Environmental Impact Assessment and Environmental … · I. TOR from SEAC Gujarat II. Compliance of TOR III. GWIL Letter IV. Land Possession Documents V. Technical Details of Induction

Environmental Impact Assessment andEnvironmental Management Plan

(FINAL EIA/EMP REPORT)

Of

Proposed project for Manufacturing of Billets/Ingots

@ 2, 22,000TPA

For

M/s SAI INDUCTOMELT PRIVATE LIMITED

Survey no: 1020& 1021/1,Bhavnagar - Vallabhipur Highway,Village:Chamardi, Taluka: Vallabhipur, District: Bhavnagar

By:

Pollution and Ecology Control Services

Near Dhantoli Police Station, Dhantoli, Nagpur-12.

[email protected]

NABET No. 119

CONTENTS

Sr. No. Particulars Page No.

CHAPTER 1: INTRODUCTION 1-10

1.1 Preamble 1

1.2 Purpose of the Study 1

1.3 Identification Of Project & Project Proponent 2

1.4 Site Selection Criteria 2

1.5 Details of Project Site 3

1.6 Project Importance To The Country And/ Or Region 6

1.6.1 Steel Production in India 7

1.6.1 Steel Billet Industry 7

1.7 Need for the Project 8

1.8 Applicable Environmental Regulatory Framework 8

1.9 Scope Of The Study 9

1.10 EIA/EMP Report Scheme 9

CHAPTER2: THE PROJECT DESCRIPTION 11-24

2.1 Need of the Project and Magnitude of Operation 11

2.2 Plant Layout 11

2.3 Size or Magnitude of Operation 13

2.3.1 Raw Material Requirement 13

2.3.1.1 Characteristics of MS scraps 14

2.3.1.2 Proposed Infrastructure Facility 15

2.3.2 Water requirement & Waste Water Generation 16

2.3.3 Power Requirement 17

2.3.4 Man-Power Requirement 18

2.3.5 Land Requirement 18

2.3.6 Capital project cost projection 18

2.4 Proposed Schedule for Approval and Implementation 19

2.5 Technology and Project Description 19

2.6 Mitigation Measures 21

2.6.1 Air Pollution 21

2.6.2 Water Pollution 22

2.6.3 Noise Pollution 22

2.6.4 Solid waste Management 22

2.6.5 Green belt Development 22

2.6.6 Transportation 23

2.6.7 Fire Protection System 23

2.6.8 Occupational Health and Safety 23

2.7 Assessment of New & Untested Technology for the Risk ofTechnology Failure

24

CHAPTER 3: BASELINE ENVIRONMENTAL STATUS 25-66

3.0 Baseline Environmental Status 25

3.1 Methodology 26

3.2 Micrometeorology 27

3.3 Air Quality 30

3.3.1 Ambient Air Quality Monitoring 30

3.3.2 AAQ Monitoring Stations and Observation 32

3.4 Water Environment 37

3.5 Noise Environment 46

3.6 Soil Quality 49

3.7 Land Use Pattern 54

3.8 Socio-Economics of the Study Area 58

CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS AND

MITIGATION MEASURES

67-83

4.1 Identification of Impacts 67

4.1.1 Issues Scoping / Pathway Analysis - Summary of MatrixValued Ecosystem Components of Concerns (VECs)

68

4.2 Construction Phase 69

4.3 Operation Phase 72

4.3.1 Impact on Air Quality 72

4.3.1.1 Prediction of Air quality 73

4.3.2 Noise Levels 79

4.3.3 Impact on Water 80

4. 3.4 Solid Waste Generation 81

4.3.5 Impact on Socio-Economic Environment 82

4.3.6 Prediction of Impacts on Occupational Health 82

4.3.7 Prediction of Impacts on Flora and Fauna 82

CHAPTER 5: ANALYSIS OF ALTERNATIVES FOR TECHNOLOGY AND

SITE

84-85

5.1 Alternate Technology 84

5.1.1 Details of Alternative Site Considered 85

CHAPTER 6: ENVIRONMENTAL MONITORING PROGRAM 86-88

6.1 Introduction 86

6.2 Environmental Monitoring Program 86

6.3 Budget Allocation for Environmental Monitoring 87

CHAPTER 7: ADDITIONAL STUDIES 89-116

7.0 Social Impact Assessment 89

7.1 Risk Assessment 89

7.1.1 Approaches to the Study 89

7.1.2 Hazards Identification 90

7.1.3 Occupational health impacts on the workers 93

7.1.4 Do’s & Don’ts of preventive maintenance 97

7.1.5 Personal Protective Equipment and Periodic Medical

Examination

99

7.2 Disaster Management Plan 100

7.2.1 On-Site Emergency Plan 102

7.2.2 Disaster Management Plan for Sai Inductomelt Pvt Ltd. 113

CHAPTER 8: PROJECT BENEFITS 117-120

8.1 Improvement in the Physical Infrastructure 117

8.2 Employment Potential 117

8.3 Improvement in Infrastructure 118

8.4 Education 118

8.5 Green Belt Development 119

8.6 Social Infrastructure 119

8.7 Other Tangible Benefits 119

8.8 Corporate Environment Responsibility Plan (Cer) 120

CHAPTER 9: ENVIRONMENTAL COST BENEFIT ANALYSIS 121

CHAPTER 10: ENVIRONMENT MANAGEMENT PLAN 122-133

10.0 Introduction 122

10.1 Purpose of Environmental Management Plan 122

10.2 Overview of the Pollution Control Management 123

10.2.1 Construction Phase 123

10.2.2 Operation Phase 125

10.3 Environment Management Policy & Environment Committee 131

CHAPTER 11: SUMMARY AND CONCLUSION 134-145

11.1 Project Description 134

11.1.1 Introduction 134

11.1.2 Project Location & Environment Sensitivity 134

11.1.3 Size or Magnitude of Operation 135

11.2 Description of Environment 136

11.3 Anticipated Environmental Impacts & Mitigation Measures 137

11.4 Environment Monitoring Programme 138

11.5 Environment Management Plan 139

11.6 Conclusion 145

CHAPTER 12: DISCLOSURE OF CONSULTANTS 146-149

LIST OF TABLES


1.1 Details of Project Site (10 Km Radius) 3

2.1 Production Details 11

2.2 Land Distribution Details 13

2.3 Annual Raw Material Requirement 14

2.4 Material Balance 14

2.5 Plant Infrastructure 15

2.6 Water Requirements and Waste Water Generation 16

2.7 Energy Balance 17

2.8 Project Cost Projection 18

3.1 Onsite Meteorological Data (Period: October to December 2018) 28

3.2 Methodology of Ambient Air Quality Monitoring 32

3.3 Ambient Air Quality Monitoring Sampling Stations 33

3.4 Summarized Report of Ambient Air Quality 34

3.5 National Ambient Air Quality Standards 35

3.6 Water Sampling Location 37

3.7 Methodology for Sampling and Analysis of Water 38

3.8 Water Quality: Surface Water Samples 42

3.9 Water Quality: Ground Water Samples 44

3.10 Noise Level Sampling Stations 46

3.11 Measured Noise Levels at Monitored Stations 48

3.12 National Ambient Noise Level Standards 49

3.13 Analytical methodology for soil samples 50

3.14 Soil Sample Monitoring Station 50

3.15 Physio-Chemical Properties of Soil 52

3.16 Standard Soil Classification 53

3.17 Land use/Land Cover Analysis 57

3.18 Village wise Demographic Structure of the Study Area 63

3.19 Employment Pattern 65

4.1 Stacks & Emissions Details 73

4.2 Predicted 24 hourly Ground Level Incremental Concentrations 75

4.3 Resultant PM10 at Monitoring Locations, µg/m3 77

4.4 Estimation of Transportation of the Raw Material 78

4.5 Water Requirement and Waste Water Generation 81

4.6 Solid Waste Generation & Mitigation Measures 81

6.1 Proposed Environmental Monitoring Schedules 87

6.2 Proposed Budget for Environmental Monitoring Programme 88

LIST OF FIGURE


1.1 Location Map of the Proposed Project Site 4

1.2 Topographical Map of Study Area (10 Km Radius) 5

1.3 Satellite Image of the Site 6

2.1 Plant layout 12

2.2 Water balance Flow Chart 17

2.3 Process Flow Chart of the Manufacturing Billets 21

3.1 Satellite Image of Project site showing 10 km study area 25

3.2 Windrose Diagram during study period (October –December 2018) 29

3.3 Ambient Air Quality Sampling Station 33

3.4 Map showing Ground and surface water sampling 38

3.5 Map showing Noise level Monitoring Station 47

3.6 Location of Soil sampling Stations 51

3.7 Satellite Imagery 56

3.8 Land Use/Land Cover map 57

3.9 Sex Ratio Comparison 60

3.10 Breakup of SC & ST in the study area (Census 2001) 60

3.11 Literacy rate in Study area (Census 2001) 61

3.12 Vocational Pattern of the Study Area 62

4.1 Predicted GLC of PM10 due to Propose Plant (With APCD) 75

4.2 Predicted GLC of PM10 due to Propose Plant (Without APCD) 76

10.1 Organizational Set-up for Environmental Committee 132

ANNEXURES

Sr. No ANNEXURE

I. TOR from SEAC Gujarat

II. Compliance of TOR

III. GWIL Letter

IV. Land Possession Documents

V. Technical Details of Induction Furnace

VI. One complete season base line ambient air quality data (Raw AAQ data)

VII. List of Flora and Fauna

VIII. Emergency Exit Gate

IX. Undertaking for Local Employment Generation

X. Source Specific Pollution Control Scheme

XI. Copy of Supply of Iron Ore agreement

XII. Mutual Agreement with Doctor

XIII. Details of firefighting Plan

XIV. Five Years Green Belt Development Plan

XV. Ownership of EIA

XVI. NABET Certificate

EIA on Proposed project for manufacturing of Billets/Ingots @ 2, 22, 000TPA

Project Proponent: M/s SAI INDUCTOMELT PRIVATE LIMITED

Chapter 1:Introduction

Pollution and Ecology Control Services, Nagpur P a g e | 1

CHAPTER-1

INTRODUCTION

1.1 PREAMBLE

Sai Inductomelt Pvt. Ltd is a Private Company incorporated in 2004. It is classified as

Indian Non-Government Company and is registered at Registrar of Companies,

Ahmedabad. M/s Sai Inductomelt Pvt. Limited Corporate Identification Number is (CIN)

U35117GJ2004PTC044607 and its registration number is 044607. Its registered address

is plot no. 1497/B, Theosophical Lodge, Rupani Circle, Bhavnagar - 364001, Gujarat,

India.

