1.0 Introduction - MPPCB

M/s Venus Alloys Pvt. Ltd. (Unit-2)

Executive Summary

CES, BHOPAL 1

1.0 Introduction

The M/s Venus Alloys Pvt. Ltd. (Unit -2) is proposed to setup a mini steel plant in

village Fatehgarg, Tehsil Dalauda, Dist. Mandsaur (M.P.). The company a part

of Venus Alloys Group having one more mini steel plant, under operation from

last ten years in Industrial Area, Mandasur. The company having its corporate

office at 67, Industrial Area Mandsaur. The Group is a well know name in the

steel industry and has good presence in Western & Northern India. The Group is

involved in the manufacturing of Steel Billets, Ingots and roll product.

1.1 Identification of the Project Proponent

M/s Venus Alloys Pvt. Ltd. (Unit-2) is having its registered office in at 67, Industrial

Area Mandsaur (M.P.) The proposed project is capacity of M.S. Ingots-84000

TPA, TMT Bar-77700 TPA, TMT bars.

Promoter Directors

Name Qualification Business Experience

(Years)

Shri Sagarmal Jain M.Com (Gold Mad list) 1962,

LLB

47

Shri Komal Singh

Duggad

B.E.(Telecommunication)

1969

41

Shri Pradeep Kimtee B. Com 38

Shri Abhay Porwal Higher Secondary 38

Shri Abhaya

Sancheti

B.Com 2

1.2 Size of the Project

The total project cost for expansion of project shall be approx. 46.04 crores.

Table No. 1.0

Break up of Project Cost

S.No. Item (Rs. Cr.)

1. Land & Site Development 2.5

2. Civil Construction 6.5

3. Plant & Machinery 26.0

Miscellaneous Fixed Assets Included in above

4. Contingency 0.5


Executive Summary

CES, BHOPAL 2

5 Total Hard Cost 35.5

6. Interest during construction 1.05

7. Preliminary & Start-up

expenses

3.25

8. Margin Money for working

capital

3.5

9. Total Soft Cost 10.54

10.0 Total Cost of the project 46.04 cr.

1.3 Environmental Setting

The Topographical map of the project site is shown in Figure-1.1.& 2.0

Table-2.0

Details of Environmental Setting

Village Fatehgarh

Tehsil Dalauda

Location Toposheet No. 46 M/I, Khasra No. 612/1/1

Latitude : 23058’02” North

Longitude : 75005’59” East

Nearest City Mandsaur -012 km

Nearest Railway Station Dalauda -2.7 km

Nearest Airport Indore – 200 km

Nearest Highway NH -79, Jaora Mandsaur – 0.8 km in E

Ecological Sensitive Zone No national parks and wild life sanctuary & Bio

diversity within 10 km radius. (as per letter from

DFO Mandsaur.

Nearest Industries Rathi Industry 2 km from proposed site.

Interstate boundary Interstate border of Rajasthan – M P is 21 km as

per letter from EE PWD, Mandaur Div.

1.4 Connectivity

Fatehgarh is located on NH-79, connecting Jaora-Neemuch & with Rajasthan

touches its fringes. The site is 0.6 km from east direction in NH-79. It is also

connected to Jaora-Chittor There are regular scheduled Minibus/City

Bus/Private Bus services between Ujjain, Indore to Mandsaur passing through

jaora throughout the day with good frequency. Also there are regular services

to District Headquarter Mandsaur and beyond to Ratlam.


Executive Summary

CES, BHOPAL 3

Air connectivity

Nearest airport is Devi Ahilyabai Holkar Airport at Indore which is about 200 km

with multiple daily connections and operators to Mumbai, Delhi, Ahmedabad,

Hyderabad, Nagpur, Pune, Bangalore, Kolkata, Jaipur, Bhopal, Raipur, and

Gwalior.

Train connectivity

The nearest railway stations are Daluada 02 km, with limited connectivity to

nearby areas whereas Indore (INDB) is a Broad Gauge Terminus and has good

connectivity and daily connections to all metros and all major towns of country

and the state.


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CES, BHOPAL 4


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CES, BHOPAL 5

Fig. 1.0 Location Map

2.0 Utilities

2.1 Power

Total Electrical Power Requirement - 26.25 x 106 kwh shall be meet by MPSEB,

the company shall also install one D.G. set of 500 KVA equipped with acoustic

enclosure.

