from different plant operations,

extent recycled and reused for

different purposed shall be included.

Complete scheme of effluent

Domestic wastewater generated (135KLD) from plant and

colony will be treated in the existing Sewage Treatment

Plant (STP) based on Conventional Activated Sludge

Process (ASP) technology having capacity of 200 KLD and

sludge generated will be utilized as manure for greenbelt



WHRB





MAY' 2018 58

treatment. Characteristics of

untreated and treated effluent to

meet the prescribed standards of

discharge under E(P) Rules.

development/ plantation within the plant premises.

Water Balance for different plant operations, extent

recycled and reused for different purposed has been given

in Section – II, Sub-Section-2.5.2 of Draft EIA/ EMP Report.

About 194 KLD water will be recycled and reused for

cooling tower, plantation and dust suppression, general

cleaning.

The complete scheme of Sewage Treatment Plant has been

given in Section – IV, Sub-Section – 4.3.2.3 of Draft EIA/

EMP Report. Photographs showing Sewage Treatment Plant

is enclosed as Annexure –IX.

Rain water harvesting is being practiced inside the plant

and colony premises. Photographs showing rain water

harvesting is enclosed as Annexure-XXXI.

Characteristics of untreated and treated effluent to meet the

prescribed standards of discharge under E (P) Rules has

also been given in Section – IV, Sub-Section – 4.3.2.3 of Draft

EIA/ EMP Report.

v. Details of stack emission and action

plan for control of emissions to meet

the standards.

The stack detail, emission generated along with action plan

to control the emissions has been given in Section – IV, Sub-

Section -4.3.3 of Draft EIA/ EMP Report.

The photographs showing stacks are enclosed as Annexure

– XXXII.

Efficient Air Pollution Control Equipment (APCE) is being

/will be installed for control of emissions from all the

sources within the prescribed limit. Details of the same

have been given in Section – IV, Sub-Section –4.3.3 (Table

No 4.4) of Draft EIA/ EMP Report.



WHRB





MAY' 2018 59

Stack Emission Details (Existing)

Stack Emission Details (Proposed Expansion)

S.

No

.

Parameters Unit

s

Captive

Power

Plant

(25MW

)

Stack-I

Rotary

Kiln No.

1 & 2

Stack-II

Rotary

Kiln No.

3 & 4

Stack-

III

Inductio

n

Furnace

No. 1 & 4

Stack-IV

Inducti

on

Furnace

No. 2 &

3 Stack-

V

Inductio

n

Furnace

No. 5

Stack-VI

Coal

Crushe

r

Stack-

VII

Re-

heating

Furnace

Stack-

VIII

DG Sets

3 nos of

Stack-IX

1 Stack Height M 95 40 35 48 48 48 30 30 12

2 Top

diameter of

flue

M 2 1 1 1 1 1 1 1 0.5

3 Flue gas

velocity

m/se

c

10 10 10 7 7 7 10 8 10

4 Exit Flue gas

temperature

oK 393 393 393 373 373 373 373 423 453

5 Flue gas flow

rate

m3/s

ec

31.41 7.85 7.85 5.5 5.5 5.5 7.85 6.28 1.96


A

PM10

emission

rate

g/s 1.7 0.81 0.81 0.55 0.55 0.55 0.8 0.25 0.09

B PM2.5

emission

rate

g/s 1.05 0.51 0.51 0.34 0.34 0.34 0.5 0.16 0.06

C NOx g/s 31.05 7.76 7.76 5.15 5.15 5.15 -- -- 1.84

D SO2 g/s 12.2 4.22 4.22 -- -- -- -- -- 0.75

7 APCM ESP ESP ESP Bag

House

Bag

House

Bag

House

Bag

House

Bag

House

--

S.

No.

Parameters Units Captive Power

Plant (10 MW)

Stack-I

Rotary Kiln No.5

Stack-II

Induction Furnace

No. 6

Stack-III

1 Stack Height M 90 48 48

2 Top diameter of

flue

M 2 1 1

3 Flue gas

velocity

m/sec 10 10 7

4 Exit Flue gas

temperature

oK 393 393 373

5 Flue gas flow

rate

m3/sec 31.41 7.85 5.5



WHRB





MAY' 2018 60


A

PM10 emission

rate

g/s 0.8 0.32 0.22

B PM2.5 emission

rate

g/s 0.5 0.2 0.137

C NOx g/s 3.15 3.925 --

D SO2 g/s 3.15 2.4 --

E Mercury (Hg) g/s 0.0009 -- --

7 APCM ESP ESP Bag House

vi. Measures for fugitive emission

control.

To control the fugitive emissions from the process in the

plant following measures is being/will be adopted:-

� High efficiency Bag filter +Spark trapper, ESP, Side draft

hood for induction furnace, Kiln, Reheating furnace,

boiler to maintain limit of 50mg/ Nm3 for the PM

emissions;

� Good House-keeping;

� Adequate stack height;

� Green area (24.8% at present) along the plant periphery

and within the plant premises and 10.20 Acre area is

proposed under the greenbelt plantation. The action

plan to achieve the 33% Green area is given in Section

X- sub point no. 10.4 in Draft EIA/EMP report.

� To avoid the tail-pipe emissions and exhaust gas, new

and PUC certified vehicles will be used;

� Ambient air quality and stack emissions will be

regularly monitored to ensure that ambient air quality

standards and suggested limits of the stack emission

loads are met honestly all the time.

• Photographs showing Bag filter, ESP are enclosed as

Annexure-XXXIII.

All adequate measures will be strictly followed to keep

the pollution level well within the limits.

vii. Details of hazardous waste As per MSIHC rules, no hazardous substances or materials



WHRB





MAY' 2018 61

generation and their storage,

utilization and disposal. Copies of

MOU regarding utilization of solid

and hazardous waste shall also be

included.

EMP shall include the concept of

waste-minimization, recycle, and

reuse/ recover technique, Energy

conservation, and natural resource

conservation.

will be used, which affect the human health or the

environment.

The details of Hazardous waste generation existing as well

as proposed and their storage, utilization and disposal have

been given in Section –IV, Sub-Section – 4.3.1.2 of Draft

EIA/ EMP Report. Hazardous waste disposal manifest form

and invoice is enclosed as Annexure-XII&XIII

Waste - minimization, recycle/ reuse/ recover techniques,

Energy conservation and natural resource conservation has

been included in the EMP and details regarding the same

have been incorporated in Section-X of Draft EIA/EMP

Report.

viii. Proper utilization of fly ash shall be

ensured as per Fly Ash Notification,

2009. A detailed plan of action shall

be provided.

Fly ash generated from CPP is being/will be totally utilized

in the brick manufacturing process or used as binding

material for land filling. Management plan is given in

chapter –X. A Copy of MoU is enclosed as Annexure-VIII.

ix. Action Plan for the green belt

development plan in33% area i.e.

land with not less than 1,500 trees

per ha. Giving details of species,

width of plantation, planning

schedule etc. shall be included. The

green belt shall be around the

project boundary and a scheme for

greening of the road used for the

project shall also be incorporated.