M/s Sai Inductomelt Pvt. Ltd has proposed a project for manufacturing of Billets/Ingots

@ 2, 22,000TPA by installation of new induction furnace of capacity 2 x 25TPH and 2 x

12TPH The proposed project to be sited atSurvey no: 1020& 1021/1,Bhavnagar -

Vallabhipur Highway, Village:Chamardi, Taluka: Vallabhipur,District:Bhavnagar

(Gujarat). The total 13.29 Acre land has acquired for the proposed project.

Project activities falls category ‘B’ of the Schedule of EIA Notification dated 14th

September, 2006 and its subsequent amendments

1.2 PURPOSE OF THE STUDY

The proposed project involves manufacturing of Billets/Ingots @ 2, 22,000TPA, the

project fall under the Category ‘B’ of project activity 3(a) as per the Schedule of EIA

Notification, 2006 and needs to obtain prior environmental clearance from SEIAA.TORs

was issued vide 455th meeting of the SEAC, Gujarat held on 29th November, 2018, copy

of awarded TORs along with its compliance report is attached as Annexure I and

Annexure II with this report. The purpose of EIA study report is to assess the impacts of

proposed industrial activity on environment and to plan appropriate environmental

control measures to minimize adverse impacts and to maximize favorable impacts. The

following major objectives have been considered:

• To assess the existing status of environment





• To assess the impacts due to the project

• To suggest pollution control measures

• To prepare an action plan

1.3 IDENTIFICATION OF PROJECT & PROJECT PROPONENT



Ahmedabad. Sai Inductomelt Pvt. Limited Corporate Identification Number is (CIN)



India.

Company Details

Company’s name : M/s. Sai InductomeltPrivate Limited

Address : Survey no: 1020 & 1021/1,Bhavnagar-Vallabhipur

Highway, Village: Chamardi, Talluka:Vallabhipur, District:

Bhavnagar(Gujarat)

Telephone No.

E-mail Address

:

:

9825705700

[email protected]

Name of the Directors 1) Bidhichand Kakaram Bansal

2) Saroj Bidhichand Bansal

1.4 SITE SELECTION CRITERIA

• No National Park, Biosphere Reserve and Wildlife Sanctuary and Notified Eco

Sensitive Areas within 10 km radius.

• No archaeological monument, interstate boundary and defense installation.

• No notified critically polluted area within 10 km radius.

• No nallah/water body, public roads, forests within the project site.





• Availability of Raw Material.

• Availability of Water (source: Gujarat Water Infrastructure Limited).

• Assured Power Supply.

• Market available for finished products.

• Availability of adequate man power.

• No R & R issue is involved.

1.5 DETAILS OF PROJECT SITE

The proposed project to be sited at Survey no: 1020& 1021/1,Bhavnagar - Vallabhipur

Highway, Village:Chamardi, Taluka: Vallabhipur,District:Bhavnagar (Gujarat). The

details of the project site (10 km radius) are presented in Table 1.1 and location map is

presented in Figure 1.1, Study Area (10 Km radius) is shown in Figure 1.2 and Google

Earth image of the proposed project site is given in Figure 1.3.

TABLE 1.1: DETAILS OF PROJECT SITE (10 KM RADIUS)

Sr No Particulars Details

1 Project Site Survey no: 1020 & 1021/1,Bhavnagar - Vallabhipur

HighwayVillage:Chamardi, Talluka :Vallabhipur,

District:Bhavnagar

2 Latitude Latitude : 210 48’ 30.29” N

3 Longitude Longitude : 710 54’ 07.37 E

4 Elevation above MSL 12 m

5 Topo sheet NF 42 - 12

6 Present landuse Vaccant land, NA is obtained7 Nearest National

Highway/State Highway

SH 36:1.3 km in East Direction

8 Nearest Airport/ Air Strip Bhavnagar 30.Km (ESE)

9 Nearest Village/Habitates Chamardi 2.5 kms South direction

10 Forest Blackbuck National Park 30 km in NE direction





Source: Maps of India

Figure 1.1:Location Map of the Proposed Project Site

11

Ecologically Sensitive

Zones like wild life

sanctuaries, national parks

and biospheres

Archaeological structures, Historical places, Sanctuaries

and Biosphere are not present within 10 km

12 Water Bodies Rangholi River 0.6Km South direction

Kalubar River 1.5Km NE direction

Gautameshwar Dam 13 Km SE Direction

Gulf of Khambhat 36.0Km in East Direction

Ghelo River 7.8 Km in North Direction





Source: SOI Toposheet

Figure 1.2: Topographical Map of Study Area (10 Km Radius)





Source: Google Earth

Figure 1.3: Satellite image of the site

1.6 PROJECT IMPORTANCE TO THE COUNTRY AND/ OR REGION

Global steel production grew enormously in the 20th century from a mere 28 million tons

at the beginning of the century to 1011 million tonnes at the end of 2005. That was the

period when the steel industry developed in Western Europe and the USA followed by

the Soviet Union, Eastern Europe and Japan. However, steel consumption in the

developed countries has reached a high stable level and growth has tapered off. Towards

the end of the last century, growth of steel production was in the developing countries

such as China, South Korea, Brazil and India. Steel production and consumption grew

steadily in China in the initial years but later it picked up momentum China produced

220.1 million tons in 2003, 272.2 million tons in 2004 and 349.36 million tons in 2005.

That is much above the production of Japan at 112.47 million tonnes, the USA at 93.90

million tons, Russia at 66.15 million tones and India around 42 million tons in 2005.





India is the third-largest crude steel producer in the world. In FY18, India produced

104.98 million tonnes (MT) of finished steel. Crude Steel production during 2017-18

stood at 102.34 MT. Exports and imports of finished steel stood at 1.35 MT and 1.89 MT,

during Apr-Jun 2018.Steel consumption is expected to grow 5.7 per cent year-on-year to

92.1 MT in 2018. India’s steel production is expected to increase from 102.34 MT in

FY18 to 128.6 MT by 2021. The Government of India has allowed 100 per cent foreign

direct investment (FDI) in the steel sector under the automatic route. India’s per capita

consumption of steel grew at a CAGR of 3.96 per cent from 46 kgs in FY08 to 65.25 kgs

in FY17. The figure stood at 68 kgs during April-February 2017-18. National Steel

Policy 2017 seeks to increase per capita steel consumption to the level of 160 kgs.

1.6.1 Steel Production in India

India is one of the few countries where the steel industry is poised for rapid growth.

India's share in world production of crude steel increased from 1.5% in 1981 to around

3.5 % in 2004. While plant closures and privatization are rare in India, the private sector

is considered to be the engine of growth in the steel industry and technological changes

and modernization are taking place in both the public and the private sector integrated

steel plants in India. Steel production of India accounted for 14.33 million tons in 1990-

91, which gradually increased to 36.12 million tons in 2003-04, as shown in Table below.

The Indian steel industry got a giant importance in the recent past when the Tata Steel

purchased the Corus steel. Today India plays a significant role in the production of steel

in the world. The Indian steel industry is growing at 8.74 % of CAGR.

1.6.2 Steel Billet Industry

Steel billets are manufactured either by ingot casting and rolling through blooming &

billet mills or by forging or by continuous-casting of billets directly from liquid steel.

Billets manufactured by forging are mostly alloy or special steels. Pencil ingots of

smaller sizes, manufactured in mini steel plants are also used as substitute of billets. Due

to better yield, less energy consumption and capital investment, continuous-casting is

being practiced even for production levels of 25,000-30,000 TPA of billets. The billet





being a semi-finished product is used for further processing for production of suitable

products. It is used as a feedstock to rolling mills for production of long products like

wire rods, bars/rods and light structural. Billet is also used extensively in forge shops and

machine shops for production of engineering goods and also as feedstock for seamless

tubes.

While projecting all-India demand for steel billets, the requirement of the same for

integrated steel plants (primary producers) has not been considered, since their captive

requirement goes for finished steel production. The anticipated production of mild steel

bars and rods and structural from secondary producers during 2006-07 is of the order of

11.8 million tons. Billet requirement for producing the above products will be around

12.5 million tons. The production of pencil ingots/billets from secondary sector during

2006-07 is likely to be about 10 million tons, which includes mild steel, medium/high

carbon steel, alloy steels etc. This indicates that there is a lot of potential for increasing

the steel consumption in India. To meet the increasing demand and to stimulate economic

growth the Sai Inductomelt Private Limited has proposed the project.

1.7 NEED FOR THE PROJECT

The demand for steel in the country is currently growing at the rate of over 8% and it is

expected that the demand would grow over by 10% in the next five years. However, the

steel intensity in the country remains well below the world levels. Our per capita

consumption of steel is around 110 pounds as compared to 330 Pounds for the global

average. This indicates that there is a lot of potential for increasing the steel consumption

in India. To meet the increasing demand and to stimulate economic growth the M/s Sai

Inductomelt Private Limited has been proposed the project.

1.8 APPLICABLE ENVIRONMENTAL REGULATORY FRAMEWORK

The proposed project will abide and function under the purview of the following Rules,

Acts & Regulations which are formulated by the Govt. of India to protect the

environment and development in a sustainable way.





• The Water (prevention & Control of Pollution) Act, 1974

• The Air (Prevention & Control of Pollution) Act, 1981

• The Environmental (Protection) Act, 1986

• Environmental Impact Assessment Notification dated 14th September 2006 and

subsequent amendments

• The Hazardous & Other Waste (Management and Transboundary Movement)

Rules, 2016

• Solid Waste Management Rules, 2016

• Noise Pollution (Regulation and Control) Rules, 2000 and its amendments

• The Public Liability Insurance Act, 1991

1.9 SCOPE OF THE STUDY

This report represents environmental impact assessment and environmental management

plan of the proposed project of manufacturing of M.S. Billets/Ingots at Village:

Chamardi, Talluka Vallabhipur, District: Bhavnagar (Gujarat).As per the requirements

stated in the Environmental Impact Assessment Notification 2006 and its subsequent

amendments, Environmental Impact Assessment (EIA) study has been undertaken to

assess the environmental impacts of the proposed project and to develop a site specific

environmental management plan and risk mitigation measures. Subsequently, baseline

environmental studies have been conducted during October to December 2018 as per the

standard TOR issued via vide letter no SIA /GJ/IND/29097/2018 dated 29th November

2018 in 455thmeeting of the State Level Expert Appraisal Committee and accordingly

EIA report has been prepared.

1.10 EIA/EMP REPORT SCHEME

Chapter 1: Introduction- Provides a background to the M/s. Sai Inductomelt Private

Limited project, the project proponent, and the process of environmental impact

assessment.





Chapter 2: The Project Description- Describes the characteristics of the proposed plant,

the processes, location details and operations associated with proposed manufacturing of

2, 22,000 TPA M.S. Billets/Ingots.