2.2 Water

Total water requirement will be for two purpose mainly for construction and

operational purpose. The requirement is as follows:

Construction phase – 15 kld Source borewell

Operational phase-

Head Water consumption Discharge

Cooling 75 kld Nil

Domestic 15 kld 5.0 kld

Total 90 kld 5.0 kld

Source borewell

2.3 Manpower

The Plant Management of an industry is the vital part of the unit for its survival.

The management will responsible for overall efficiency of the unit.

Management shall be supported by group of highly skilled persons of varied

expertise and experience who function individually and collectively for the

overall performance of the unit. Based on the above principle we fix an

organization for this unit who will look after the various activities of the unit.

Following man power is required for the proposed unit.

Table 3.0

Man power requirement

S. No. Particulars Proposed No.

01 Manager Production 4

02 Engineer (Mech., Process & Electrical

and instrumentation)

10

03 Foreman 15

04 Fitter cum operator 20

05 Electrician 10

06 Chemist 3


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CES, BHOPAL 6

07 Helper for chemist 5

08 Unskilled labour 100

Total 167

Table 4.0

Land use break of factory area

Total land of factory 50,000 sqm

Factory shed / finish goods storage 15000 sqm

Utility building 5000 sqm

Roads 1000 sqm

Open area 29000 sqm

2.4 Capacity

S. No. Products Capacity

1. MS Ingots / Billets 84000 TPA

2. TMT Bar 77700 TPA

2.5 Process Flow Chart I. F.

2.6 Raw Material Requirement

S. No. Raw Material Per Ton Source


Executive Summary

CES, BHOPAL 7

Requirement

1. MS Scrap 1050 kg Indigenously Available

2. Ferro Alloys 10 kg Indigenously Available

3 Refractories

Consumable

20Kg./set Indigenously Available

2.7 Detail of Manufacturing Process Of Billets

2.8 Detail of Manufacturing Process Hot (Rolling Mill)


Executive Summary

CES, BHOPAL 8

3.0 Land Environment

3.1 Land Use and Land Cover

The project site, which is located about 12 km away from the district

headquarter Mandsaur is devoid of agricultural field and deciduous forest. The

land use land cover map for the study area was prepared by processing the

standard False Color Composite (FCC) of IRS P6 LISS III satellite imagery with 24

× 24 m resolution, November 2014. The land use classification is tabulated in

Table 5.0

Table No. 5.0

Land Use Details

S.No. Description Area in Ha

1 Dense Forest 193.15

2 Open Scrub 314.85

3 Degraded Forest 997.42

4 Open Land 2.00

5 Fallow Land 40.36

6 Mining Area 347.99

7 Cropped Area 28012.54

8 Plantations 40.19

9 Nala 19.19

10 Pond 61.62

11 Reservoir 25.70

12 Railway Line 31.61

13 River 83.53

14 Roads 192.00

15 Plant 19.62

16 Settlements 1020.82

Total 31402.60


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CES, BHOPAL 9

3.2 Ambient Air Quality Monitoring

This section describes the ambient air quality of the study area. Five numbers of

sampling locations were selected to delineate the ambient air quality. The

monitoring was carried out from 01 January- 31 march 2014. The locations of

the monitoring stations were selected to accord an overall idea of the ambient

air quality scenario in the study area. Logistic considerations such as

accessibility, security, and availability of reliable power supply etc. were also

taken into consideration while finalizing the locations of such stations. The

locations of the Ambient Air Quality Monitoring Stations in the study area are

given in Table 6.0 and summary of Air Quality Monitoring status in table -8.0

below.

Table. 6.0

Location of Ambient Air Quality Monitoring Station

S.N

o

Locations Direction from

Site

Distance from

Site

Location

Details

A1 Project Site -- 00 Industrial

A2 Village Fatehgarh NE 0.8 km Village

A3 Dalauda town S 2.7 km Village

A4. Village Pipliya

Mughra

SW 2.3 km Village

A5. Village Banikheri SW 2.6 km Village

Table No. 7.0

Summary of Air Quality Monitoring Status

Monitoring Station PM 10

(µg/m3)

PM 2.5

(µg/m3)

NOx

(µg/m3)

SO2

(µg/m3)

A-1 Project Site 32.2-70.6 12.5—23.2 10.4-18.7 9.2-15.3

A-2 Village

Fatehgarh

29.7-63.2 14.3-26.2 9.6-17.5 8.9-15.2

A-3 Dalauda Town 36.7-69.5 12.4-24.6 11.3-23.4 8.4-14.5

A-4 Village Pipliya

Mughra

24.3-65.2 21.3-36.4 10.4-21.3 9.2-16.7

A-5 Village

Banikhedi

20.4-54.6 15.6-30.2 10.2-18.6 8.6-13.9

4.0 Environmental Management during Construction Stage


Executive Summary

CES, BHOPAL 10

� During excavation and transportation on roads at the plant site, there is a

scope for local fugitive dust emissions. Frequent water sprinkling in the

vicinity of the construction activity should be done.