The existing unit has already developed approximately

24.8% in green belt of total land area. Now, for the

proposed expansion additional 10.20Acre green belt will be

developed. Thus, after expansion the total land area in the

green belt will be 33%. The map showing green belt

existing as well as proposed is enclosed as Annexure –

XXIII.

Action Plan for Green Belt development plan is given in

Chapter- X on page no.290-291.

S. No. Year Name of Species No. of Species

1. 2018-19 Neem, Sheesham, Karanj,

Peepal, Banyan, Amla,

Ashok, Salvadora species

etc. Above all many shrubs

species i.e. Kaner,

Boganvelia etc

1250

2. 2019-20 1235

3. 2020-21 1235

4. 2021-22 1240

5. 2022-23

1240



WHRB





MAY' 2018 62

Total 6200

Photographs showing existing Greenbelt development are enclosed as Annexure – XXIII.

x. Action plan for rainwater harvesting

measures at plant site shall be

submitted to harvest rainwater from

the roof tops and storm water drains

to recharge the ground water and

also to use for the various activities

at the project site to conserve fresh

water and reduce the water

requirement from other sources.

Action plan for rain water harvesting structure has been

given in Chapter IV- sub section - 4.3.2.5 and rain water

harvesting pits exist at plant site to augment the ground

water table by roof tops and storm water drains to recharge

the ground water and also to use for the various activities at

the plant site to conserve fresh water requirement from

other sources.

The photographs showing rain water harvesting structure

is enclosed as Annexure – XXXI .

xi. Total capital cost and recurring

cost/ annum for Environmental

Pollution Control Measures shall be

included.

The total expected capital investment after proposed

expansion will be Rs. 596 Crore (Existing: - – Rs. 380.0

Crore; Proposed:- Rs. 216.0 Crore; Total:- Rs. 596.0Crore).

The amount has been already incurred for Environmental

Pollution Control Measures as given below:

S. No. Description of Item Capital Cost

(In Lacs)

Recurring Cost

(In Lacs)

1 Air Pollution Control/ Noise 600 40

2 Water Pollution Control 30 04

3 Environmental Monitoring and Management 80 10

4 Green Belt Development 20 05

5 Occupational Health 10 06

Total 740 65

xii. Action Plan for Post-Project

Environmental Monitoring shall be

submitted.

Action Plan for Post –Project Environmental monitoring has

been given in Section – V, Sub-Section – 5.4 of Draft EIA/

EMP report.

xiii. Onsite and Offsite Disaster (Natural

and Man-made) Preparedness and

Emergency Management Plan

including Risk Assessment and

damage control. Disaster

Management Plan should be linked

Onsite and Offsite Disaster (Natural and Manmade)

Preparedness and Emergency Management Plan including

Risk Assessment and damage control have been

incorporated in Section-VII of Draft EIA/ EMP Report.



WHRB





MAY' 2018 63

with District Disaster Management

Plan.

8. Occupational Health

i. Details of existing Occupational &

safety Hazards. What are the

exposure levels of above mentioned

hazards and whether they are within

Permissible Exposure Level (PEL)? If

these are not within PEL, what

measures the company has adopted

to keep them within PEL so that

health of the workers can be

preserved.

� The occupational health impact is very insignificant. No

health impact has been reported so far. No evident

history related to health problems arising from

industrial activity is reported. The same was evident in

the primary survey. However, following mitigation

measures will be adopted as preventive action:-

� All employees are being/will be trained, educated and

encouraged to follow best and safe work practices.

� Personnel Protective Equipments like face mask,

earmuffs, ear plugs, gloves, safety goggles and safety

boots are being provided.

� Awareness programme regarding the use, maintenance

and up-keep of respirators will be conducted on regular

basis so that employees are trained to handle the

equipment properly.

� Permissible exposure level is well within the limits.

The Occupational Health report of the workers has been

enclosed as Annexure –XXXIV.

ii. Details of exposure specific health

status evaluation of worker. If the

workers’ health is being evaluated

by pre-designed format, Chest X-

rays, Audiometry, Spirometry, Vision

Testing (Far and Near Vision, Color

Vision and any other ocular defect)

ECG, during pre-placement and

periodical examinations give the

details of the same. Details regarding

last month analyzed data of above

mentioned parameters as per age,

The Occupational Health report of the workers has been

enclosed as Annexure – XXXIV.



WHRB





MAY' 2018 64

sex, duration of exposure and

department wise.

iii. Annual report of health status of

workers with special reference to

Occupational Health and Safety.

Annual report of health status of worker with special

reference to Occupational Health and Safety has been

enclosed as Annexure – XXXIV.

iv. Plan and fund allocation to ensure

the occupational Health & Safety of

all contract and causal workers.

Plan and fund allocation to ensure the occupational health

and safety of all contract and casual workers have been

given below:-

S. No. Parameters Frequency

a. Blood Pressure Every Year

b. Blood Group and RH Every Year

c. Blood Sugar (RBS) Every Year

d. Spirometry Every Year

e. Audiometry Every Year

f. Vision Every Year

g. Drug Allergy Every Year

The fund allocation for Occupational Health and Safety of all contract and casual workers are as given

below:-

Workers : Fund Allocation (In Rs.)

Contract Workers : 2,00,000/ Annum

Casual Workers : 4,00,000/Annum

9. Corporate Environment Policy.

i. Does the company have a well laid

down Environment Policy approved

by its Board of Directors? If so, it

may be spelt out in the EIA report.

The company has a well laid down Environmental Policy

duly being executed under the supervision of

Environmental Cell. Enclosed as Annexure –XXXV.

ii. Does the Environment Policy

prescribe for Standard operating

process/ procedures to bring into

focus any infringement/ deviation/

violation of the environmental or

forest norms/ conditions? If so, it

may be spelt out in the EIA report.

The company has well defined procedures to bring into

focus any infringement/ deviation/ violation of the

environmental and forest norms. Enclosed as Annexure –

XXXVI.



WHRB





MAY' 2018 65

iii. What is the hierarchical system or

administrative order of the

Company to deal with the

environmental issues and for

ensuring compliance with the EC

conditions may also be given?

Details of this system may be given.

The company has well defined hierarchical system to deal

with the environmental issues and for ensuring compliance

with the Environmental Clearance conditions. Enclosed as

Annexure – XXXVII.

iv. Does the company have system of

reporting of non-compliances/

violations of environmental norms

to the Board of Directors of the

Company and/ or shareholders or

stakeholders at large? This reporting

mechanism shall be detailed in the

EIA report.

Management Representative will appraise the highest

authority on quarterly basis regarding the performance of

the plant on environmental measures. Enclosed as

Annexure – XXXVIII.

10. Details regarding infrastructure

facilities such as sanitation, fuel,

restroom etc. to be provided to the

labour force during construction as

well as to the casual workers

including truck drivers during

operation phase.

The proposed expansion envisages improvement in the

facilities provided to workers. Provision for the same has

been made as given below:-

S.

No.

Activities Capital Cost

(Rs. In Lacs)

Recurring Cost

(Rs. In Lacs)

1. Shelter/ Housing

Facility

8.0 1.50

2. Health Facility 4.0 2.00

3. Drinking Water 3.0 1.25

4. Sanitation Facilities 5.0 0.25

5. Education 1.0 0.50

Total 21.0 5.50

11. Enterprise Social Commitment

(i) To address the public hearing,

issues, 2.5% of the total project cost

of (Rs. …….Crores), amounting to

Rs……..Crores shall be earmarked by

the project proponent towards the

Enterprise Social Commitment based on Public Hearing

issues and item-wise details along with time bound action

plan will be incorporated after public hearing.



