Shri Girija Alloy & Power (I) Pvt. Ltd. - a...

Executive Summary

0

SUMMARY ON

ENVIRONMENTAL IMPACT ASSESSMENT

REPORT

OF

Expansion of Ferro Alloys unit

at

Peddapuram Village & Mandal,

East Godavari District, Andhra Pradesh

Shri Girija Alloy & Power (I) Pvt. Ltd.

Submitted to

ANDHRA PRADESH POLLUTION CONTROL BOARD


Expansion of Ferro Alloy unit Peddapuram Village & Mandal,


Executive Summary

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1.0 PROJECT DESCRIPTION

Shri Girija Alloy & Power (I) Pvt. Ltd. is an existing Ferro alloy & Power plant situated at Sy.

Numbers 148 P, 149 P, 151, 152 P, 153 P, 162 P, 164, 355 P, 397 P, 400 P, 428 P,

Peddapuram Village, Peddapuram Mandal, East Godavari District, Andhra Pradesh.

Now we propose to enhance the production of existing ferro alloy products and produce

other ferro alloy products, noble ferro alloys and calcium aluminate based synthetic slag by

proposing 6 x 9 MVA, 8 x 400 Kg Crucibles & 3 x 500 KVA Submerged Electric Arc Furnace.

Proposed expansion will be taken up in the existing plant premises of 150 acres only.

As per the Ministry of Environment, Forest & Climate Change (MOEF & CC), New Delhi

notification, dated 14th September, 2006 and its subsequent amendments, all Primary

metallurgical processing industries are classified under Category ‘A’. The Ministry of

Environment, Forest & Climate Change, New Delhi has accorded Terms of Reference (TOR)

for the proposed expansion project vide letter no. J-11011/679/2009- IA II (I) dated 20th

March, 2017. The EIA Report has been prepared by incorporating the TOR stipulated by the

Expert Appraisal Committee of MoEF & CC.

Pioneer Enviro Laboratories & Consultants Private Limited, Hyderabad, which is accredited

by NABET, Quality Council of India, vide certificate No. NABET/ EIA/ 1619/ RA 026, for

preparing EIA report for Metallurgical Unit, have prepared Draft Environmental Impact

Assessment (EIA) report for the proposed expansion project by incorporating the TOR

approved by Ministry of Environment, Forest & Climate Change, New Delhi. The report

contains detailed description of the following:

Characterization of status of environment with in an area of 10 km radius from the plant

site for major environmental components including air, water, noise, soil, flora, fauna

and socio-economic environment.

Assessment of air emissions, liquid waste and solid waste from the proposed expansion

project along with the noise level assessment.

Environmental Management Plan comprising of emission control measures proposed to

be adopted in the expansion project, solid waste management, Greenbelt development.

Post Project Environmental Monitoring & Budget for Environmental Protection

Measures.




Executive Summary

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2.0 Plant Configuration and Production Capacity

The following table furnishes the existing and proposed units along with production capacities

S.No Unit Existing Proposed Production Capacity

After proposed expansion

Unit Production

capacity Unit

Production capacity

1. Ferro Manganese (High carbon / medium carbon / low carbon) SEAF -

5 X 9 & 1 X 5.4 MVA

36,000 TPA (120 TPD)

SEAF - 4 x 9 MVA

1,20,000 TPA (400 TPD)

(or)

1,56,000 TPA (520 TPD)

2. Silico Manganese (High carbon / medium carbon / low carbon)

72,000 TPA (240 TPD

85,000 TPA (283 TPD

(or)

1,57,000 TPA (523 TPD)

3. Ferro Chrome (High carbon / medium carbon / low carbon)

85,000 TPA (283 TPD)

85,000 TPA (283 TPD)

4. Ferro Silicon (High carbon / medium carbon / low carbon)

-- -- SEAF – 2 x 9 MVA

25,000 TPA (83 TPD)

25,000 TPA (83 TPD)

5. Low carbon Ferro chrome -- --

Crucibles – 8 x 400 Kg

3,600 TPA (12 TPD)

3,600 TPA (12 TPD)

6. Ferro Molybdenum -- -- 3,600 TPA (12 TPD)

3,600 TPA (12 TPD)

7. Ferro Titanium -- -- 3,600 TPA (12 TPD)

3,600 TPA (12 TPD)