� There is a likelihood of fugitive dust from the construction activity and

material handling from the truck movement in the premises of the

proposed plant. The industry shall take up tree plantation program

around the plant site.

� It shall be ensured those construction vehicles are properly maintained.

The vehicle maintenance area shall be located in such a manner, so as

to prevent contamination water sources by accidental spillage of oil.

� Proper care shall be taken for storage of HSD etc. Site shall be identified

for the storage of such flammable liquids, away from the main plant. The

storage shall be as per institutional safety standards.

� The construction workers shall be provided with sufficient and suitable

toilet facilities to allow proper standards of hygiene.

� Onsite workers using high noise equipment shall adopt noise protection

devices. Noise prone activities will be restricted to daytime hours only.

� Hazardous material will be stored in proper areas.

� After completion of construction activities the rubbish shall be cleared

and disposed to nearby authorized sites.

EMP for Construction Phase Impacts "Site Clearing"

Environmental

Impacts

Mitigation Remarks

Soil erosion Extent of vegetation removal shall

be minimized to prevent extent of

soil erosion.

Vegetative cover shall be re-

projected /rehabilitated at the

earliest practicable time to minimize

duration & extent of soil erosion.

Implementation

responsibility:

1. Project

Proponent

2. Contractor

There is no

vegetation on the

proposed site.

Noise

generation

� Selection of equipment with less

noise generation to be used.

� The earth moving equipment

Implementation

responsibility:

� Project Proponent


Executive Summary

CES, BHOPAL 11

shall be periodically checked

and maintained for noise levels.

Since the site is more or less even

use of these earth-moving

� Equipments may not be

necessary.

� The workers shall be provided

with adequate PPE such as

earplugs to reduce impact of

high noise levels.

� Contractor

Dust

generation

� The site cleared shall be

periodically watered to reduce

emission of dust particles.

� The workers shall be provided

with PPE such as nose masks and

goggles to reduce impact on

health.

Implementation

responsibility:


� Contractor

EMP for Construction Phase Impacts

"Transportation of Construction Materials”

Environmental

Impacts

Mitigation Remarks

Noise

generation

Periodic maintenance of

equipments is required.

Implementation

responsibility:


� Contractor

Dust

generation

� Construction materials shall be

covered with tarpaulin sheets

to prevent the material from

being air borne.

� The vehicle speed shall be

Regulated

� The workers transporting

materials shall be provided with

PPE such as nose asks to

reduce impact of air borne

dust on their health

Implementation

responsibility:


� Contractor

Vehicular

emissions

� Periodic emission check for

vehicles is required.

� Clean fuel shall be used for

vehicles.

Implementation

responsibility:


� Contractor

EMP for Construction Phase Impacts "Construction Activities”


Executive Summary

CES, BHOPAL 12

Environmental

Impacts

Mitigation Remarks

Noise

generation

� Personnel Protective Equipment

(PPE) such as ear plugs and

helmets shall be provided for

construction workers.

� The working hours shall be

imposed on construction

workers.

Implementation

responsibility:


� Contractor

Dust generation � PPE in the form of nose masks

shall be provided for

construction workers.

� Use of water sprays to prevent

the dust Contractor from being

air borne.

Implementation

responsibility:

� Project

Proponent

� Contractor

Air Emissions

from

Construction

machinery

� Periodic check and regular

maintenance of construction

machinery for emissions

� Clean fuel shall be used in

equipments.

Implementation

responsibility:

� Project

Proponent

� Contractor

5.0 Air Quality

During Construction period, there is likely hood of generation of dust and NOx

emission. This can be attributed to leveling activity and vehicular movement.

The transport vehicles using petrol or diesel will be properly maintained to

minimize smoke in the exhaust. Since, there is likelihood of fugitive dust from the

construction activity, water sprinkling will be done. In addition to this following

measures will be taken during the construction phase to reduce the impact on

the air quality.

� Any vehicle not meeting the vehicular pollution standards will not be

allowed within the construction activity.

