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
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 2
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
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 3
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
(From Project Boundary)
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
Gandhidham, Kutch-370201 Gujarat, India.
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)
Existing Proposed Total
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
Existing Proposed Total
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):-
Information/ Checklist
confirmation.
Yes/
No
Details thereof (with approximate quantities/ rates, wherever
possible) with source of information data.
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)
Existing Proposed Total
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.
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.
Information/ Checklist
confirmation.
Yes/
No
Details thereof (with approximate quantities/rates, wherever
possible) with source of information data.
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
Details thereof (with approximate quantities/rates, wherever
possible) with source of information data.
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
Existing Proposed Total
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
Existing Proposed Total
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.
Information/Checklist
confirmation
Yes/
No
Details thereof (with approximate quantities/ rates, wherever
possible) with source of information data.
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
6 Emission rate at stack exit
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.
Information/Checklist
confirmation
Yes/
No
Details thereof (with approximate quantities/rates, wherever
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.
Information/Checklist
confirmation
Yes/
No
Details there of (with approximate quantities/rates, wherever
possible) with source of information data.
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)
Existing Proposed Existing Proposed
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.
Information/ Checklist
confirmation.
Yes/
No
Details thereof (with approximate quantities/rates, wherever
possible) with source of information data.
8.1 From explosions, spillages,
fires etc from storage,
handling, use or production of
hazardous substances.
No 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)
Existing Proposed Existing Proposed
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.
Information/ Checklist
confirmation.
Yes/
No
Details thereof (with approximate quantities/ rates, wherever
possible) with source of information data.
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
(From Project Boundary)
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.
S. No. Particulars Distance (Km) Direction
(From Project Boundary)
1. R.F. Near Gamdau Village 11.50 NNE
*Source: All distances are taken with respect to Google Earth.
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
S. No. Particulars Distance (Km) Direction
(From Project Boundary)
1. NH-8A 750 m S
2. NH-15 2.90 E
3. SH-42 13.62 W
*Source: All distances are taken with respect to Google Earth.
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)
*Source: All distances are taken with respect to Google Earth.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
*****************
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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:-
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
Gandhidham, Kutch-370201 Gujarat, India.
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
Existing Proposed Total
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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)
Existing Proposed Total
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)
Existing Proposed Total
1. Power 33MWH 18MWH 51MWH
Source: - Existing & proposed CPP and remaining will be met from
State grid as and when required.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
4. Unskilled worker 250 110 360
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:-
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
2. PC/CCA-Kutch-341(3)GPCB
ID:17845/106250
02.02.2012 27.12.2015 Power Generation – 12.0MW to 17.0MW
3. PC/CCA-Kutch-341(3)GPCB
ID:17845/204290
10.01.2014 16.12.2015 Sponge Iron -14625.0 MT/Month
Power Plant (WHRB) -8MW
4. PC/CCA-Kutch-341(3)GPCB
ID:17845/349490
29.02.2016 27.12.2016 Sponge Iron -14625MT/Month
M.S. Billets -14850MT/Month
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
MAY' 2018 48
TMT Bars -14330.25 MT/Month
M S Rolled Bar-445.50 MT/Month
Runner & Raiser-74.25 MT/Month
Power Plant (AFBC/CFBC) –17MW
Power Plant (WHRB) -8MW
5. PC/CCA-Kutch-341(3)GPCB
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
M S Rolled Bar-445.50 MT/Month
Runner & Raiser-74.25 MT/Month
Power Plant (AFBC/CFBC) –25MW
Power Plant (WHRB) -8MW
6. PC/CCA-Kutch-341(3)GPCB
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
Power Plant (AFBC/CFBC) –25MW
Power Plant (WHRB) -8MW
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.
.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
Latitude 23°18’33.97” N Latitude 23°18’32.58” N
Longitude 70°29’28.95” E Longitude 70°29’41.87” E
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
The land use of the study area showing Government/ private – agriculture, forest, wasteland, water bodies,
settlements etc. has been enclosed as Annexure – XXIV.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
The same has been enclosed as Annexure – XXX.
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
The same has been enclosed as Annexure – XXX.
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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 .
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
--
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
MAY' 2018 60
6 Emission rate at stack exit
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
Public Hearing will be carried out as per EIA Notification
14th September 2006 and its subsequent amendments.
• The issue raised during public
hearing and commitment of the
project proponent on the same
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 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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
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
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
*****************
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
*************
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
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.
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
Latitude 23°18’33.97” N Latitude 23°18’32.58” N
Longitude 70°29’28.95” E Longitude 70°29’41.87” E
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.
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
MAY’ 2018 76
2.4.3 NEAREST HIGHWAY
Table 2.2: Highway
Particulars Distance (Km) Direction
(From Project Boundary)
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)
Existing Proposed Total
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)
Source: - Water from GWIL water supply system.
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
Existing Proposed Total
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 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.
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. 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
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
Table 2.8: Details of Raw Material
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
Table 2.9: Details of Raw Material
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:
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
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
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
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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%
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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)
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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
PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S.
BILLET/ S.S. BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT &
WHRB
SECTION – II – PROJECT DESCRIPTION
APPLICANT : GALLANTT METAL LIMITED
DOCUMENT NO.: EESPL/GML/011/EC/Ind./2017-18/426
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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.