Chapter 3: Baseline Environmental Status- Describes the background environmental

characteristics and the other economic activities in the area.

Chapter 4: Anticipated Environmental Impacts and Mitigation Measures- The major

impacts both adverse and positive are predicted and the consequent mitigation measures

are provided in this chapter. The impacts are identified with respect to the present

environmental baseline conditions.

Chapter 5: Analysis of Alternatives for Technology and Site -The technology and

project site alternatives are discussed in the chapter five.

Chapter 6: Environmental Monitoring Program- The monitoring to be carried out in

the proposed plant will be described in detail along with the frequency and sampling

locations.

Chapter 7: Additional studies -This chapter will include outcomes of public

consultation, Identification of hazards and risk assessment and social impact assessment.

Chapter 8: Project Benefits - This chapter deals with improvements in the physical

infrastructure, social infrastructure employment potential and other tangible benefits due

to proposed project activity.

Chapter 9: Environmental Cost Benefit Analysis:

Chapter 10: Environment Management Plan –This chapter will include the description

of administrative aspects of ensuring that the mitigation measures suggested are

implemented and their effectiveness is monitored, after approval of the EIA

Chapter 11: Summary and Conclusion -The summary of the EIA report has been given

in this chapter along with conclusions.

Chapter 12: Disclosure of Consultants

Brief introduction of the consultancy organization involved in EIA report is given in this

chapter.



Chapter 2:Project Description


CHAPTER 2

PROJECT DESCRIPTION

2.1 NEED OF THE PROJECT AND MAGNITUDE OF OPERATION

The proposed project of manufacturing of M.S. Billets/Ingots of M/s Sai Inductomelt

Private Limited is located at Survey no: 1020 & 1021/1, Bhavnagar-Vallabhipur

Highway, Village: Chamardi, Talluka:Vallabhipur, District: Bhavnagar, Gujarat.

The Bhavnagar region in Gujarat state is a potential zone for establishment of iron and

steel industries because of its accessibility, numbers of unit are comes in this region

hence, unit proposes to produce M.S. Billets/Ingots at the above said location.

In addition to this, easy availability of Scrap (MS scrap & Sponge iron, etc.) as raw

material, consistent electricity supply, availability of water, basic transportation facility

including good road network has motivated to establishment of new project at particular

site. In addition to this, consumption of finished product has increased day by day with

average Annual Growth Rate (CAGR) of 6%. This has given the opportunities for the

production of Steel in Private sector.

The proposed project will installed four induction furnace having capacity of 2 x 25 TPH

and 2 x 12 TPH. The total production capacity of M.S.Billtes /Ingots will be

2, 22,000TPA.

TABLE 2.1: PRODUCTION DETAILS

Sr. No Name of Product Quantity (TPA)

1 M.S.Billets/Ingots 2, 22,000

2.2 PLANT LAYOUT

The topography of site is plain and is suitable for construction of heavy structures,

buildings and foundations. The proposed capacity of manufacturing of M.S.

Billets/Ingots, has been proposed in Survey no: 1020 & 1021/1, Bhavnagar-Vallabhipur

Highway, Village: Chamardi, Talluka: Vallabhipur, District: Bhavnagar, Gujarat. All





facilities in the plant area will be identified so as to rationalise and minimize the extent of

land required. The layout will also facilitate movement of men and materials between the

various facilities during construction, operation and maintenance of the plant.

FIGURE 2.1: PLANT LAYOUT

Land Area 53781.00 Sq.M.1)

Green Land Area Sq.M.2)

Sq.M.

Sq.M.

Sq.M.

Sq.M.

1DRG.NO. :

DATE :28.11.2018

sr.no.1020 & 1021P

village :-CHAMAR DI, tal.: -VALLBHIPUR

dist :- bhaVnagar

SAI INDUCTOMELT PVT. LTD.

EnginEER

P.C.Pitroda & co.

134, First Floor Geetanjali Complex,

Kalanala, Near Municipal Corporat ion,

Bhavnagar

[email protected]

Mob. 9426918490

Road Center Line

Ad

j.S

r.N

o.1

019

Ad

j. Sr. N

o. 1018

Adj.Sr .No.1027

Marag

Boundary Of Navagam Village

H.L

.Lin

e

H.L

.Lin

e

18.01.2019

26.01.20191)

2)

3)

29.01.20194)

A rea = 71 57.96

A rea = 1401.55

A re a = 5372.44

3945.80

7157.96

1401.55

5372.44

17877.75

A rea = 3945 .80A

B

A

B

C

D

C

D

Factory Shed Area3) Sq.M.22259.29

Water Complex & Bag Filter4) Sq.M.2150.98

3

2

2

2

2

4

Electric Sub Station5) Sq.M.1923.38

Office Building6) Sq.M.116.37

Weighbridge7) Sq.M.62.93

5

6

7

Labour Quarter8) Sq.M.1033.23

8

Road and open Space8) Sq.M.8468.12

53781.00 Sq.M.

Emergency Exit

SINGLE HYDRANT VALVE

I NDEX

DOUBLE HYDRANT VALVE

PLANT AT IONDGSET

DG SET

A

B

C

D

EF

G

H

PLOT BOUNDARY DEM ARCATI ON

53781.00





The proposed project activity will be constructed in industrial land .The total plot area is

53781.0 Sq. m land. Out of total area approximately 33.24% i.e. 17877.75 area will be allotted

for green belt development. Detailed area statement is mentioned in below table

TABLE 2.2: LAND DISTRIBUTION DETAILS

Sr.No

Particular Proposed Area in(Sq. m)

1 Total Plot Area 53781.002 Factory Shed Area 22259.293 Green belt Area 17877.753 Water complex and bag filter 2150.984 Electric sub station 1923.385 Office building 116.376 Weighbridge 62.937 Clock Room 1033.238 Road & Open space 8468.12

2.3 SIZE OR MAGNITUDE OF OPERATION:

The company will manufacture M.S. Billets/Ingots by using sponge Iron and MS scrap

as raw materials with proposed capacity of 2,22,000 TPA. The three induction furnace

will be installed at plant with a capacity of 2X15 TPH and 1X 20 TPH. This will require

for the melting of sponge iron and scrap. Bag filter as an air pollution control system of

specified size with 30 m stack will be installed at discharge point of flue gases. The

company has acquired 53781.0 Sq. m of land for the proposed project.

2.3.1 Raw Material Requirement :

The annual raw material required for the production of M.S.Billets/Ingots is given in

Table 2.3 and Material balance is given in Table 2.4





TABLE 2.3: ANNUAL RAW MATERIAL REQUIREMENT

TABLE 2.4: MATERIAL BALANCE

S.N Input Quantity (T/T) Output Quantity (T/T)1 MS Scrap 1.00 M.S. Billet/Ingots 1.002 Sponge Iron 0.0504 Slag 0.0504Total 1.0504 Total 1.0504

2.3.1.1 Characteristics of MS scraps

All raw materials like Iron ore, MS scraps and sponge iron will be received and stored in

respected closed storage shed. Scrap from ship is low carbon and good quality. All raw

scraps is separated by magnetic separator to remove foreign particle. Separated scrap is

manually examined for removal of painted, oily and dirty residual scrap. Such scrap is

sorted out. After sorting scrap will be sent for cleaning section where scrap will be

cleaned manually by wire brush and compress air. Separated scrap is then crushed to

make homogeneous block. These block of metal finally feed to induction furnace for

melting. Maximum one month raw material inventory will be maintained in the plant for

continuous operation.

Name of Raw Materialas Input

TPAProposed Source

MS Scrap 2,20,000 Locally procured from the vendorsand imported- by road as the statehighway no. SH 36 at 1.3 kmaway from the project site

Sponge Iron 11,100 Procured from the open market- byroad

Additives(Silicon, Manganeseetc.)

As per productRequirement

Procured from the open market- byroad





2.3.1.2 Proposed Infrastructure Facility

The following infrastructure development and machinery will be installed in proposed

project.

Table 2.5 PLANT INFRASTRUCTURESr. No Facilities Proposed Quantity (Nos.)1 25TPH induction Furnace 2

2 12 TPH induction Furnace 2

3 Slag Crusher As required4 Bag Filter 15 Suction hood with Exhaust 45 Concast machine As required

EOT Crane

Magnet For

Scrap cleaning

Raw MS Scrap Stock 1 Removal of Plastic and Rubber material Raw MS Scrap Stock 2

Rejected ScrapClean and final Scrap Stock 3HydrolicBlockMaker

Final induction feeding MSScrap Block

Cleaning

Manual examination for removal of dirt, only and painted scrap

Raw Scrap Storage Shed No. 1

Transport to factory

Raw Scrap from Alang Ship Breaking Yard





2.3.2 Water Requirement & Waste Water Generation

In this production of M.S billets/Ingots plant, water will be basically required for concast

machine, domestic and other miscellaneous purpose. The total water requirement for

proposed project will be 150 KLD. The water requirement will be procured from Gujarat

Water Infrastructure Limited for which application has been made to GWIL (Copy of

Application is attached per Annexure III). The breakup of water requirement and waste

water generation for proposed plant is given in Table 2.6 and water balance chart is

presented in Figure 2.2

TABLE 2.6 WATER REQUIREMENTS AND WASTE WATER GENERATION

Maximum water is required in Concast machine used for molding of billets, due to high

temperature maximum water will get evaporated during molding & cooling process.

Hence, maximum industrial water requirement is for the make-up of water losses. No

waste water will be generated from the industrial activities. Domestic waste-water

is/will be disposed of through soak-pit system.

Sr.No.

Unit Total WaterRequirement

m3/day

WastewaterGeneration

m3/day

Mode of disposal of wastewater

1 Domestic 16.5 13 Domestic wastewater will bedisposed of through soak pit/septictank system

2 Gardening 5.5 - -

3 Industriala) Process Nil Nil -

b) Washing Nil Nil -c) Boiler NA - -d) Cooling 123 - Water will be used in concast

machine for moulding of moltenmetal through water spray. So thewater will gets evaporated due totemperature difference. The unitwill be zero discharge unit.

d) Others 5 - Dust Suppression within Premises

Total 150 13 -





FIGURE 2.2: WATER BALANCE FLOW CHART

2.3.3 Power Requirement:

The total power requirement for proposed project will be 20 MW and will be supplied by

Gujarat State Electricity Board. One DG set of 125 KVA capacity will be installed in

case of power failure.