� Water will be sprayed by water tankers during dust generating

construction activities e.g. excavation, crushing/demolishing, concrete

mixing, material handling etc. to suppress dust; and


Executive Summary

CES, BHOPAL 13

� Vehicles delivering loose and fine materials like sand and fine

aggregates shall be covered by tarpaulin to reduce spills on roads.

� The height from which excavated materials are dropped shall be

controlled to a minimum practical height to limit fugitive dust generation

from unloading.

� The random Ambient Air Quality Monitoring shall be done to ensure that

the significant impacts are being mitigated adequately.

6.0 Noise Level

The noise impact on the surrounding population during the construction phase

will be within the acceptable limits. High noise generation equipment, if used

will be operated during the daytime only and completely restricted during

night hours and this eliminates any possible discomfort to the nearby

communities. Community noise levels are not likely to be affected because of

the vegetation and likely attenuation due to the physical barriers. The following

recommendations will be implemented:

� Provision of insulating caps and ads at the exit of noise source on the

machinery; Construction equipment generating minimum noise and

vibration be chosen:

� The use of damping materials such as thin rubber / lead sheet for

wrapping the work places line compressors, generators sets.

� Shock absorbing techniques will be adopted to reduce impact;

� Inlet and outlet mufflers will be provided which are easy to design;

� Ear muffs will be provided to the workers and it will be enforced to be

used by the workers; and

� Greenbelt will be developed along the periphery of the proposed site.

� Ambient Noise Level Monitoring shall be conducted at suitable location

at periodic intervals during construction phase to conform to the

stipulated standards both during day and night time.


Executive Summary

CES, BHOPAL 14

7.0 Solid /Hazardous Waste Management

The hazardous materials used during the construction may include petrol,

diesel, Welding gas and paints. These materials will be stored and handled

according to the MPPCB guidelines.

� Diesel and other fuels will be stored in separate enclosures;

� Wherever possible, hazardous raw materials to be substituted by non-

hazardous materials, e.g. cleaning solvent can be replaced with film –

free biodegradable cleaners. Usage of non chlorinated strippers instead

of strippers containing methylene chloride and substitution of water

based paint for oil based ones;

� Separate storage of waste paints, thinners, contaminated rags and

brushes will be adopted.

� Vehicle maintenance area to be designed to prevent contamination of

ground water by accidental spillage of oil; and

� Maintaining appropriate inventory control.

8.0 Socio -Economic

� Local people from Fatehgarh village and nearby villages of the

surroundings of the site will be employed for construction work to the

maximum extent possible.

� Proper facilities for domestic water supply and sanitation services will be

made available to the construction workers at the site.

� An ambulance shall be available in the premises 24x7 to take off any

emergency. First aid boxes are provided in each section of all shop floor

departments. All weather related precautions are taken care of.

� In rainy season raincoats are provided to the personnel who are required

to work in open.


Executive Summary

CES, BHOPAL 15

9.0 Operation Stage

9.1 Air Environment:

The mitigation measures needs to be adopted during the operation stage to

control the negative impacts on air environment of the surrounding of the

project area given below:

� Dense green belt is planted around the dust generation points at

surface.

� Trees are planted on both sides of the roads used for transportation in

order to arrest dust.

� Afforestation around the unit to act as barrier

� Water sprinkling along the haul road

� Proper maintenance air pollution control equipment

� Regular maintenance of vehicles and machinery’s in order to control

emissions

� Cabins for shovel and dumpers and dust masks to workmen.

� A good housekeeping and proper maintenance will be practiced in the

industry, which helps in controlling pollution.

In addition to the above, the following measures shall be taken:

� To Control the emission from the furnace a 32 m high Chimney shall be

provided for batter air dispersion attached with IF. Details of Air Pollution

Control Equipments are given in Table 9.4

� Port holes shall be provided with the chimney along with ladder.

� A chimney shall be provided with the DG set of 125 KVA.

� Water spraying shall be adopted at loading and unloading points,

storage yards and near solid waste dumping yards which will reduce

fugitive emissions due to movement of truck.

� All the internal roads shall be made with RCC to reduce the fugitive dust

due to truck movement.


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CES, BHOPAL 16

� Green belt cover shall be provided. For this, the project has proposed

developed green belt cover over an area 33% of the total plot.

Table 8.0

Details of Air Pollution Control Equipments

Sources Control Equipments

Induction Furnace Type of hood to capture fumes – Canopy Type

Outlet Stack emission system < 50 mg/Nm3

Type of filter Used – Reverse Pulse Jet cleaning

Stack height – 32m

D. G. Set (125

KVA)

Acoustic Canopy shall be installed.