8. Ferro Vanadium -- -- 3,600 TPA (12 TPD)

3,600 TPA (12 TPD)

9. Calcium Aluminate based Synthetic slag -- -- SEAF – 3 x 500 KVA

15,000 TPA (50 TPD)

15,000 TPA (50 TPD)

10. Power generation -- 108 MW -- 108 MW




Executive Summary

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1.2 Raw Materials

The following will be the raw material requirement for the proposed expansion project:

Raw Material Quantity

(TPA) Sources Mode of Transport

Ferro alloys

Manganese Ore 4,41,000 Imported / indigenous from

Karnataka / Orissa / Madhya

Pradesh / Andhra Pradesh

Sea, rail, road

Chrome Ore 1,95,500 Sea, rail, road

Coke 1,14,320 Imported / Indigenous /

Singareni Colleries / imported Sea, road Coal 1,59,975

Charcoal 40,000

Quartz 1,05,250 Andhra Pradesh Rail, road

Dolomite 82,000 Andhra Pradesh Rail, road

Mill Scales 10,000 Andhra Pradesh Rail, road

EC paste 7,815 Andhra Pradesh Rail, road

Magnesite 5100 Andhra Pradesh Rail, road

Ferro manganese slag 34,000 In plant generation conveyor

Noble Ferro alloys

Chrome Ore 7,059 Import & Indigenous – Orissa Sea, rail, road

Aluminimum Telic 5,690 Import -Dubai Sea, Road

Flourspar 630 Import – China Sea, Road

Ferrosilicon 1,525 Captive

Ilmenite 3,727 Indigenous - Orissa / Kerala Road

Iron Nails 1,680 Indigenous – Andhra Pradesh Road

lime 784 Indigenous – Gujarat Road

mill scale 5,690 Indigenous – Andhra Pradesh Road

Sodium Nitrate 530 Indigenous – Gujarat Road

rutile 508 Import & Indigenous – Orissa

/ Kerala

Sea, Road

V2O

5 4,000 Import Sea, Road

MO3

(Moly Oxide) 3,600 Import Sea, Road

Calcium aluminate based Synthetic slag

Hydrated Lime 9,000 Indigenous – Rajasthan Road

Bauxite 4,500

Indigenous - Chhattisgarh /

Orissa

Road

Aluminium telic 900 Import Sea

Aluminium catalyst 600 Indigenous / Gujarat Road




Executive Summary

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1.3 Manufacturing Process

1.3.1 Ferro alloys

Ferro manganese or silicon-manganese will be produced using manganese ore as main raw

material in a sub-merged arc furnace using reducer (Coke) under high voltage. Similarly

Ferro silicon will be produced using Quartz as main raw material and Ferro chrome using

Chrome ore as raw material.

Ferro Chrome Recovery unit The slag generated during Ferro chrome manufacturing will be sent to Ferro chrome

recovery unit. Ferro chrome will be recovered through process of crushing, screening and

jigging.

Noble Ferro alloys Noble Ferro alloys are manufactured through Alumino Thermit Process. Alumino thermic

process aims at the production of Ferro Alloys from the oxides of elements by reduction

with Aluminum powder using exothermic heat of the reaction for smelting purpose.

Calcium Aluminate based Synthetic slag Calcium Aluminate based Synthetic Slag is made of select raw material of Calcium and

Aluminium, blended at a proper proportion, ground to powder, pelletized after churning,

sintered or melted in kiln.

1.4 Water Requirement

Total water requirement after expansion will be 1400 m3/day. Water required for the

expansion project will be sourced from Samalkot canal. Approval from the Irrigation

department for drawing 1400 m3/day of water has already been obtained.




Executive Summary

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The following is the break-up of the water requirement for proposed expansion project.

WATER REQUIREMENT (For Expansion)

S.No. Details of water requirement Quantity in (m3/day)

1. Make-up water for cooling 96

2. Domestic 10

Total 106

1.4 Waste Water Generation

There will be not be any effluent generation from the proposed expansion as closed circuit

system will be followed in the Ferro alloy unit. The only source of effluent generation will

be sanitary waste water of 8 KLD will be treated in septic tank followed by sub-surface

dispersion trench. In the existing plan also zero effluent discharge is being maintained.

The following will be the total wastewater & it’s break-up.