TABLE 2.7: ENERGY BALANCE

Input/output Particular Percentage MW

Heat Input From transformer 100% 20

Total 100 % 20

Heat Output Heat transfer to

Metal 40 8

Slag 10 2

Furnace walls 10 2

Cooling system 20 4

Other Losses 20 4

Total 100 % 20





2.3.4 Man-Power Requirement:

The manpower requirements for the operational phase of the proposed project will be

about 325 people. In addition, there will be an indirect employment for skilled/ semi-

skilled people during project life. All attempts will be made to employ suitable, locally

available, skilled personnel from the nearby area. The undertaking for recruitment of

local employment is attached as Annexure IX

2.3.5 Land Requirement

The total plot area is 53781.0 Sq. m. Out of total area approximately 33.24% i.e.

17877.75 area will be allotted for green belt development. The land is owned by the

company and N.A. is obtained. Land document is attached herewith as Annexure V.

2.3.6 Capital project cost projection

The total Project cost required for the project is Rs 60 Crore. The details of cost

requirement is given in Table 2.8

TABLE 2.8: PROJECT COST PROJECTION

Sr. NoComponent Capital Cost

(Rs. in Crore)

1 Land & Building 10.77

2 Plant & Machinery 44.00

3 Electrification 3.23

4 Emission control Engineering 0.50

5 Water & Waste watermanagement

0.10

6 Solid Waste Management 1.00

7 Green Belt development 0.05

8 Environmental Monitoring 0.10

9 Other aspect 0.25

Total Rs. 60.0





2.4 PROPOSED SCHEDULE FORAPPROVAL ANDIMPLEMENTATION

The proposal was submitted under EIA notification, 2006 on dated 18-09-2018. The

proposal was appraised by SEAC, Gujarat in their 455thmeetingand standard TOR was

issued vide letter number SIA/GJ/IND/29097/2018 dated 29th November 2018.

The commissioning of the project will be taken up after receipt of environmental

clearance and consent to operate. It is estimated that the procurement of equipment,

engineering, construction of sheds, buildings and equipment foundations, erection of

equipment, piping and cabling work shall be completed in a period of 10 months from the

day of approval. Another 3-4 months will be required for Trials. There after the

commercial production shall commence. Thus, overall 12 months shall be required for

actual starting of the plant.

2.5 TECHNOLOGY AND PROJECT DESCRIPTION

The company will manufacture M.S. Billets/Ingots by using sponge Iron and scrap as raw

materials. Silicon & manganese will be added as alloying elements using medium

frequency induction furnace and continuous casting technology.

Sponge Iron and scrap are used as raw materials. Silicon & Manganese will be

added as alloying elements using medium frequency induction furnace and

continues casting technology.

In the Induction Melting Furnace where the iron melts at a temperature of about

16000C.

For production of billets/Ingots the molten material is poured into a ladle and then

transported to Continuous Casting machine.

In Continuous casting machine water is used to mold molten metal into

billets/ingots which results in water evaporation due to temperature difference

The Cut Billets/Ingots are transported by a handling crane and stored in the

Storage yard as per the Grade and Quality for dispatch.

Melting capacity of Furnace will be 25000Kg





Working of Induction Furnace

Induction Furnace is a device to melt the charge material using electrical power. It

consists of Crucible lined with water cooled induction coils, Electrical system to give

controlled power to induction coil, Hydraulic tilting system, Heat exchanger to cool the

circulating water, furnace transformer, Power Factor improvement system and surge

suppressor. Induction furnace consists of iron shunts which cover up to 60% of the outside of

the coil to ensure adequate control of the magnetic field and direct mechanical support of the

coil.

After the furnace is switched on; current starts flowing at a high rate and a comparatively

low voltage through the induction coil of the furnace, producing an induced magnetic

field inside the central space of the coils where the crucible is located. The induced

magnetic fluxes thus generate cut through the packed charge in the crucible. As the

magnetic fluxes cut through the scraps and complete the circuit, they generate an induced

current in the scrap. This induced current, as it flows through the highly resistive path of

the scrap mix, generates tremendous amounts of heat and melting of scrap starts. As soon

as the charge has melted clearly, any objectionable slag is skimmed off, and the necessary

alloying elements are added. When these additives have melted completely, the power

input may be increased to bring the temperature of metal up to the point most desirable

for pouring. The current is then turned off and the furnace is tilted for pouring into a

ladle. As soon as pouring has ceased the crucible is leaned completely from any slag or

metal droplets adhering to the wall of the crucible and the furnace is now ready for

charging again. Liquid Metal from Induction Furnace is carried in a ladle over the Con-

cast Machine. The technical details of Induction furnace is given in Annexure V. The

process flow chart of the manufacturing of Billet/ingots are shown in Figure 2.3 and

Plant layout is given in Figure 2.4





Figure 2.5: Process Flow Chart of the Manufacturing Billets/Ingots

2.6 MITIGATION MEASURES

2.6.1 Air Pollution

Air in and over the plant area and beyond its boundaries gets polluted with gases, fumes

and dust particles emitted from the stacks, transfer points of conveying and handling

equipment. The flue gases are generated during melting of scrap. Quantity and quality of

flue gases mainly depends upon type of scrap used in the furnace, i.e. with the degree of

contamination of scrap. These flue gases need proper treatment for removal of dust

particles before being discharged into the atmosphere. Dust and fumes will be collected

with the help of Bag filter as air pollution control system of specified size followed by 30

meter stack. Proper measures will be adopted by installing sprinkler, nozzles for control

of fugitive emission. Internal roads will be concreted to minimize fugitive emission due

to transportation. The raw material transporting vehicle will be regular checked





&maintained, it will be ensured that all trucks carrying raw material will be covered by

Tarpaulin.

2.6.2 Water Pollution

Requirement of water for proposed unit is only for cooling & domestic purpose; the same

will be recycled for cooling purpose through closed cooling circuit and there will not be

any effluent generation. However for domestic effluent Septic tank will be provided.

2.6.3 Noise Pollution

Noises from fans, centrifugal pumps, electrical motors etc. will be kept in control so that

the ambient noise level shall not exceed 75dBA during daytime and 70dBA during

nighttime. Noise pollution control measures will be provided in respective departments

by way of providing silencers soundproofs cubicles / covers and proper selection of less

noise prone machinery and by development of green belt. Necessary protective measures

will be taken to minimize the noise level as per the requirement of OSHA (Occupational

Safety and Health Administration) Standards

2.6.4 Solid waste Management

The solid waste generated will be in the form of slag. The total quantity of proposed slag

generation will be approx. 11,100 TPA. Slag crushers will be installed to recover iron

particles to be reused in Induction Furnace. Slag generated from Induction Furnace will

be used for hardening of working area, internal road, brick manufacturers and concreting.

The used machine oil of 0.1 TPA will be sell to registered oil vendors only.

2.6.5 Green belt Development

The company have total 13.29 Acres land. Out of this,33% i,e 4.38 Acres (17748 Sq. m)

land will be developed as green belt. Locally available types of trees will be plant in

proposed project. The plantation will be done in a phased manner simultaneously to

commencement of operation of the Plant.

During plantation landscaping pattern will be considered. The plantation scheme covers

the plantation of ornamentals plants and some local fruit bearing species.





2.6.6 Transportation

• The raw material will be transported by Road.

• Raw material & Finished Products will be transported by road.

• About 25 trucks of 30 T Capacity will be required Per Day.

• It will be ensure that all trucks carrying raw material are tarpaulin covered.

• Internal roads are being Tarred / Concreted with installation of water sprinklers to

suppress dust due to transportation.

2.6.7 Fire Protection System

The firefighting system will be designed in conformity with the recommendations of the

Tariff Advisory Committee (TAC) of Insurance Association of India. While designing

the fire protection systems for proposed facilities its extreme ambient conditions need

special attention. Codes and Standards of National Fire Protection Association (NFPA)

will be followed, as applicable.

2.6.8 Occupational Health and Safety

• The operating and maintenance personnel will be provided with all the necessary

safety equipment such as hand gloves, gum boots, aprons, helmets, protective

glasses, ear muffs etc.

• Workers training will focus on reduction of wastes, utilization of wastes and

generally maintaining a clean and healthy environment.

• At work place, first aid facilities will be maintained at a readily accessible place

where necessary appliances including sterilized cotton wool, disinfectants, bandages

etc. will be available.

• Emergency medical treatment will be facilitated at local hospital.





2.7 ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR THE RISK OF

TECHNOLOGY FAILURE

The production of M.S. Billets/Ingots using Induction Furnace technology is a globally

proven technology adopted by all for medium scale industry. It is latest technology with

advantage of low capital cost, low power consumption; low slag generation compared

with other technology. Its installation is relatively easier and its operation is simpler.

Among other advantages, there is very little heat loss due to rotation from the furnace as

the bath is constantly covered and there is practically no noise attending its operation.

The molten metal in an induction furnace is circulated automatically by electro-magnetic

action so that when alloy additions are made, a homogeneous product is ensured in

minimum time. In pursuance of this, the induction furnace based technology is proposed

for this project.



Chapter 3:Description of the

Environment

Pollution and Ecology Control Services(PECS), Nagpur P a g e | 25

CHAPTER 3

DESCRIPTION OF THE ENVIRONMENT

3.0 BASELINE ENVIRONMENTAL STATUS

The Baseline environmental status around the proposed activities indicates the exiting

quality of Air, Water, Noise, Soil, and Socio-economic environment. The baseline

environmental data were generated within 10 km radial distance area of proposed project

site. The satellite image is provided in Figure 3.1.

Figure 3.1: Satellite Image of Project site showing 10 km study area




Environment


The impact identification always commences with the collection of baseline data such as

Ambient Air Quality, Micro-Meteorology, Ground and Surface Water Quality, Noise

levels, Soil Quality, Land use pattern, Biological Environment and Socio-economic

aspects, Solid and Hazardous waste, and risk assessment within the study zone of 10 km.

radius. The baseline environmental study has been done for the period October to

December 2018 in accordance with the Guidelines for EIA issued by the Ministry of

Environment Forests and Climate Change, Govt. of India and CPCB, New Delhi.

Secondary data was also collected from different sources.

3.1 METHODOLOGY

The data was collected from both primary and secondary sources. The baseline

information on micro-meteorology, ambient air quality, water quality, noise levels, soil

quality and floristic descriptions were collected. Micrometeorological data at site was

recorded using automatic weather station. Apart from these, secondary data have been

collected from various governmental agencies.

For reconnaissance survey the sampling locations were identified based on:

• Existing topography and meteorological conditions

• Locations of water intake and waste disposal points.

• Location of human habilitation and other sensitive areas present in the vicinity of

the proposed project site.

• Representative areas for baseline conditions.