9.2 Water Environment

Water requirement for proposed project will be met bore wells. The water will

be used mainly for cooling purposes. The proposed steel making and rolling

facility shall have efficient cooling water recycling system with minimum drift

was by using proven cooling tower and heat exchanger. For the soft water

circulating in the closed loop , a dedicated softener plant has been proposed

and the waste , water shall be used for water the coconut trees .Plants shall

also be planted in the vicinity of water plant.

There is no any effluent generation from this process. The quantity of canteen

wastewater generated of about 5m3/day will be treated in the Septic Tank and

Soakpit. Apart from above, following additional measures will minimize

operational impacts:

� There will be no any effluent water in this process

� Closed circuit cooling system will be provided in cooling of products.

Hence there will not be any waste water generation from process and

cooling in the steel plant. The only wastewater that is generated will be

sanitary waste water..


Executive Summary

CES, BHOPAL 17

� Use of high pressure hoses for area cleaning

� For removal of oil, oil skimmer will be provided, and collect in separate

MS drums and the clean water shall be reused for process of cooling.

� Storm water drains shall be provided to avoid flooding in the proposed

project site area and provision will be made for runoff get diverted to

recharge pits.

� Rain water Harvesting sump of capacity 50 Cu.m shall be provided.

9.3 Design Details for Septic Tank And Soak Pit

Septic Tanks shall be constructed of brickwork, stone masonry or concrete or

other suitable materials. The Septic Tank shall be plastered inside with rich

cement mortar in which some water proofing materials shall be mixed up. The

floor shall be of 1:2:4 Cement Concrete and given a slope towards the sludge

outlet. Airtight concrete or steel cover shall be provided on the top of the

Septic Tank. Manholes shall be provided in the cover for inspection and

cleaning of the Tank.

9.4 Noise Environment:

� Personnel working near noisy areas shall be provided with adequate

personal protective equipment such as earplugs and earmuffs, use of

which will be strictly enforced.

� Sophisticated and low noise generating equipments will be selected.

� The equipments will be maintained at all times to ensure permissible noise

levels.

� Appropriate advanced silencers, acoustic barriers; vibration-reducing

pads will be provided for all noise generating equipments.


Executive Summary

CES, BHOPAL 18

� The sources of continuous noise generating equipment such as

compressors, pumps, motors etc will be designed to have noise level not

exceeding 85-90dB(A).

� It would be ensured that there would not be any operator near the noise

generating equipments on continuous basis.

� Boundary walls and dense green belt will be erected to act as acoustic

barriers.

� Adequate and appropriate type of green belt would be developed in

and around the proposed project site for noise mitigation in the area.

9.5 Solid Waste & Hazardous Waste Generation

The proposed Solid waste and Hazardous waste generation from the plant is

given below:

1. Oil from the furnace

2. Spent oil from DG sets

3. Canteen Waste

4. Municipal Solid Waste

� Hazardous waste (Used Oil) generated from D.G Sets will be

collected and stored in barrels or drums and later sale to

Authorized recycler.

� The canteen waste shall be used as manure after vermin-

composting.

9.6 Greenbelt Development

An extent of about 33% of total site area in the plant premises is proposed for

greenbelt Development. The species selected for greenbelt development shall

fulfill the following specific requirements of the area:

� Tolerate to specific conditions.

� Shall have rapid growth rate.


Executive Summary

CES, BHOPAL 19

� They shall rich canopy and shielding property.

� Large bio-mass and leaves to provide fodder and fuel.

� As for as possible shall be native in nature.

9.7 Socio Economic Aspects

� Local people of Fatehgarh Village and nearby villages surrounding the

site will be employed to the maximum extent.

� Proper medical, firefighting, transportation, potable water supply, proper

sanitation facility, and other necessary services infrastructure will be

provided to take care the basic needs of the project employees and

their families.

Table 9.0

Expenditure on Environmental Management Plan

Sr.

No.

Particular Total Cost (Rs. In

Lacs)

1 Air Pollution Control 600.0

2. Rain water harvesting 3.5

3. Emission monitoring at source and

ambient air quality monitoring

3.5

4. Green belt development 2.0

5. Establishment of environmental

management cell and environmental

monitoring

2.0

Total capital expenditure 611.0

6. Recurring expenditure on environmental

management cell and on pollution

control system

20.0

Documents

1.0 Introduction - MPPCB