WHRB





MAY' 2018 66

Enterprise Social Commitment

(ESC). Distinct ESC projects shall be

carried out based on Public Hearing

issues. Project estimate shall be

prepared based on PWD schedule of

rates for each distinct item and

schedule for time bound action plan

shall be prepared. These ESC

projects as indicated by the project

proponent shall be implemented

along with the main project.

Implementation of such programme

shall be ensured by constituting a

Committee comprising of the project

proponent, representative of village

Panchayat & District Administration.

Action taken report in this regard

shall be submitted to the Ministry’s

Regional Office. No free distribution/

donation and or free camps shall be

included in the above ESC budget.

12. Any litigation pending against the

project and/ or any direction/ order

passed by any court of law against

the project, if so, details thereof shall

also be included. Has the unit

received any notice under the

Section 5 of Environment

(Protection) Act, 1986 or relevant

sections of Air and Water Acts? If so,

details thereof and compliance/ ATR

to the notice(s) and present status of

the case.

No litigation is pending against the company and the project

in any court of law to the best of our knowledge.

Undertaking for the same is enclosed as Annexure-V.



WHRB





MAY' 2018 67

13. A tabular chart with index for point

wise compliance of above TORs.

The same has been complied.

14. The TORs prescribed shall be valid

for a period of three years for

submission of the EIA-EMP reports

along with Public Hearing

proceedings (wherever stipulated).

The same has been noted.

15. The following general points shall

be noted:-

i. All documents shall be properly

indexed, page numbered.

All documents have been properly indexed and page

numbered.

ii. Period/ date of data collection shall

be clearly indicated.

Period: - Winter season (December’ 2017, January and

February’ 2018).

Date of data collection: - 01.12.2017 to 28.02.2018.

iii. Authenticated English translation of

all material in Regional languages

shall be provided.

English translation of public hearing will be provided after

the public hearing.

iv. The letter/ application for

Environmental Clearance shall quote

the MoEF&CC file no. and also attach

a copy of the letter.

Terms of Reference have been issued from Ministry of

Environment, Forests & Climate Change, New Delhi vide

letter no. J-11011/ 52/ 2013 – IA.II (I) dated 19.12.2017.

Enclosed as Annexure – XVI.

v. The copy of the letter received from

the Ministry shall be also attached as

an annexure to the final EIA-EMP

report.

Terms of Reference have been issued from Ministry of

Environment, Forests & Climate Change, New Delhi vide

letter no J-11011/ 52/ 2013 – IA.II (I) dated 19.12.2017.

Enclosed as Annexure – XIII.

vi. The index of the final EIA-EMP

report must indicate the specific

chapter and page no. of the EIA-EMP

report.

The same has been noted and complied.

vii. While preparing the EIA report, the

instructions for the proponents and

instructions for the consultants

The same has been noted and complied.



WHRB





MAY' 2018 68

issued by MoEF vide O.M. No. J-

11013/41/2006-IA.II (I) dated 4th

August, 2009, which are available on

the website of this Ministry should

also be followed.

viii. The Consultants involved in the

preparation of EIA-EMP report after

accreditation with Quality Council of

India (QCI)/ National Accreditation

Board of Education and Training

(NABET) would need to include a

certificate in this regard in the EIA-

EMP reports prepared by them and

data provided by other

organization/ Laboratories

including their status of approvals

etc. Name of the Consultant and

Accreditation details shall be posted

on the EIA- EMP Report as well as on

the cover of the hard copy of the

presentation material for EC

presentation.

Enkay Enviro Services Pvt. Ltd.

Accredited EIA Consultant Organization by NABET, QCI,

New Delhi at S. No. 44 (MoEF&CC). List of Accredited EIA

Consultant Organizations (as on March 5, 2018).

Validity: -28.05.2018. Enclosed as Annexure – XXXVIII.

Monitoring Agency: En-Vision Environmental Services &

Testing Laboratory, Surat, Gujarat

� NABL recognized laboratory

� Recognized by NABL, NABET – QCI,

� ISO: IEC 17025:2005: valid up to 22.02.2019.

Vendor Code: -

EES/ADM/LSUP/031/032

Date of Monitoring: - 01.12.2017to 28.02.2018.

ix. TORs’ prescribed by the Expert

Appraisal Committee (Industry)

shall be considered for preparation

of EIA-EMP report for the project in

addition to all the relevant

information as per the “Generic

Structure of EIA” given in Appendix

– III and IIIA in the EIA Notification’

2006. Where the documents

provided are in a language other

than English, an English translation

This is the Draft EIA/EMP Report for the Public Consultaion.

Public Hearing will be carried out as per EIA Notification

14th September 2006 and its subsequent amendments and

issue raised during public hearing and commitment of the

project proponent on the same along with time bound

action plan to implement the commitment and financial

allocation will be incorporated after public hearing.



WHRB





MAY' 2018 69

shall be provided. The draft EIA-EMP

report shall be submitted to the

State pollution Control Board of the

concerned State for conduct of

Public Hearing. The SPCB shall

conduct the Public Hearing/ Public

Consultation, district-wise, as per

the provisions of EIA

Notiifcation’2006. The public

hearing shall be chaired by an

Officer not below the rank of

Additional district Magistrate. The

issues raised in the Public Hearing

and during the consultation process

and the commitments made by the

Project Proponent on the same shall

be included separately in EIA-EMP

report in a separate chapter and

summarized in a tabular chart with

financial budget (capital and

revenue) along with time schedule

of implementation for complying

with the commitments made. The

final EIA report shall be submitted to

the Ministry for obtaining

Environmental Clearance.

x. Public Hearing

• Public Hearing to be conducted by

the concerned State Pollution

Control Board.


14th September 2006 and its subsequent amendments.

• The issue raised during public

hearing and commitment of the

project proponent on the same


14th September 2006 and its subsequent amendments and

issue raised during public hearing and commitment of the



WHRB





MAY' 2018 70

along with time bound action plan

to implement the commitment and

financial allocation thereto should

be clearly provided.

project proponent on the same along with time bound

action plan to implement the commitment and financial

allocation will be incorporated after public hearing.

• The project proponent should

carry put social impact assessment

of the project as per Office

Memorandum No.J-

11013/25/2014.IA.I dated

11.08.2014 issued by the Ministry

regarding guideline on

Environment Sustainability and

Enterprise Social Commitment

(ESC) related issues. The social

Impact assessment study so

carried should part of EIA EMP

report.

The social impact assessment has been carried out and the

public hearing issued are awaited as per Office

Memorandum No.J-11013/25/2014.IA.I dated 11.08.2014

the details are give in Section III and IV of EIA/EMP Report.

• Certified compliance of earlier EC

from the Regional office of SPCB

shall be submitted along with

EIA/EMP report

Certified compliance of earlier EC from the Regional office

of Bhopal has been certified. Enclosed as Annexure-XVII.