• Accessibility for sampling

The baseline studies started with reconnaissance survey and the site visits in the study

area for fixing the monitoring locations for collection of the primary data. Various

Government and other organizations were approached for getting information for the

secondary data generation. The various parameters surveyed and studied for the baseline

study are discussed in the following components:




Environment


3.2 MICROMETEOROLOGY

The meteorological data recorded during the study period was very useful for selection of

sampling locations as per upwind and down-wind directions for proper on-site

monitoring to be undertaken for various meteorological variables in order to generate the

site specific data. Data was collected for proposed project site on hourly basis

continuously during October to December 2018. Data of wind velocity, wind direction,

ambient temperature, relative humidity, cloud cover and rainfall data were recorded at

hourly intervals along with atmospheric pressure for 24 hours for the study period.

Wind velocity and wind direction were recorded using cup anemometer and wind vane

respectively. Ambient temperature was noted by wet and dry bulb thermometer. Relative

humidity was measured by hygrometer. An barometer was used for measuring

atmospheric pressure and a self-recording rain gauge was used for rainfall data collection.

Cloud cover data was collected by visual inspection. Apart from these, secondary data

have been collected from Census Handbook, Revenue Records, Statistical Department,

Soil Survey and Land use Organization, District Industries Centre, Forest Department,

Central Ground Water Authority, etc..

Windrose

The meteorological data was collected at the site by installing an automatic weather

station during winter season (October-December 2018). Wind Speed, Wind Direction,

Temperature and Relative Humidity were recorded for the total study period. Wind roses

on sixteen sector basis (N, NNE, NE, ENE, E, ESE, SE, SSE, S, SSW, SW, WSW, W,

WNW, NW, and NNW) have been drawn for 24 hours. The data on wind patterns are

pictorially represented by means of wind rose diagrams for study period October to

December 2018 as shown in Figure 3.1.The metrological data reflecting minimum,

maximum temperature in 0C, relative humidity in %, wind speed in m/s, for the year

2018-19 has been given Table 3.1.




Environment


Table 3.1. Onsite Meteorological Data (Period: October to December2018)

Month Temperature

(0C)

Relative Humidity

(RH)

Wind Speed (km/hr)

Min Max Min Max Min Max

October 20.2 38.8 32.5 92.9 1.2 11.8

November 15.6 38.6 32.6 96 1.3 12.1

December 12.4 30.8 23 93 2.8 20.8

During the study period, average wind speed measured on site is 1.45 m/s. The

wind rose diagram indicates predominant wind direction is from NE with 7.25 % calm

condition




Environment


Figure- 3.1: Windrose Diagram during study period (October –December 2018)




Environment


3.3 AIR QUALITY

3.3.1 Ambient Air Quality Monitoring

The baseline status of the ambient air has been established through a scientifically

designed ambient air quality monitoring network. The following criteria were taken into

account during selection of the sampling stations:

• Topography of the area

• Human settlements within the study area

• Safety, accessibility and non-interference with general routine of the people

residing near the station

• Prediction of maximum concentration of the air pollutants through dispersion

modeling

• The impact of air pollutants release from the other nearby industry

• Prevailing meteorological conditions in this region

To assess the ambient air quality status, eight air quality monitoring locations were

identified on the basis of meteorology in the upwind and downwind direction as well as

to represent the cross sectional scenario of the project site.

Methodology Adopted for the Study

As per revised norms for Ambient air quality standards prescribed by Ministry of

Environment & Forest vide Notification No. “Schedule VII” of Rule 3(3B) of

Environment (Protection) Seventh Amendment Rules, 2009 from MoEF notification

dated 16 November 2009, five air pollutants viz. PM10, PM2.5, Sulphur dioxide (SO2),

Oxides of Nitrogen (NOX) were monitored on the basis of 24- hour sampling and twice in

a week at each and Carbon Monoxide (CO) were monitored twice in a month for three

month during study period at all locations. The ambient air quality samples were

collected during October to December 2018. The samples were preserved and analyzed

as per the standard methods recommended by Standard Operating Procedure (SOPs) of

the Central Pollution Board (CPCB).




Environment


PM10, PM2.5, SO2 and NOX

Respirable Dust Samplers of Envirotech Instruments (duly calibrated) with gaseous

sampling attachment have been used for monitoring of PM10, SO2, & NO2, Fine

particulate samplers of Envirotech Instruments (duly calibrated) have been used for

monitoring of PM2.5. PM10 and PM2.5 was analysed on electronic balance by Gravimetric

Method whereas, SO2& NO2 were analysed on UV – Visible Spectrophotometer (CPCB

guidelines 2011). The methodology adopted for sampling and analysis of ambient air

quality is as mentioned in Table 3.2

CARBON MONOXIDE

Samples for Carbon Monoxide (CO) were collected in gas bladder and analyzed by Gas

chromatography.

The techniques used for ambient air quality monitoring and minimum detectable level are

given in Table 3.2.




Environment


TABLE 3.2

Methodology of Ambient Air Quality Monitoring

SamplingLocations& TimePeriod

Parameters Frequency Equipment

Sample Analysis

MethodologyAnalyticalInstrument

Sensitivity/DetectionLimit

8Locations

DuringOct’18 –Dec’18

PM10

Twice in aweek for12 weeks

RespirableDustSamplerwithCyclone &Flowmeasurement

Electronicbalance

10 µg/m3

IS 5182(Part23):2012(byGravimetry)

PM2.5

FineParticulateSampler

Electronicbalance

10 µg/m3

PL/SOP/120(40CFR 60byGravimetry)

SO2Gaseoussampler

UV-visiblespectro-photometer

5 µg/m3

IS 5182(Part2):2001ModifiedWest &Geakemethod

NO2Gaseoussampler

UV-visiblespectro-photometer

8 µg/m3

IS 5182(Part6):2006Jacob&Hochheissermethod

CarbonMonoxide

Twice inMonth

Gas bladder& pump

GasChromatography

0.1 mg/m3 Sensor/GCmethod

3.3.2 AAQ Monitoring Stations and Observation:

The Ambient Air Monitoring Stations are given in Table 3.3 and Figure 33. The

summary of results of Ambient Air Quality monitoring is given in Table 3.4. The

detailed ambient air quality results is given in Annexure VI. The Revised National

Ambient Air Quality Standards are given in Table 3.5




Environment


Table 3.3

Ambient Air Quality Monitoring Sampling Stations

Source: SOI ToposheetFigure 3.3 Ambient Air Quality Sampling Station

Sr.

No.

Description of monitored

stationsSample code

Distance from

proposed plantDirection

1. Project Site A-1 ---- ----

2. Dambhaliya A-2 2.5 Km. W

3. Bhangadh A-3 5.7 Km. E

4. Manglana A-4 5.0 Km. SE

5. Navagam A-5 4.0 Km. S

6. Ukharala A-6 4.5 Km. SW

7. Chamardi A-7 2.5 Km. N

8. Chogath A-8 4.5 Km. NW




Environment


TABLE – 3.4

SUMMARIZED REPORT OF AMBIENT AIR QUALITY

(OCTOBER-DECEMBER 2018)

Ambient Air

Quality StationParticulars

PM10 PM2.5 SO2 NOx *CO

µg/m3 mg/m3

A-1 Project Site

Minimum 70 23 10 14 0.81

Maximum 84 39 23 25 0.91

Average 78 31 17 20 0.87

A-2 Dambhaliya

Minimum 55 22 10 12 0.48

Maximum 76 33 17 18 0.62

Average 66 28 13 15 0.55

A-3 Bhangadh

Minimum 47 20 10 13 0.34

Maximum 68 29 19 22 0.67

Average 58 25 15 18 0.50

A-4 Manglana

Minimum 69 21 11 12 0.58

Maximum 83 38 21 26 0.90

Average 78 30 16 19 0.73

A-5 Navagam

Minimum 66 18 9 11 0.38

Maximum 81 30 17 20 0.63

Average 74 24 12 16 0.48

A-6 Ukharala

Minimum 56 21 10 13 0.20

Maximum 79 33 15 20 0.46

Average 67 27 12 16 0.31

A-7 Chamardi

Minimum 56 24 10 15 0.23

Maximum 77 32 14 21 0.52

Average 68 28 12 18 0.35

A-8 Chogath

Minimum 57 22 10 13 0.23

Maximum 76 30 19 22 0.72

Average 68 27 15 18 0.46

*CO was monitored twice in a month for three month during study period.




Environment


TABLE – 3.5

NATIONAL AMBIENT AIR QUALITY STANDARDS

Pollutant UnitTime weighted

Average

Concentration in airIndustrial

Areas, residentialrural & other areas

Sensitiveareas

PM10 µg/m3 Annual Average24 hours

60.0100.0

60.0100.0

PM2.5 µg/m3 Annual Average24 hours

40.060.0

40.060.0

NitrogenDioxide (NOx)

µg/m3 Annual Average24 hours

40.080.0

30.080.0

Sulphur dioxide(SO2)

µg/m3 Annual Average24 hours

50.080.0

20.080.0

Carbonmonoxide (CO)

mg/m3 1 hours8 hours

4.02.0

4.02.0

Refer : GSR 826(E) dated 16th Nov. 2009

RESULT

On the basis of observations the parameter wise result of monitored parameters are

discussed below.

PM10 PARTICULATE MATTER (<10 μm)

PM10 is a measure of particles in the atmosphere with a diameter of less than 10 or equal

to a nominal 10 micrometers. PM10 is particulate matter with an aerodynamic diameter of

up to 10 µm, i.e. the fine and coarse particle fractions combined.

The Average PM10 concentration at all air quality monitoring stations A-1, A-2, A-3,A-4,

A-5, A-6, A-7, and A-8 are 78, 66, 58, 78, 74, 67, 68, and 68 µg/m3 respectively. All

monitored stations have PM10 concentrations well within stipulated 24 hours average

limit, 100 µg/m3 as prescribed for industrial, residential, rural and other areas as in

revised NAAQ Standards from MoEF. These values represent quite satisfactory condition

regarding PM10 concentration in ambient air.




Environment


PM2.5 PARTICULATE MATTER (<2.5 μm)

Particulate Matter-2.5 particles are air pollutants with a diameter of 2.5 micrometers or

less, small enough to invade even the smallest airways. The average PM2.5 concentration

at all air quality monitoring stations A-1, A-2, A-3,A-4, A-5, A-6, A-7, and A-8 are 31,

28, 25, 30, 24, 27, 28, and 27 µg/m3 respectively. All monitored stations have PM2.5

concentrations well within stipulated annual 24 hours limit, 60 µg/m3 as prescribed for

industrial, residential, rural and other areas as in revised NAAQ Standards from MoEF.

These values represent quite satisfactory condition regarding PM2.5 concentration in

ambient air.

SULPHUR DIOXIDE (SO2)

The average SO2 concentrations at all sampling stations A-1, A-2, A-3,A-4, A-5, A-6, A-

7, and A-8 are 17, 13, 15, 16, 12, 12, 12, and 15 µg/m3 respectively. All monitored

stations have SO2 concentrations well within stipulated annual 24 hours limit, 80 µg/m3

as prescribed for industrial, residential, rural and other areas as in revised NAAQ

Standards from MoEF.