WASTE WATER GENERATION (Expansion)

S.No. Source Generation (m3/day)

1. Sanitary Wastewater 8

Total 8

1.5 Wastewater Characteristics

PARAMETER Sanitary waste water

pH 7.0 – 8.5

BOD (mg/l) 200 – 250

COD (mg/l) 300 – 400

TDS (mg/l) 800 – 900

2.0 DESCRIPTION OF ENVIRONMENT

Base line data has been collected on ambient air quality, water quality, noise levels, flora

and fauna and socio economic details of people within 10 km radius of the plant.




Executive Summary

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2.1 Ambient air quality

Ambient air quality was monitored for PM2.5, PM10, SO2, NOx & CO at 8 stations including

plant site during October 2016 to December 2016. The following are the concentrations of

various parameters at the monitoring stations:

Parameter Concentration

PM2.5 : 18.9 to 36.4 g/m3

PM10 * : 32.4 to 65.8 g/m3

SO2 : 9.8 to 16.3 g/m3

NOX : 11.7 to 20.4 g/m3

CO : 360 to 680 g/m3

2.2 Water Quality

2.2.1 Surface Water Quality

Samalkot canal (5.2 Kms.) is flowing within 10 Km. radius of the plant site. Two nos. of

Surface water samples have been collected, one from upstream & other on downstream of

Samalkot canal w.r.t the plant site to assess surface water quality. The analysis of samples

shows that all the parameters are in accordance with BIS-2296 specifications.

2.2.2 Ground Water Quality

8 No. of ground water samples from open wells / bore wells have been collected from the

nearby villages to assess ground water quality impacts and analyzed for various Physico-

Chemical parameters. The analysis of samples shows that all the parameters are in

accordance with BIS: 10500 specifications.

2.3 Noise Levels

Noise levels were measured at 8 locations during day time & Night time. The noise levels at

the monitoring stations are ranging from 46 dBA to 64.6 dBA.




Executive Summary

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3.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

3.1 Prediction of impacts on air quality

The likely emissions from the proposed project are PM10, NOx & CO. The predictions of

Ground level concentrations have been carried out using Industrial Source Complex (ISC-3)

model. Meteorological data such as wind direction, wind speed, max. and min.

temperatures collected at the site have been used as input data to run the model.

Net Resultant maximum ground level concentrations during operation of expansion project

Item PM10

(g/m3)

NOX

(g/m3)

CO

(g/m3)

Maximum baseline conc. in the study area 65.8 20.4 680

Maximum predicted incremental rise in

concentration due to emission from proposed

expansion project

1.2 12.3 --

Maximum predicted incremental rise in

concentration due to vehicular emissions

0.7 5.3 3.5

Net resultant concentrations during operation of

the plant

67.7 38 683.5

National Ambient Air Quality Standards 100 80 2000

The predicted results show that the net resultant concentration (max. baseline conc. +

max. incremental rise in conc.) of PM10, NOx and CO are well within the National Ambient

Air Quality Standards after commissioning of proposed expansion project. Hence there will

not be any adverse impact on air environment due to the proposed expansion project.

3.2 Prediction of impacts on noise quality

The major sources of noise generation in the proposed expansion project will be DG sets.

The ambient noise levels will be within the standards prescribed by MoEF i.e. the noise

levels will be less than 75 dBA during day time and less than 70 dBA during night time. 50.0

acres (inclusive of existing) of extensive greenbelt already developed which helps to

further attenuate the noise levels. Hence there will not be any adverse impact due to noise

on population in surrounding areas due to the proposed expansion project.




Executive Summary

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3.3 Prediction of impacts on Water Environment

Water drawl permission already obtained for entire quantity from State Irrigation

Department. There will be not be any effluent generation from the proposed expansion as

closed circuit system will be followed in the Ferro alloy unit. The only source of effluent

generation will be sanitary waste water which will be treated in septic tank followed by

sub-surface dispersion. In the existing plant, zero discharge is being maintained and will be

continued even after expansion.

Hence there will not be any adverse impact on water environment due to the proposed

expansion project.

3.4 Prediction of Impacts on Land Environment

There will not be any effluent generation from the proposed expansion as closed circuit

system will be adopted in the ferro alloy unit. Sanitary waste water generated will be

treated in septic tank followed by subsurface dispersion.