• The plantation shall inter alia

include plantation all along the

boundary of the plant.

The same has been noted.

The plantation details with action plan & Budget are given

in Section X in point no.-10.4.

16. Additional TORs Point

1. Complete process flow diagram

describing each unit, its process and

operation, along with material and

energy input & outputs (material

and Energy balance)

Complete process flow diagram describing each unit, its

process and operation, along with material and energy

input & outputs (material and Energy balance) is given in

Section- II, sub-section 2.6.1. in Draft EIA/EMP Report.

2. Emission from sulphuric acid plant

and sulphur muck management.

Not Applicable.



WHRB





MAY' 2018 71

3. Details on installation of continuous

Emission monitoring System with

recording with proper calibration

system.

Continuous Stack monitoring system for emission is being

done. Enclosed as Annexure-XXXIX.

4. Details on toxic metals including

fluoride emission.

Not Applicable.

5. Details of stack height Details of stack heights are given in Section –IV, Sub section

-4.3.3 of Draft EIA/ EMP Report.

6. Details on ash disposal and

management.

The ash management is given in Section – X.

7. Complete process flow diagram

describing process of

lead/zinc/copper/aluminum etc.

Not Applicable

8. Details on smelting, thermal refining,

melting, slag fuming and Waelaz kiln

operation.

Not applicable.

9. Details on holding and de-gassing of

molten metal from primary and

secondary aluminum, materials

pretreatment and from melting and

smelting of secondary aluminum.

Not applicable.

10. Details on toxic metal content in the

waste material and composition and

end use (Particularly of slag)

Slag analysis report is attached as Annexure-XL.

11. Trace metals in waste material

especially slag.

Slag analysis report is attached as Annexure-XL.

12. Plan for trace metal recovery No trace metal recovery is envisaged.

13. Trace Metal in water Water analysis results are given in Section- III, Sub-Section

– 3.5.1, Table No. – 3.5 and 3.6 of Draft EIA/ EMP report.



WHRB





MAY' 2018 72

1.6 POST- ENVIRONMENTAL CLEARANCE MONITORING

The Company will submit a half yearly compliance report in respect of stipulated prior

Environmental Clearance terms and conditions on 1st June and 1st December of each calendar

year. The latest such compliance report will be displayed on the website of the concerned

regulatory authority.

1.7 GENERIC STRUCTURE OF ENVIRONMENTAL IMPACT ASSESSMENT DOCUMENT

In terms of EIA Notification of the MoE&F, New Delhi dated 14th September 2006 and its

subsequent amendments on dated 01.12.2009 and 04.04.2011, the generic structure of the EIA

document is as under:-

Table 1.4: Generic structure of EIA document

S. No. Chapters Page Nos.

1. Introduction 33-72

2. Project description 73-96

3. Description of the Environment 97-156

4. Anticipated Environmental Impact & Mitigation Measures 157-198

5. Analysis of Alternatives 199-200

6. Environmental Monitoring Programme 201-213

7. Additional Studies 214-244

8. Project Benefits 245-249

9. Environmental Cost Benefits Analysis 250- 251

10. Environmental Management Plan 252- 265

11. Summary & Conclusion 266-289

12. Disclosure of Consultant Engaged 290-293

*****************



WHRB

SECTION – II – PROJECT DESCRIPTION




MAY’ 2018 73

INDEX

SECTION-II

2.1 PROJECT DESCRIPTION ........................................................................................................................ 74

2.2 NEED FOR THE PROJECT EXPANSION .............................................................................................. 74

2.3 LOCATION .................................................................................................................................................. 75

2.4 INFRASTRUCTURE .................................................................................................................................. 75

2.4.1 NEAREST RAILWAY STATION ............................................................................................................. 75

2.4.2 NEAREST AIRPORT ................................................................................................................................. 75

2.4.3 NEAREST HIGHWAY ............................................................................................................................... 76

2.5 POWER, WATER SUPPLY AND OTHER INFRASTRUCTURE REQUIREMENTS ..................... 76

2.5.1 POWER ........................................................................................................................................................ 76

2.5.2 WATER DEMAND ..................................................................................................................................... 76

2.5.3 MANPOWER REQUIREMENTS ............................................................................................................. 79

2.5.4 LAND USE BREAK-UP ............................................................................................................................. 79

2.6 PROJECT DETAILS ................................................................................................................................... 80

2.6.1 RAW MATERIALS REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE

AND MODE OF TRANSPORTATION OF RAW MATERIALS. ......................................................... 80

2.6.2 PRODUCTS ................................................................................................................................................. 81

2.7 EQUIPMENT DETAILS .......................................................................................................................... 81

2.8 PROCESS/ MANUFACTUIRNG DESCRIPTION ................................................................................. 83

2.8.1 Process Description of Sponge Iron Manufacturing Unit .......................................................... 83

2.8.2 Process Description of Captive Power Plant ............................................................................ 103

2.9 MATERIAL BALANCE ............................................................................................................................. 95

2.10 PLANT LAYOUT ....................................................................................................................................... 96

*************



WHRB





MAY’ 2018 74

2.0 PROJECT DESCRIPTION

2.1 PROJECT DESCRIPTION

Gallantt Metal Limited (GML) is a large scale existing industrial unit which is situated at

Survey No. 175/1, Village - Samkhaiyali, Tehsil- Bhachau, District - Kutch, Gujarat. The

proposed expansion is for manufacturing-

S. No. Product Existing (TPA) Proposed (TPA) Total (TPA)

1. Sponge Iron 2,25,000 1,48,500 3,73,500

2. M.S. Billets 3,36,600 92,400 4,29,000

3. TMT Bars 3,30,000 92,400 4,22,400

4 M S Rolled Bar 5346 1,497 6,843


Power Generation

6 Power Plant (AFBC/CFBC) 25 MW 10MW 35 MW


The proposed expansion is coming up within existing plant area 116.0 Acres (4,

73,325Sq.m). No additional land is required for the proposed expansion. The expected

capital investment for the proposed expansion will be Rs. 216.0 Crore and the total project

cost will be 596.0 Crore.

2.2 NEED FOR THE PROJECT EXPANSION

The need for the expansion unit is due to the rising demand from the existing unit and to

keep its continuous supply, owing to the mega infrastructural growth in the region.

The need for the expansion unit for Sponge Iron, TMT Bars, M.S. Billet/S.S. Billet and

Captive power plant and WHRB. This is due to the rising infrastructural demand from the

existing unit and to keep its continuous supply, owing to the growth in the region. Captive

Power plant will be installed to meet the demand of electricity.

India is world's largest sponge iron producer with an annual production of about 26-28

MnT against installed capacity of 46-47 MnT. There are over 400 sponge iron units in India.

Indian sponge iron industry is highly fragmented. Top 20 producers contribute about 60-

65% of total production where as rest contribute 35-40% of the production. Sponge iron

contributes 25% of India's total crude steel production of 90 MT.



WHRB





MAY’ 2018 75

The production for sale of DRI or Sponge Iron has increased from 1.31 mt in 1991-92 to

14.83 mt in 2016-17 (prov). India was the largest producer of DRI in the world during the

period 2003 to 2015 and emerged as the 2nd largest global producer in 2016, based on

provisional ranking released by the World Steel Association.