OXIDES OF NITROGEN (NOX)

The average NOx concentrations at all sampling stations A-1, A-2, A-3,A-4, A-5, A-6, A-

7, and A-8 are 20,15, 18, 19, 16,16, 18 and 18 µg/m3respectively. All monitored stations

have NOX concentrations well within stipulated annual 24 hours limit, 80 µg/m3 as

prescribed for industrial, residential, rural and other areas as in revised NAAQ Standards

from MoEF.

CARBON MONOXIDE (CO)

Samples of air were collected and analysed for CO content. The average CO concentrations

at all sampling stations A-1, A-2, A-3, A-4, A-5, A-6, A-7, and A-8 are 0.87, 0.55, 0.50,

0.73, 0.48, 0.31, 0.35, and 0.46 mg/m3respectively. All sampling stations have less CO

content than stipulated annual average 2 mg/m3 limit recommended for sensitive area as in

revised NAAQ Standards from MoEF&CC.




Environment


3.4 WATER ENVIRONMENT

The water quality monitoring stations were selected with a view to represent the surface

and ground water sources in and around 10 kilometer radius of the study area of proposed

Project site. Sampling stations for water samples were selected taking all water sources

into account, as per MOEF norms. A total number of 10 including four surface water

&six ground water samples were collected and analyzed. Surface and ground water

sampling locations are presented in Table 3. 6 and are shown in Figure 3.4.

Table 3.6

Water Sampling Location

Sr. No. Description of the sampling stationSample

code

Distance from


Surface Water Samples

1. Mangalana (Pond) SW-1 5.0 Km. SE

2. Chamardi ( Pond) SW-2 2.5 Km. N

3. Rangholi river SW-3 3.5 Km. SE

4. Ukhrala SW - 4 4.5 Km. SW

Ground Water Sample

5. Navagam GW-1 4.0 Km. S

6. Dambhaliya GW-2 2.5 Km. W

7. Ukhrala GW-3 4.5 Km. SW

8. Manglana GW-4 5.0 Km. SE

9. Chogath GW-5 4.5 Km. NW

10. Pipaliya GW-6 6.0 Km. S




Environment



Figure 3.4: Map showing Ground and surface water sampling

The methodology for sample collection and preservation techniques was followed as per

the standard methods for the examination of water and wastewater, published by APHA,

AWWA, 22nd Edition, 2012 .Standard Procedure for Water and Wastewater Sampling are

presented in Table 3.7

Table 3.7

Methodology for Sampling and Analysis of Water

SamplingLocation& Period

SamplingParameters

SampleCollection

AnalysisEquipment

Sensitivity/Detection

Methodology

Groundwater– 6 locations

Surfacewater – 4locations

Grab

pH Manualsampling inCarboy/glassbottles

pH meter 2.0 APHA 22nd Ed. 4500pH, IS 3025(Part11):1983(RA 2002)

Temp (°C) Thermometer 5oC APHA 22ndEd.,2550B

Colour (pt.co.Scale)

Spectrophotometer

ColourUnit

APHA 22nd Ed.,2120 B & C

Odour Manual Qualitative APHA 22nd Ed.,2150




Environment



SamplingParameters

SampleCollection

AnalysisEquipment


Methodology

SamplingOctober to –December2018

Turbidity,(NTU)

Nephlometer 0.1 NTU APHA 22nd Ed.,2130 BIS 3025(Part10):1984, (RA 2012)

TotalDissolvedSolids

ElectronicBalance

5 mg/l APHA 22nd Ed. 2540CIS 3025(Part16):1984

EC ConductivityMeter

10 µS/cm APHA 22nd Ed.2510-B

Oil & Grease ElectronicBalance

0.2 mg/l APHA 22nd Ed.,5520 BIS 3025(Part39):1991 (RA 2003)

BOD Incubator,Titration

2.0 mg/l IS 3025(Part44):1993(RA 2009), Amds.1

COD Titration 5.0 mg/l APHA 22nd Ed.,5220BIS 3025(Part58):2006

Phenoliccompounds

Spectrophotometer

0.001 mg/l APHA 22nd Ed.,5530 CAPHA 22nd Ed.,5530 DIS 3025 (Part43)1992 (RA 2003)

TotalAlkalinity

Titration 5.0 mg/l APHA 22nd Ed. 2320B.IS 3025(Part23):1986

Total Hardness Titration 2.0 mg/l IS 3025(Part21):2009APHA 22nd Ed.2340 C.EDTA -TitrimetricMethod

Calcium Titration 2.0 mg/l APHA, 22nd Ed.,3500-B,EDTA TitrimetricMethod




Environment



SamplingParameters

SampleCollection

AnalysisEquipment


Methodology

IS 3025(Part40):1991 (RA 2003)

Magnesium Titration 2.0 mg/l APHA 22ndEd.,3500- Mg-BIS3025(Part46):1994(RA 2009)

Chlorides asCl

Titration 5.0 mg/l APHA 22nd Ed. 4500Cl. BIS 3025(Part32):1988

Nitrates asNO3

Spectrophotometer

0.1 mg/l APHA 22ndEd.,4500-NO3-B(UV Screeningmethod)

Sulphates asSO4

Spectrophotometer

1.0 mg/l APHA 22nd Ed.,4500SO42 –EIS 3025(Part24):1986 (1st Rev)(RA 1992) (TurbidityMethod)

Phosphates asPO4

Spectrophotometer

0.1 mg/l APHA 22nd Ed.,4500- P-DIS 3025(Part31):1988 (RA 2003)

Fluorides as F Ion Meter 0.1 mg/l EPA 340.2(By Ion SelectiveElectrode)

Sodium AAS 0.5 mg/l APHA, 22nd Ed.,3500-Na, B, IS3025(Part 45):1993

Potassium AAS 1 mg/l APHA22ndEd.,3500-K, BIS 3025(Part45):1993

Iron AAS 0.1 mg/l APHA, 22nd Ed.,3111-B,IS 3025(Part53):2003 (RA 2009)

Manganese AAS 0.05 mg/l APHA, 22nd Ed.3500-Mn, B,IS 3025(Part




Environment



SamplingParameters

SampleCollection

AnalysisEquipment


Methodology

59):2006Cyanide Ion Meter 0.02 mg/l APHA 22nd Ed.,

4500-CN- F(by ISE)IS 3025(Part27):1986 RA 2003

Copper AAS 0.02 mg/l APHA, 22nd Ed.,3111-BIS 3025(Part42):1992

Nickel AAS 0.01 mg/l APHA 22nd Ed.,3111BIS 3025 (Part54):2003 (RA 2009)

Lead AAS 0.001 mg/l APHA 22nd Ed.,3111BIS 3025(Part47):1994 (RA 2009)

Zinc AAS 0.2 mg/l APHA, 22nd Ed.,3111-BIS 3025(Part49):1994(RA 2009)

TotalChromium

AAS 0.02 mg/l APHA 22nd Ed.,3111BIS 3025(Part52):2003 (RA 2009)

Observations

The characteristics of surface water samples are presented in Table 3.8 and that of

ground water in Table 3.9. These tables have desirable as well as permissible limits of

Indian Standard for each parameter. It was observed that the characteristics of the surface

and ground water samples were found to be within the permissible limits of Indian

Standards except the total coliforms in surface water samples which may be due to the

human activities observed during sampling and requires disinfection before use for

drinking purpose.




Environment


TABLE 3.8Water Quality: Surface Water Samples

Parameters

Units SW1 SW2 SW3 SW4 As Per IS 10500 of 2012

MangalanaPond

ChamardiPond

Rangholiriver

Ukhrala

Acceptable PermissiblePond Pond River stream pond

pH - 7.80 7.90 7.70 8.15 6.5-8.5 NR

Temperature °C 28 28 28 28 - -

Colour Hazan <5 <5 <5 <5 5 25

Odour - U/O U/O U/O U/O 5 10

Turbidity NTU 0.8 1.1 0.5 0.8 1 5

EC ms/cm 1.02 1.29 0.64 1.45 - -

Total Dissolved Solids mg/l 658 822 408 920 500 2000

Oil & Grease mg/l <0.1 <0.1 <0.1 <0.1 - -

COD mg/l 20 36 16 26 - -

Dissolved Oxygen mg/l 5.5 4.5 5.7 5.6 - -

BOD mg/l 9 12 5 8 - -

Phenolic compound mg/l <0.001 <0.001 <0.001 <0.001 - -

Total Alkalinity mg/l 123 143 34 66 200 600

Total Hardness mg/l 366 319 132 440 200 600

Calcium mg/l 47 78 22 40 75 200

Magnesium mg/l 18 12 5 13 30 100

Chloride mg/l 112 237 136 221 250 1000

Sulphates mg/l 60 80 32 86 200 400

Phosphates mg/l 6 8 3 9 0.05 NR

Fluorides mg/l <0.1 <0.1 <0.1 <0.1 1 1.5

Sodium mg/l 75 141 80 123 - -

Potassium mg/l 18 36 20 41 - -




Environment


Iron mg/l 0.3 0.2 0.2 0.3 0.3 1

Manganese mg/l <0.05 <0.05 <0.05 <0.05 0.1 0.3

Cyanide mg/l <0.02 <0.02 <0.02 <0.02 0.001 0.002

Copper mg/l <0.02 <0.02 <0.02 <0.02 0.05 1.5

Lead mg/l <0.01 <0.01 <0.01 <0.01 0.05 NR

Nitrates mg/l 34 36 16 6 45 NR

Nickel mg/l <0.01 <0.01 <0.01 <0.01 - -

Zinc mg/l <0.2 <0.2 <0.2 <0.2 5 15

Chromium mg/l <0.02 <0.02 <0.02 <0.02 0.05 NR

Total Coliform MPN/100ml 38 43 41 49 - -

Feacal Coliform(MPN/100ml)