All the required air pollution control systems will be provided to comply with CPCB / APPCB

norms. All solid wastes will be disposed / utilized as per CPCB / APPCB norms. 50.0 Acres

(inclusive of existing) of greenbelt has already been developed as per guidelines. Hence

there will not be any adverse impact on land environment due to the proposed expansion

project.

3.5 Socio - Economic Environment

There will be lot of opportunities in employment to local people during construction as

well as in operation phase. There will be further upliftment in Socio Economic status of the

people in the area. 2.5% of expansion project cost will be allocated for CSR activities.

Hence there will be further development of the area due to the proposed expansion

project.




Executive Summary

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4.0 ENVIRONMENTAL MONITORING PROGRAMME

In the existing plant online stack monitoring has been provided. Ambient Air Quality, Sack

monitoring & effluent analysis will be carried out regularly as per CPCB norms and the

analysis reports will be submitted to Ministry of Environment & Forest, Chennai & APPCB

regularly. Online stack monitoring facility will be provided o furnace stacks.

5.0 ADDITIONAL STUDIES

No Rehabilitation and Resettlement is involved in the proposed project. Hence no R & R

study has been carried out.

6.0 PROJECT BENEFITS

With the establishment of the proposed expansion project employment potential will

increase. Land prices in the area will further increase. The economic status of the people in

the area will improve due to the proposed expansion project. CSR activities will be taken

up as per norms. Periodic medical checkups will be carried out. Top priority will be given to

locals in employment.

7.0 ENVIRONMENT MANAGEMENT PLAN

7.1 Air Environment

The following are air emission control systems proposed in the proposed expansion

project:

S.No. Source Control Equipment Maximum Particulate emission at the outlet

1. Submerged Electric Arc Furnace (6 x 9 MVA)

Fume extraction & cleaning system

With bagfilters 50 mg/Nm3

2. Crucibles (8 x 400 Kg)



3. Submerged Electric Arc Furnace (3 x 500 KVA)



The following air pollution control systems/ measures are proposed in the Plant:

All conveyors will be completely covered with G.I. sheets to control fugitive dust.




Executive Summary

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All bins will be totally packed and covered so that there will not be any chance for dust

leakage.

All the dust prone points material handling systems will be connected with de-dusting

system with bag filters.

All discharge points and feed points, wherever the possibility of dust generation is there a

de-dusting suction point will be provided to collect the dust.

Raw material unloading areas will be provided with dust suppression system

Greenbelt developed will help in attenuating air emissions further

7.2 Water Environment



be sanitary waste water which will be treated in septic tank followed by sub-surface

dispersion.

7.3 Noise Environment

The major sources of noise generation in the proposed project will be DG sets. Acoustic

enclosure will be provided to the DG set. All the machinery will be manufactured in

accordance with MoEF&CC norms on Noise levels. The employees working near the noise

generating sources will be provided with earplugs. The extensive greenbelt developed

within the plant premises will help in attenuating the noise levels further.

7.4 Land Environment



be sanitary waste water which will be treated in septic tank followed by sub-surface

dispersion. All the required Air emission control systems will be installed and operated to

comply with MOEF&CC / CPCB / APPCB norms. Solid wastes will be disposed off as per

norms. Extensive greenbelt has been developed in the plant premises. Hence there will not

be any impact on land environment due to the proposed expansion project.




Executive Summary

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Solid waste generation and disposal

S.No Waste / By product Quantity (TPA)

Method of disposal

1. Ferro Manganese slag 96,000 Will be used in manufacture of Silico manganese as it contains high MnO2.

2. Silico Manganese slag 1,02,000

Will be utilized in road construction / land filled

3. Ferro Chrome slag

1,02,000


4. Ferro Silicon slag

10,000


5. Low carbon Ferro chrome

slag

6,426 Once the product is manufactured, TCLP test will be conducted for the slag and will be used for landfill / as per outcome of TCLP test sent to TSDF.

6. Ferro Molybdenum slag 3,600

7. Ferro Titanium slag 3,960

8. Ferro Vanadium slag 3,960

7.5 Greenbelt Development

Greenbelt of 50.0 acres (inclusive of existing) has already been developed in the site

premises.

Capital cost for environment protection for the proposed expansion project will be Rs. 13.0

Crores.

*********

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