In order to meet the in house demand of raw material for billets and TMT bars and also to

meet the market requirement in timely manner the proposed expansion project is

undertaken.

2.3 LOCATION

The proposed expansion project is coming up in same premises situated at Survey No.

175/1, Village - Samkhaiyali, Tehsil- Bhachau, District - Kutch, Gujarat. The project site falls

in Survey of India Toposheet No.- 41I/7,8, 11 & 12. The geographical location of the plant

is:-

Table 2.1: Geological Coordinates

N E



S W



The map showing location of the project site on toposheet is enclosed as Annexure-VII.

2.4 INFRASTRUCTURE

2.4.1 NEAREST RAILWAY STATION

The nearest railway station is Samakhaiyali –which is about 1.04 Km towards SE from the

project site.

2.4.2 NEAREST AIRPORT

The nearest airport is Kandla-which is about 45.72 Km, SW from the project site.



WHRB





MAY’ 2018 76

2.4.3 NEAREST HIGHWAY

Table 2.2: Highway

Particulars Distance (Km) Direction


NH-8A 750 m S

NH-15 2.90 E

SH-42 13.62 W

2.5 POWER, WATER SUPPLY AND OTHER INFRASTRUCTURE REQUIREMENTS

2.5.1 POWER

The total power requirement for the proposed expansion is as given below:-

Table 2.3: Power Demand

Phase Demand (MW) Expected Source

Operational 33 MWH (Existing)

18 MWH (Proposed)

51 MWH (Total)

Existing & proposed CPP and remaining will

be met from State grid as and when required.

2.5.2 WATER DEMAND

The total water requirement for the Existing – 1,318KLD; Proposed : - 537 (Fresh =343 +

194 Recycled) KLD; Total:- 1,855 KLD will be met through Gujarat Water Infrastructure

Limited(GWIL).. The detailed breakup of the same is given below:-

Table 2.4: Water Demand

S. No. Particulars Water Demand (KLD)


1. Industrial

a. Cooling 485 133 618

b. Boiler 428 233 661

c. Process 145 96 241

2. Domestic 215 61 276

3. Plantation/Oth

ers

45 14 59

Total 1318 537 (343 Fresh +

194 Recycled)

1855 (1661 fresh +

194 Recycled)




WHRB





MAY’ 2018 77

EXISTING WATER BALANCE

Fig- 2.0: Flow chart for the existing water demand

Evaporation 561

Make Up Water - 1318

Gardening/

sprinkling-45

Induction

furnance-485

Cooling Blow

Down-33

STP-105 Cooling-

168

DM Reject-23

Neutralization-66.5

Power Plant-428

Boiler-237

Process

water-145 Domestic water-215

� Water Sprinkling

� Dust Suppression

� Green Belt Development

DM Water

260

Collection Pit-135.5

Neutralization -45

Boiler Blow Down-10.5

DM Regeneration-12

Consumption

110



WHRB





MAY’ 2018 78

Proposed Water Balance

Existing Daily Water Requirement:1318 + Proposed :343KLD

Total Daily Water requirement after expansion=1661 KLD

Proposed Water Requirement in KLD One Time water demand.=

537

Fresh Water Demand=343

Recycled Water =194

Figure- 2.1: Flow chart for the proposed water demand

Evaporation 160

Evaporation 83

150

Sludge-5

Induction

furnance-133

Cooling Blow

Down-09

STP-49 Cooling-

92

Recycle to

cooling tower

gardening -44

DM Reject-13

Treated

Water-44

Neutralization-75

Power Plant-233

Boiler-122

Process

water-96 Domestic water-61

� Water Sprinkling

� Dust Suppression on non metalled area

� Green Belt Development

� General cleaning

DM Water

141

Manure for

greenbelt

development

Collection Pit-75

Neutralization -42

Evaporation

117

Boiler Blow Down-5

DM Regeneration-6

Consumption

12



WHRB





MAY’ 2018 79

2.5.3 MANPOWER REQUIREMENTS

The proposed expansion project generates employment for around 290 people (after

expansion). Priority for employment is given to local persons. Following staff & workers are

proposed to be employed:-

Table 2.5: Manpower Details

S.

No.

Category No. of Persons


1. Permanent Staff 355 70 425

2. Skilled Workers 225 60 285

3. Semi-Skilled worker 130 50 180


Total 960 290 1250

2.5.4 LAND USE BREAK-UP

The expansion project is coming up within existing premises; no additional land is required

for the expansion. Area for existing and for the future expansion is earmarked given below:

Table 2.6: Land Use of Project Site

S.

No.



1. Plant Area Office Area,

Residential Colony (All

covered area).

40.60 - 40.60 35.0%

2. Paved Area (Road, Corridor,

Parking and Drainage).

2.10 2.10 1.810%

3. Green Belt Area 28.08 28.08 24.20

4. Future for expansion 45.22

38.98%

Plant Area - 18.10 18.10

Paved area - 0.40 0.40

Greenbelt - 10.20 10.20

5. Open area - 16.52 16.52

Total 116.00 - 116 100



WHRB





MAY’ 2018 80

2.6 PROJECT DETAILS

2.6.1 RAW MATERIALS REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE

AND MODE OF TRANSPORTATION OF RAW MATERIALS.

Following raw materials will be required for the manufacturing of Sponge Iron Plant.

Table 2.7: Details of Raw Material

S. No. Raw Material Existing Proposed Total Source Mode of transport

Consumption In TPA

1 Iron ore 3,60,000 2,37,600 5,97,600 Imported/ Indian Transported by ships

to nearest port and

later transported via

dumper to site

2 Coal 2,41,200 1,59,192 4,00,392

Imported / Indian

Billets:

Following raw materials will be required for the manufacturing of Billets.


S. No. Raw Material Existing Proposed Total Source Mode of

transport Consumption in TPA

1 Sponge 2,25,360 1,48,140 3,73,500

In-house

production

Internal

Transported by

Trucks

2 Scrap 1,56,660 - 1,56,660 Local Market/

Imported

Transported by

Trucks

TMT Bars


S. No. Raw Material Existing Proposed Total Source

Consumption in TPA

1 MS Billets 3,41,976 87,024 4,29,000 In house production

AFBC/CFBC Power Plant

Coal and char will be mainly used as raw material for AFBC/CFBC power plant. The list of

raw material is as mentioned in:



WHRB





MAY’ 2018 81

Table 2.10: Raw Material For Power Plant

Materials Existing

Consumption

Proposed

Consumption

Total

consumption

Source Transportation

Coal 1,87,618 TPA 75,047 TPA 2,62,665 TPA Imported

/Indian

coal

Transported by ships to nearest

port and later transported via

dumper to site

Coal Char 66,795 TPA 26,718 TPA 9,3512 TPA In-house

production

Transported by Trucks

2.6.2 PRODUCTS

The products to be manufactured are as given below:-

Table 2.11: Details of Product

S. No. Product Existing (TPA) Proposed (TPA) Total (TPA)

1. Sponge Iron 2,25,000 1,48,500 3,73,500

2. M.S. Billets 3,36,600 92,400 4,29,000

3. TMT Bars 3,30,000 92,400 4,22,400

4 M S Rolled Bar 5346 1,497 6,843


Power Generation

6 Power Plant (AFBC/CFBC) 25 MW 10MW 35 MW


2.7 EQUIPMENT DETAILS

The list of equipment to be installed as a part of expansion project with the existing list

is as mentioned below:

Table 2.12: Equipment details for proposed plant

Name of Process Nos of Equipments Capacity

Sponge Iron Kiln 01 450 TPD

Induction Furnace 01 30 TPH

Power Plant Boiler (AFBC/CFBC) 01 10 MWH

Power Plant Boiler(WHRB) 01 8 MWH

Rolling Mill (TMT Bars) 01 280 TPD



WHRB





MAY’ 2018 82

Table 2.13: Equipment details for existing plant

Name of Process Nos of Equipments Capacity

Sponge Iron Kiln 04 175 TPD EACH KILN

Induction Furnace 05 20 TPH EACH FURNACE

Power Plant Boiler (AFBC/CFBC) 01 25 MWH

Power Plant Boiler (WHRB) 01 8 MWH

Rolling Mill (TMT Bars) 01 1000 TPD



WHRB





MAY’ 2018 83

2.8 PROCESS/ MANUFACTUIRNG DESCRIPTION

2.8.1 Process Description of Sponge Iron Manufacturing Unit

Rotary Kiln

The process of the production of sponge iron consists of the reduction of Pellets with solid

carbonaceous material (coal/coke/lignite) in a rotary kiln at high temperature, cooling to

room temperature in the rotary cooler with indirect water cooling system, screening and

magnetic separation of the product. Sponge iron, being magnetic, gets attracted and

separated from the non-magnetic char. In the process for the production of sponge iron, raw

materials (pellets, Sponge Iron, feed coal and lime stone /dolomite) are fed to the rotary kiln

through feed tube in a pre-determined ratio by electronic weighing equipment. It is

internally lined with refractory of 300 mm thick. It is rotated by an AC variable speed motor

at a steeples variable speed ranging from 0.2 to 1.0 rpm. Due to inclination and rotary

motion of the kiln, the material moves from the feed’s end of the kiln to the discharge end in

approximately 5.5 hrs (Tendency time).

Fine coal is blown counter currently from the discharge end of the kiln to maintain required

temperature and carbon concentration in the bed. Kiln has seven shells, air fans mounted on

the top which blow air in the respective zones to maintain the required temperature profile.

Material and hot gasses move in the counter current direction and as a result, pellets gets

pre-heated and gradually reduced by the time it reaches discharge end.

Kiln is divided into two zones namely pre-heating zone and reduction zone. The pre-heating

zone is normally 30 per cent of the total length of the kiln and rest is taken as reduction zone.

Material gets heated to the reduction temperature in pre-heating zone up to 200°C, iron ore,

coal and limestone gets dried and all the moisture is vapourised. Upto 800°C, pellets gets

roasted and any carbonates in it get calcinated.

In the coal, volatile matter starts getting released. Limestone also gets calcinated and

becomes active. Pellets, which are in the form of hematite, gets reduced to magnetite.

Afterwards, materials enter to the reduction zone where the magnetite is reduced to wustite

and then to metallic iron. Coal contains sulphur. During the decomposition of coal, sulphur is

released in the form of Iron sulphide. Iron sulphide (FeS) has deleterious effect in the steel

making and has to beremoved. Hence, limestone is used to prevent the sulphur pick up by

sponge iron. All the above reactions are possible only in the presence of CO.



WHRB





MAY’ 2018 84

Therefore, generation of CO is most important reaction, which is called as ‘Boundary

reaction’. This reaction is highly endothermic which is also reversible. Conditions favorable

for the forward reaction i.e. generation of CO, is higher temperature higher the production of

CO. Concentration of the reactants has to be high so that the forward reaction occurs. Low

pressure also favors CO generation.

Oxygen required for the burning of these combustibles is supplied from the air tubes placed

along the length of kiln. By controlled combustion, temperature in various zones is

maintained so that the reduction is proper and to required degree. Reduction of iron ore is

topo-chemical i.e. reduction proceeds from the surface to core. Iron ore on partial reduction

has all the different stages of reduction. Hot material, after reduction is complete, is

transferred to the rotary cooler via transfer chute. The rotary cooler is 1.8 Mts. in diameter

and 30 Mts. long made up of Mild Steel shell. It is also inclined at 2° approximately and

rotates at variable speed from 0.2- 1.2 rpm. It is driven by an AC variable speed motor. Water

is sprayed on the top of the shell, which cools the material inside the cooler indirectly.

Heat from the material is extracted by the shell. In order to increase the surface area for the

heat extraction fins are welded inside. Complete shell is covered by thin layer of water. Heat

is transferred from the shell to the water by convection. By this, the material gets cooled to

80oC and is discharged on the belt conveyor by double pendulum valve.

The double pendulum valve acts as the seal for the prevention of the atmospheric air into

kiln cooler system. The total kiln cooler system is kept under positive pressure about 0.3-0.5

mbar. This prevents the atmospheric air from getting into the system. The kiln has to be

always operated on positive pressure, as any leakage into the system will cause the re-

oxidation of the sponge iron thereby causing the drop in the quality of the product. The

material after the discharge from the cooler is dropped on to the cooler discharge conveyor.

A diversion chute is provided at head end of this conveyor for diversion of the material in

case of break down in the production separation. The material is then sent to product

separation system. In product separation system consisting of double deck screen, material

is screened to 0-15 mm size fractions. Oversize i.e. +20 mm obtained is small quantity so it is

taken on the floor or diverted to the sponge iron bin. The 0-3mm size fraction, called as fines,

are fed to a drum type magnetic separator where the magnetic sponge iron fines and the

non-magnetic dolochar separated and fed to the respective bins through the chutes and

conveyor.



WHRB





MAY’ 2018 85

The coarser fraction is similarly separated by another magnetic separator and fed so

respective bins. This magnetic fraction is called the sponge iron lumps and the non- magnetic

as char which is the unburned coal. This char can be recycled depending on the quality

obtained after processing. The gasses, which flow in the counter current direction of the

material, go to the dust-settling chamber where the heavier particles settle down. These

particles are continuously removed by the wet scrapper system. The gasses then pass to the

after burner chamber where the residual carbon or CO is burned by the excess air available.

The gasses are at high temperature and have lot of heat energy, which can be utilized for the

power generation through the waste heat recovery boiler. The hot gas after the heat

recovery boiler gets cooled to 200°C. The gases are then scrubbed and let-off to the

atmosphere through the chimney. Alternatively the hot gasses are quenched and scrubbed to

clean all the dust in it, and then let off to the atmosphere through the stack.

Chemical reactions taking place in reduction zone is represented by following equation:

Fex Oy + CO FexOy-1 + CO2

The carbon dioxide formed is converted to carbon monoxide by means of the carbon in the

reluctant in accordance with the boundary reaction:

C + CO2 2CO

Burning of small amount of carbon and excess carbon monoxide by means of outside air

supplied through tubes to provide heat for the process reactions can be shown by the

following equations:

CO + 1/2 O2 CO2

It is to be noted that a reducing and oxidizing atmosphere prevail side by side in the rotary

kiln. Within the material charge, it is reducing atmosphere accompanied with endothermic

reaction while in the free board above are the oxidizing conditions with the exothermic

reactions.