MPN/100ml21 27 26 33

- -




Environment


TABLE 3.9WATER QUALITY: GROUND WATER SAMPLES

Parameters Unit GW 1 GW 2 GW 3 GW 4 GW 5 GW 6 As per IS 10500 OF 2012

Navagam Dambhaliya Ukhrala Manglana Chogath PipaliyaDesirable Permissible

pH - 7.95 7.8 8.1 7.25 7.82 7.33 6.5-8.5 NR

Temp °C 28 28 28 28 28 28 - -

Colour (CU) Hazan <5 <5 <5 <5 <5 <5 5 25

Odour - U/O U/O U/O U/O UO UO AG AG

Turbidity NTU 0.4 0.5 0.5 0.2 0.8 0.4 1 5

EC ms/cm 3.09 2.88 2.57 1.53 3.16 2.25 - -

Total Dissolved mg/l 1976 1860 1644 961 2027 1430 500 2000

Oil & Grease mg/l <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 - -

Phenoliccompound (mg/l)

mg/l<0.001 <0.001 <0.001 <0.001 <0.001 <0.001

- -

Total Alkalinity(mg/l)

mg/l273 272 136 159 178 106

- -

Total Hardness(mg/l)

mg/l480 450 492 210 532 488

- -

Calcium mg/l 152 145 107 52 75 98 - -Magnesium mg/l 24 28 54 19 35 10 200 600

Chloride mg/l 856 783 630 406 792 563 200 600

Sulphates mg/l 86 91 132 43 87 46 75 200Phosphates mg/l 0.6 1.6 0.8 2.4 0.85 0.1 30 100

Fluorides mg/l 0.3 0.2 <0.1 0.2 0.4 0.4 250 1000Sodium mg/l 487 440 297 262 428 289 200 400

Potassium mg/l 36 62 32 12 116 25 0.05 NR




Environment


Iron mg/l 0.9 0.3 0.22 0.4 0.35 0.8 0.3 1Manganese mg/l <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 0.1 0.3

Cyanide mg/l <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 0.001 0.002Copper mg/l <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 0.05 1.5Lead mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 0.05 NR

Nitrates mg/l 24 21 6 12 20 2 45 NRNickel (mg/l) mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 - -

Zinc (mg/l) mg/l 0.3 0.5 0 0.5 0.4 0.2 5 15

Chromium mg/l <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 0.05 NR

Total Coliform(MPN/100ml)

MPN/100mlAbsent Absent Absent Absent Absent Absent

- -

Feacal Coliform(MPN/100ml)

MPN/100mlAbsent Absent Absent Absent Absent Absent

- -




Environment


3.5 NOISE ENVIRONMENT

In this proposed project movement of raw materials, products, fuels, tools &tackles will

takes place for its manufacturing process. The movement of personnel from their

residence to industry would also result in a moderate increase in the traffic, which would

result in drastic change in existing traffic pattern and noise levels of the area. Noise level

monitoring was carried out using SLM100 Sound Level Meter (Envirotech Instrument

(type II) at eightlocations for 24 hours at hourly intervals, during the study period. The

day time limit is for 6 am to 10 pm and night time limit is for 10 pm to 6 am. The noise

sampling locations are given in Table 3.10 and shown in Figure 3.5.

Table3.10

Noise Level Sampling Stations

Sr.

No.

Description of monitored

stations

Sample

code

Distance from


1. Project Site N-1 ---- ----

2. Dambhaliya N-2 2.5 Km. W

3. Bhangadh N-3 5.7 Km. E

4. Manglana N-4 5.0 Km. SE

5. Navagam N-5 4.0 Km. S

6. Ukharala N-6 4.5 Km. SW

7. Chamardi N-7 2.5 Km. N

8. Chogath N-8 4.5 Km. NW




Environment



Figure 3.5: Map showing Noise level Monitoring Station




Environment


TABLE 3.11Measured Noise Levels at Monitored Stations

Noise Level in dB(A)

Location ID N1 N2 N3 N4 N5 N6 N7 N8

Time Measured levels dB(A)

6:00 Day 56.6 52.2 52.2 50.7 52.0 53.1 48.9 48.0

7:00 60.1 53.5 53.5 52.7 54.5 56.8 52.6 52.0

8:00 64.5 55.2 55.6 56.4 58.1 60.5 55.6 54.1

9:00 60.2 55.7 57.8 55.8 59.2 58.5 56.5 56.9

10:00 67.4 59.8 64.4 57.3 59.7 64.6 57.3 57.8

11:00 62.9 56.7 66.5 58.6 60.1 59.9 52.7 55.8

12:00 68.8 57.7 65.8 58.8 61.8 66.1 60.0 55.9

13:00 66.1 55.8 60.6 57.6 59.8 62.6 58.8 57.8

14:00 69.0 57.8 63.5 60.4 62.5 66.5 59.3 55.4

15:00 67.1 59.0 60.7 56.5 58.6 63.5 61.2 53.6

16:00 65.9 56.0 62.5 59.6 57.8 61.2 60.2 55.8

17:00 64.0 52.0 59.7 57.8 55.2 60.5 59.9 49.2

18:00 66.9 55.4 60.4 58.6 57.8 59.0 57.8 49.3

19:00 62.5 53.2 58.9 52.6 55.6 57.8 52.9 47.8

20:00 63.5 51.6 57.8 51.5 53.6 54.6 55.5 49.8

21:00 Night 58.1 53.0 56.9 50.0 51.0 58.9 49.2 46.6

22:00 61.4 51.0 55.6 54.6 55.4 55.6 50.2 47.8

23:00 54.1 51.4 55.2 48.6 49.2 56.8 47.2 44.9

0:00 50.2 52.2 54.6 53.3 53.5 55.9 48.7 46.6

1:00 51.4 49.1 51.1 47.2 47.7 55.2 45.9 45.8

2:00 57.3 48.8 51.5 52.0 52.6 53.5 46.9 45.2

3:00 51.6 47.3 49.2 47.0 48.0 52.5 46.4 43.7

4:00 57.6 46.9 51.0 53.8 55.0 56.6 46.9 44.3

5:00 53.6 49.7 51.6 49.2 49.9 54.0 47.7 45.1

Ld 64.4 55.4 60.0 56.3 57.8 60.3 56.6 53.3Ln 55.0 49.9 53.0 50.6 51.4 55.4 47.7 45.6

Observation

The results of noise levels are given in Table 3.11. The results showed that noise levels

measured at all eight stations (N-1, N-2, N-3, N-4, N-5, N-6, N-7 and N-8) are low and

well within limit of either 65.0 dB(A) for Residential Area or 75.0 dB(A) for Industrial

Area as given in MoEF Gazette notification for National Ambient Noise Level Standard.




Environment


Ambient Noise Level Standards

Ambient Air Quality standards in respect of noise have been notified by the Ministry of

Environment & Forests vide Gazette Notification Dated 26th December 1989. It is based

on a weighted equivalent noise level (Leq). National Ambient Noise Level Standards are

given below in Table 3.12.

Table 3.12

National Ambient Noise Level Standards

AreaCode

Category of AreaLimits in dB(A) Leq

Day time Night timeA Industrial Area 75 70

B Commercial Area 65 55

C Residential Area 55 45D Silence Zone** 50 40

**Silence zone is defined as area up to 100 meters around premises of hospitals,educational institutions and courts. Use of vehicle horns, loud speakers and burstingof crackers are banned in these zones.

3.6 SOIL QUALITY

The present study on soil quality establishes the baseline characteristics in the study area

surrounding the project site. The study has been addressed with the following objectives.

• To determine the base line characteristics

• To determine the soil characteristics of proposed project site.

• To determine the impact of industrialization/urbanization on soil characteristics

• To determine the impacts on soils from agricultural productivity point of view.

For studying the soil types and soil characteristics, 4 sampling locations were selected to

assess the existing soil conditions representing various land use conditions and geological

features. The methodology adopted for sampling and analysis of soil quality is as

mentioned in Table 3.13.Samples were collected form selected points by manually using

auger. Undisturbed top soil was collected in containers. The sampling locations are given

in Table 3.14 and shown in Figure 3.6. The physico-chemical characteristics of soil

samples are reported in Table 3.15.




Environment


Table-3.13: Analytical methodology for soil samples

Table 3.14: Soil Sample Monitoring Station

Sr. No. Sampling Sites Station CodeDistance fromproposed plant

Direction

1. Dhambhaliya S – 1 2.5 Km. W

2. Bhangadh S – 2 5.5 Km. E

3. Navagam S – 3 4.0 Km. S

4. Ukharala S – 4 4.5 Km. SW


SamplingParameters

AnalysisEquipment


Methodology

4 soilsampleswerecollectedduringOctober toDecember2018

pH pH meter 1.0 IS 2720 (Part 26):1987 (RA2011)

ElectricalConductivity

Conductivity Meter 10 µS/cm IS 14767:2000 RA 2010

Nitrogen (as N) Spectrophotometer 5 mg/kg IS 14684:1999 (RA 2000)Phosphorous (as P) Spectrophotometer 5 mg/kg IS 10158-1982 (RA 2009)Potassium (as K) AAS 5 mg/kg USEPA 3050BOrganic Carbon Titrimetric 5 mg/kg IS 2720 (Part 22):2002Grain SizeDistribution

-- -- IS 2720(P-4):1985

Texture Class -- -- U.S. Texture TriangleBulk Density Glass ware -- IS 2720: Part 28/29: 1974

(By Cylinder method)Calcium Titrimetric 5 mg/kg USEPA 3050BMagnesium Titrimetric 5 mg/kg USEPA 3050BSodium AAS 5 mg/kg USEPA 3050BIron AAS 5 mg/kg EPA 3050B & EPA 7000BCopper AAS 5 mg/kg EPA 3050B & EPA 7000BManganese AAS 5 mg/kg EPA 3050B & EPA 7000BZinc Titrimetric 5 mg/kg USEPA 3050B




Environment



Figure 3.6: Location of Soil sampling Stations




Environment


Table 3.15

Physio-Chemical Properties of Soil

Parameters UnitS1 S2 S3 S4

Dhambhaliya Bhangadh Navagam Ukharala

Physical Properties

Texture - Clay Slit Clay Slit Clay Slit Clay

Sand % 42 23 21 24

Silt % 14 32 31 30

Clay % 44 45 48 46

Bulk Density (BD) gm/cm3 1.8 2.3 2.1 2.2Water Holding Capacity(WHC) % 26

3032

30

Chemical Properties

pH5%Slurry 8.34 8.22 7.8 7.82

Conductivity (EC) ms/cm 1.6 1.8 1.64 1.75

Organic Matter % 0.51 0.48 0.46 0.43

Organic Carbon % 0.68 0.62 0.65 0.65

Sodium as Na mg/kg 776 922 706 687Calcium as Ca mg/kg 748 936 468 832Magnesium as Mg mg/kg 294 299 316 371Zinc as Zn mg/kg 69.5 68.6 69.8 68.7

Copper as Cu mg/kg <5 <5 <5 <5

Manganese as Mn mg/kg <5 <5 <5 <5

Iron as Fe mg/kg 26 28 25 27

Nitrogen as N mg/kg 86 62 71 87

Phosphorus as P mg/kg 74 50 61 75

Potassium as K mg/kg 108 39 52 104




Environment


Standard Soil Classification

Standard soil classification regarding agriculture, in view of its test parameters, is

detailed below in Table 3.16. The use of soil for agriculture or for other use may be

decided on basis of soil characteristics.