The separation of the two atmospheres is ensured by the pressure generated by CO

emerging from the charge into the kiln free board. This avoids re-oxidation of the reduced

particles at the charge surface.



WHRB





MAY’ 2018 86

Fig- 2.3: Flow chart for the sponge iron manufacturing process

Sponge Iron

Lumps Bin

Sponge Iron Ore

Crushing

Screening

Iron Ore Bin

Coal

Crushing

Screening

Coal Bin

Raw Material Feeding At

Ground Hopper

Over Size Over Size

Limestone Bin

Setting up of Production of Mixed Raw Materials for Kiln Feed

Processed in Rotary Kiln at 1075o C with Air Control

Indirect Cooling in Rotary Cooler with Water Spray

Screening of Mixed end Products (Sponge Iron and un burnt Coal)

Sponge Iron Lumps + Char

Drum Type Magnetic

Separator

Char Bin

Sponge Iron Fines + Dolo Char

Drum Type Magnetic

Separator

Fines Bin Dolo Char Bin



WHRB





MAY’ 2018 87

2.8.2 Process Description of Captive Power Plant

Operation of the Plant

The waste heat recovery boilers will generate around 35 TPH of steam with the outlet

parameters of 105 Ksc (a) and 535 Deg. C., while taking in the feed water at 165 Deg.C from

the HP heater. The entire waste gas from the sponge iron kiln will be utilized in the waste

heat boiler for the steam generation.

Circulating Fluidized Bed Combustion (CFBC) / Atmospheric Fluidized Bed

Combustion (AFBC) Boiler

Fluidized bed combustion is a "Clean Technology for a better tomorrow" where technology

and economy have been interwoven harmoniously in quest of a better environment. The

environmentally friendly perspective of this technology are as follows:

At the low combustion temperature of 850°C / 900°C, no Nitrogen Oxides result from the

Nitrogen in the combustion air, with the end result of extremely low NOx emissions even

with fuels rich in Nitrogen.

Formation of SOX is essentially prevented by the addition of limestone. This is both mixed

into the fuel and blown into the combustion chamber. Due to the favourable conditions in the

fluidised bed, about 90 per cent of the resulting Sulphur Oxides can be removed.

A broad selection of fuels thereby enabling use of Char produced in the DRI Plant replacing

about 40% of coal.

Better Plant flexibility at partial loads of about 25 per cent and quick load changes.Low

Auxiliary Power consumption compared to other coal fired Boiler versions.

The Steam Generator would be semi-outdoor type, natural circulation, balanced draft, Single-

drum, designed for firing different grades of coal. Boiler is of bubbling fluidized bed type to

handle even high ash coal. Capacity of AFBC coupled with adjacent WHRB has been selected

to ensure adequate margin over the requirement of turbine at 100% MCR. AFBC would be

designed to operate with "The HP heaters out of service" condition (resulting in lower feed

water temperature at Economiser inlet) and deliver Steam to meet the Turbo-Generator

requirement at 100% MCR. Economiser section of the Boiler would be non-Steaming type.

Super heater sections would be convection type and also bed super heater and designed so

as to maintain rated Steam temperature of 535°C (:i: 5°C) at super heater outlet over the

control range of 60% to 100%, MCR. Attemperator is provided at the outlet of convection

super heater for temperature control at Steam Generator outlet. The Boiler furnace and flue

gas passages would be designed for appropriate low velocities in order to minimise erosion.



WHRB





MAY’ 2018 88

Suitable balanced draft System would be provided for the Steam Generator with two (2)

forced draft and two (2) induced draft fans. Each of these fans would be capable of meeting

the air requirement at 60% Boiler MCR load. The forced draft fans would be radial type with

inlet vane control for regulation of airflow. The induced draft fans would be radial type with

multi louver damper control the regulation. The forced draft fans would control total airflow

to Boiler and the induced draft fan would control furnace draft of the Boiler through

automatic control loops. In addition to the FD fan, two (2) primary air fan of 60% capacity

each shall be provided for transportation of fuel with one working and one standby.

The Boiler would be top supported type and would be provided with all supporting Steel

platforms, galleries and stairways for easy approach and Maintenance of the Unit. Adequate

weather protection would be provided for instruments and operating personnel. Necessary

insulation along with skin casing to limit outside surface temperature to the safe level would

be provided.

Capacity MW 18

No of Steam Generator No. 1

Superheated Steam pressure kg/cm2 (a) 105

Superheated Steam, temperature °C 535+/-5

Feed water temperature at economizer °C 165

Flue gas temperature at AH outlet °C 140

Fuel used:

Main fuel Char & Coal

Performance fuel Char & Coal

Startup fuel Light Diesel Oil

Char produced by DRI Kilns will have an outlet as fuel to FBC Boiler. Coal and Char will be

fired as a base fuel to FBC Boiler for Steam Generation with consequent proportionate

reduction in fuel cost.

Analysis Report of Char

Characteristics Char

Carbon 40.00%

Hydrogen 0.75%

Oxygen 3.00%

Sulphur 0.30%



WHRB





MAY’ 2018 89

N2 0.74%

Ash 55%

Moisture Negligible

GCV 3500 Kcal /kg

Steam Turbine Generators and Auxiliaries

Steam Turbine

The Steam Turbine will be of condensing type. The set will be complete with Condenser, Air

Evacuation System, 2 x 100% Condensate Extraction Pumps, Generator Cooling, System,

Gland Sealing with Gland Vent Condenser, Lube Oil System, LP & HP Re-generative Feed

Heaters, etc.

Generators

Generator will be rated for 18 MW with 0.8 lagging Power Factor, delivering Power at 12 KV,

3 Phase, 50 Hz Star connected in IP55 enclosure.

The Generator will be provided with brush less excitation. It shall be capable of operating in

Isolation or in parallel with the Power grid, with Voltage Variation of (+) 5% to (-) 5% and

Frequency Variation of (+) 3% to (-) 5% with Short Circuit ratio of around 0.8.

The Generator shall have class F insulation with Temperature rise limited to Class "B"

insulation and shall be designed for CACW Cooling.

All Six Terminals of the Generator shall be brought out and shorted, neutral point will be

grounded through a Resistor. Generator shall be connected through Isolated Phase Bus duct

to the 24 MVA Generator Transformer which will be provided with an "On-Load" Tap

Changing Gear of :I: 10% range.



WHRB





MAY’ 2018 90

BOILER

WHRB / CFBC/AFBC

TURBINE ALTERNATOR

18 MW POWER

AIR COOLED CONDENSERFEED WATER PUMP

MAKE UP WATER

WATER

3 %

10 MW

8 MW

Excitation System

The Excitation System envisaged will be brush-less type. The Excitation System shall be

capable of supplying the Excitation Current of the Generator under all condition of Operation

of Load, Voltage and Power. Rated current and Voltage of the Exciter shall be atleast 120% of

normal Excitation Current and atleast 110% of no Load Excitation. Voltage with maximum of

140% ceiling. The Exciter response ratio shall be greater than 1.5. The Field Breaker and

Field Suppression System will also be part of Exciter System. Automatic high speed

Thyristorised, Auto Manual AVR capable of maintaining Steady State Terminal Voltage

within :I: 0.5% of the preset Value under all Operating Conditions and capable of smooth and

continuous running over the Operating Range. The Generators shall be provided with

Temperature Detector embedded at different location, i.e. Stampings, Stator Windings, etc.

Process flow chart of Captive Power plant

Figure: Typical Flow Diagram of Steam Based Turbo Generator Set

Figure- 2.2: Process flow chart of Captive Power plant

The induction melting technology and Arc furnace technology in the Global Steel Scenario has

brought a significant change in technological and revolution where it has been proved that the

steel produced out of sponge iron mixed with Cast Iron and M.S. Melting Scrap/Pig iron coupled

with electric induction furnace, medium frequency, constant power track and arc furnace rouge

has become formidable process and can offer better economics at a relatively smaller scale



WHRB





MAY’ 2018 91

operations. The process involves the charge mix of Raw material mainly Sponge Iron 70% to

90% and C.I.Scrap/ M.S.Scrap 15% to 30%, into molten bath with

constant power track through Solid State generator converting A.C. Power into D.C. Power and

again to convert the same into A.C. Power after changing the frequency of

cycle in between 250 to 500 HZ through thyesisters (an electronic device). This converted

A.C. power with a frequency of 250 to 500 HZ is passed through capacitor Rack after achieving

the de-sired voltage and the same is passed through copper Bus Bar into Molten bath having

copper coil, cooled through water circulation, transparent the heat energy into molten bath at

constant voltage to melt the Iron and Steel at a temperature of 1550°C.

The continuous efforts made by technologists in established mini steel plants all over India,

sponge iron manufacturers and Medium Frequency Melting Induction furnace equipment

manufacturer/arc furnace manufacturers have developed the process parameters by which

considerable quantity of sponge iron are used in steel making. This has brought a new era in

steel melting technology in the country where scrap scarcity can no more be a threat to the

mini steel plants. The economy of steel making rather introduced Induction Furnace/arc

furnace to convert sponge iron and scrap into steel where better productivity could be

attained with proportionately lower scale.

Continuous Casting Machine: Liquid Metal from Induction Furnace is carried in a ladle over

the Concast Machine. The liquid metal flows from the ladle through a slide gate system

underneath it into water cooled copper mould tubes which solidifies the liquid metal into a

square shaped mould which we call as M.S. Billets. From the considered casting cycle time, the

number of strands required to cast 100 mm sq. and 110 mm sq. billets is worked out to be two

(2). Based on the above, 2 strand billet casting machine suitable for casting up to 160 mm sq.

Billets have been selected. Space provision will be made in the shop for installation of a second

billet caster in future.



WHRB





MAY’ 2018 92

Figure-2.4: Flow chart showing Process Flow for Manufacturing M.S. Billet

BILLETS

MELTING IN INDUCTION FURNACE

BLENDING IN PREDETERMINED RATIO

CASTING IN CONCAST MACHINE

TAPPING OF MOLTEN METAL

RAW MATERIAL PREPARATION SPONGE

IRON SCRAPS (SIZING & PROCESSING)



WHRB





MAY’ 2018 93

Rolling Mill

The process involves converting the shape stock viz. Ingots/billets to desired finished

section in hot condition by way of passing the material between a pair of grooved rolls and

providing suitable reduction at various stages. Whole operation is conducted at a particular

temperature range and within a limited time span.

Stages of rolling operation are comprised of heating of feed stock to rollable temperature,

rolling the feed stock in different mill stands, cropping the hot bar during process of rolling

between stands as applicable and subsequently finishing in the form of hot rolled deformed

bar in straight length. The hot bar coming out of last pass is then conveyed through TMT line

and collecting in a cooling bed after shearing.

The bars at almost ambient temperature are sheared to commercial length stored and kept

ready for dispatch. In TMT process hot bars are subjected to quenching by means of an

intense cooling installation (cooling installation specially designed water spray system). This

step hardens the surface layer to martensite while the core structure remains austenite.

When the bar is free of water chamber heat flows from core to surface and surface gets

tempered to structure called tempered marten site.

In the cooling bed due to atmosphere cooling, the hardened zone is tempered by

temperature homogenization in the cross section and the austenite core is transferred to

ducktile-ferrite-pearlite core.



WHRB





MAY’ 2018 94

Figure-2.5 Flow chart showing Process flow chart of Rolling Mill

COOLING OF THE

BARS ON COOLING BED

ROLLING OF PREHEATED SOAKED STOCKS THROUGH

NUMBER OF PASSES TILL THE REQUIRED NOMINAL

DIAMETER OF BAR IS ATTAINED

PREHEATING THE BILLETS IN DOUBLE ROW

REHEATING FURNACE/ DIRECT HOT CHRGING

SHEARING OF THE BARS WITH

FLYING SHARES

CONTROLLED SURFACE QUENCHING OF THE

BAR IN THE TMT QUENCHING LINE

SHEARING OF BARS TO

MARKETABLE LENGTH

SIZE WISE STACKING OF

ROLLED TMT BARS

DISPATCH

CUTTING OF BILLET TO DEFINITE LENGTH



WHRB





MAY’ 2018 95

2.9 MATERIAL BALANCE

The material balance for different products is mentioned below:

Sponge Iron

Table 2.14: Material Balance for Sponge Iron Plant

IN PUT OUT PUT

Qty / MT of Sponge Iron 100 M T/ day Qty / MT of Sponge Iron Qty /day,

1 : 100 M T /day

Iron ore Pellet: 1.6 T 160 Sponge Iron. 100% 100

Coal : 1.0 T 100 Coal Char 20% 33

Ash 12

Dolomite : 0.08 8 Waste solids 3

Air : 5. 5 550 Air : 6.7 Tons 670

(as waste gas for power generation )

Total In put 818 MT Total out put 818 M T

Billets Table 2.15: Material Balance for Billets (Per 100 Tons)

INPUT TONS OUTPUT TONS

Sponge Iron 93 Billets 100

Scrap 23 Slag 15

CPC, Petcoke, Silicon Mn, Ferro Al, Ferro

Si DDHR Sheet

3.5 Burning Loss 1.5

Sodium Silicate, Casting Powder And

Other Additives

0.50 Other Miscellaneous Losses 3.5

Total 120 Total 120

TMT Bars Table 2.16: Material Balance for TMT Bars:

IN PUT OUT PUT

Qty / 100 MT of billets, Qty Qty / 100 MT of TMT Qty

M.S Billets : 1.03 103 TMT 100% 97

Waste fines & gases 6

Total Input 103 M T Total Output 103 M T



WHRB





MAY’ 2018 96

2.10 PLANT LAYOUT

The plant layout showing all facilities like raw material storage, finished storage area,

plant shed, green belt area, rain water harvesting system etc is given below and the same is

enclosed as Annexure-XV.

Date post:	18-Mar-2020
Category:	Documents
Upload:	others
View:	6 times
Download:	0 times

PROPOSAL FOR ENVIRONMENTAL CLEARANCE (PUBLIC … · saurashtra enviro projects pvt. ltd. 347 xiv....

Documents