Table 3.16

Standard Soil Classification

Sr.No.

Test Parameters Classification

1. pH

< 4.50 extremely acidic4.51-5.00 very strongly acidic5.01-5.50 strongly acidic5.51-6.00 moderately acidic6.01-6.50 slightly acidic6.51-7.30 neutral*

7.31-7.80 slightly alkaline*7.81-8.50 moderately alkaline8.51-9.0 strongly alkaline> 9.0 very strongly alkaline(*tolerable to crops)

2.

Salinity orElectricalConductivity(mmhos/cm)(1mmhos/cm = 640ppm)

upto 1.00 average1.01-2.00 harmful togermination2.01-3.00 harmful to crops> 3.00 sensitive to salts

3.Organic Carbon(%)

upto 0.30 very less0.31-0.40 less0.41-0.50 medium0.51-0.80 on an averagesufficient

0.81-1.00 sufficient> 1.0 more than sufficient

4. Nitrogen (kg/ha)upto 50 very less51-100 less101-150 good

151-300 better> 300 sufficient

5.Phosphorous(kg/ha)

upto 15 very less16-30 less31-50 medium

51-65 on an averagesufficient65-80 sufficient> 80 more than sufficient

6. Potassium (kg/ha)0 very less120-180 less181-240 medium

241-300 average301-360 better> 360 more than sufficient

Source: Hand book of Agriculture ICAR (Indian Council of Agriculture Research)




Environment


OBSERVATIONS

The observations of soil characteristics are discussed parameter wise below;

• Texture of soil samples in the study area are clay and slit clay nature

• The bulk density of soil samples collected from the all sampling locations are in

the range of 1.8 to 2.3 g/cc

• Soil samples have pH values between 7.8 to 8.34. The pH values are indicating

nature of soil samples is neutral to alkaline.

• Soil samples from agricultural land have conductivities between 1.6 to 1.8 ms/cm

• The organic matter present in the collected soil samples are in the range of 0.43 to

0.51%. These values represent moderate fertility of soils.

• The available Nitrogen values in the soil samples are ranged between 62-87 kg/ha

which indicate that the less content of available nitrogen the study area

• Soil sample from land have concentration of Available Phosphorous values ranged

between 50 to 75 kg/ha

• Soil sample from waste land have concentration of Available Potassium values

range between 39 to 105 kg/ha

Characteristic of sampling locations land soil is a little deficient in nutrients concentration.

3.7 LAND USE PATTERN

Satellite imagery based land use pattern studies have been carried out to analyze the

impacts on land due to the proposed expansion activities in the study area and to give

recommendations for optimizing the future land use pattern and associated Impacts.

Remote Sensing’ has proved as a powerful tool in the field of Environment Impact

Assessment Studies in recent times. The Satellite data provides reliable and accurate

information on natural resource like water, soil, forest, etc. which forms the baseline

information; prerequisite for systematic assessment of various environmental impacts.




Environment


Remotely sensed data provides information for systematic analysis of land use – land

cover characteristics using synoptic and multi spectral coverage of the terrain.

Geographical Information System (GIS) has been proved as a powerful tool in the field of

natural resources management over the years. GIS technologies having capability of data

storage, retrieval and manipulation can play an important role in evolving the suitable

methods of arriving at alternate scenarios for natural resources development and

environmental planning.

Recent advances in the fields of remote sensing and GIS provide useful tools in

environment impact assessment studies. These two new technological tools have emerged

to meet the ever increasing demand for more precise and near real time information. An

integrated element for generating map information is the combination and comparison of

variety of data derived from different sources such as remotely sensed imagery, ground

survey and existing topographic and other maps.

An attempt has been made to generate a land use/ land cover map of the study area using

SOI topographical sheets, remotely sensed images and field survey data. The generated

information has been integrated in GIS.

Data Used: In order to strengthen the baseline information on existing land use pattern,

the following data along Latitude: 210 48’ 30.29” Nand Longitude: 710 54’ 07.37 Eis

used.

Collateral Data: Survey of India Degree sheet No NF 42-12were also used to study the

Land use / Land cover of the study area.

Methodology

Salient features of the methodology adopted are given below:

Acquisition of satellite data.

Preparation of base map from Survey of India toposheets.

Data analysis using visual interpretation techniques.

Ground truth studies or field checks.




Environment


Finalization of the map.

Digitization using heads up vectorisation method.

Area calculation for statics generation.

The interpretation of the satellite imagery was done by heads up vectorisation using

various interpretation keys. Tone, color, texture, structure, and association criteria are

used for categorization different Land use / Land cover classes to their respective units.

The various interpretation keys are cross verified on ground for refining the map.

Land Use / Land Cover Details:

The Satellite imagery procured is given in Figure 3.7. The land use / land cover map of

the entire study area are given Figure 3.8 whereas statically breakup of land use / land

cover classes is given Table 3.17.

Figure 3.6: Satellite Imagery




Environment


Figure 3.7: Land Use/Land Cover map

Table 3.17 Land use/Land Cover Analysis

Sr.

No

Land use/ Land cover Area in Ha. %

1 Coastal Wetland 175 1.2%2 Cropland 0 0.0%3 Fallow land 10833 73.1%4 Reservoirs/ Lakes/ Ponds 7 0.0%5 River/ Stream/ Canals 519 3.5%6 Rural 207 1.4%7 Scrub land 3016 20.4%8 Urban 63 0.4%

Total 14820 100




Environment


Geology

Regional Geology:

The state of Gujarat comprises an area of approximately 1,96,000 sq.km and is enclosed

within the North Latitude 20°10° to 24° 50° and East Longitude 68° 40° to 74° 40°.

Geologically Gujarat provides a wide spectrum of rock types of different ages. All the

important lithological types Ignious, Sedimentry and Metamorphic occur within the state.

Local Geology

Bhavnagar is a coastal city on the eastern coast of Saurashtra, also known

as Kathiawar. It has an average elevation of 24 metres (78 ft). It occupies an area of

3.3 km2 (20.6 sq mi). The general slope dips towards the northeast at the apex of Gulf of

Khambhat. The region of Saurashtra is a geologically active part of West India, and falls

in the seismic zone 3 of the Zoning Map of the Bureau of Indian Standards.

Flora and Fauna

Natural Flora and Fauna are important biotic components for environment. The various

terrestrial biological components which can be influenced by proposed activities in the

form of emissions.

No National Park, Sanctuary, Elephant or Tiger Reserve is situated within 10 km radius

area surveyed around the project site. No migratory route of wild animals has been

reported to have existed in the study area. The details of Flora and Fauna are attached as

Annexure VII

3.8 SOCIO‐ECONOMICS OF THE STUDY AREA

The socio-economic component of environment with reference to human interests.

Aesthetics and cultural attributes need to be studied while delineating Environmental

management Plan for achieving desired target without impairing the quality of life.




Environment


The study area of 10 km radial zone mainly falls in the District Bhavnagar, Gujarat.

There are total 31 villages in study area. The latest available data has been complied to

generate the existing socio‐economic scenario of the study area. Information on

socio‐economic profile was collected from the Govt. Agencies, Census book, Statistical

abstract and health agencies.

Demographic Profile

Total Population of the Study area as per Census of India, 2011 is 63,191. The total

number of household being 12,006. Total Male Population of the Study area is 32,671

and total Female Population of the Study Area is 30,520. Village-wise details of

population are given in Table 3.18. The number of females per 1000 males is 934 as

compared Gujarat (919) and India (933) The Sex Ratio of the Study area found to be higher

than State and slightly higher than India (Figure 3.9). Out of the total population, 7%

populations are belongs to backward class in the study area (Figure 3.10).

Summary of Demographic Structures in Study Area

Description Total % of the total Population

Total Population 63191 -

No. of Households 1200619%

Male Population 3267152%

Female Population 3052048%

Schedule caste 41647%

Schedule Tribe 1420%

Male literates 2379238%

Female literates 1693427%

Total literates 4072664%




Environment


Literacy Rate

Literacy rate of the study area is 64.4% Distribution of male 77.82 % and female literacy

rate is 55.48% in the study zone. The comparative graph shown in Figure 3.10.This

indicates that the literacy rate is low for male as well as female in study area as compared

to Gujarat state.

Figure 3.9: Sex Ratio Comparison

Figure 3.10: Breakup of SC & ST in the study area (Census 2011)

910

915

920

925

930

935

Study Area Gujarat India

934.16

919

933

Sex Ration Comparision

93%

7% 0%

SC ST & Other PopulationComparision in %

Others

SC

ST




Environment


Figure 3.11: Literacy rate in Study area (Census 2011)

Economic Resource Base

The employment pattern mainly depends upon its economically active group i.e. the

working populations involved in different economically productive activities. The total

workers further categorized as main worker, cultivated worker, Agricultural labour,

marginal and the non-working population.

The workers coming under the main and marginal workers category are cultivators,

agricultural labors and those engaged in livestock, forestry, fishing, hunting, and

plantations, manufacturing, processing, servicing and repairs in household industry,

construction trade and commerce, transport, storage & communication, and other

services. Out of the total population 26% comes under the main workers category from

the villages near by proposed project site and majority are non-worker (43%). Main

workers are further classified into 4 categories viz., cultivators, agricultural laborers and

household workers and other main workers. The employment pattern of the study area is

depicted in Figure 3.12.

0

10

20

30

40

50

60

70

80

90

Literacy Male % Literacy Female %

Gujrat 85.75 69.68

Study Area 72.82 55.48




Environment


Figure 3.12: Vocational Pattern of the Study Area

26%

5%9%

0%

12%5%

43%

Vocational Pattern of the Study Area

Main Worker

Cultivator Worker

Agril Lab

HH industry

Other Worker

Marginal Worker

Non-Worker




Environment


Table 3.18Village wise Demographic Structure of the Study Area

S.N. VillageName

Taluka No. ofHouseholds

Population SC ST Literate

Total M F M F

1 Anandpur vallabhipura 69 333 161 172 0 0 136 123

2 Rajpara (Bhal) vallabhipura 99 435 233 202 23 6 209 157

3 Pati vallabhipura 100 569 296 273 30 0 185 161

4 Juna Rampar vallabhipura 237 1177 610 567 63 0 463 347

5 Chamardi vallabhipura 704 3658 1921 1737 99 0 1412 951

6Vallabhipur(M) vallabhipura 3025 15852 8183 7669 782 75 6278 4663

7 Rajpipala Gadhada 463 2360 1209 1151 155 22 744 526

8 Dhamnaka Umrala 89 524 274 250 34 0 180 121

9Chogath(Thapnath) Umrala 1352 7397 3772 3625 381 0 2641 1827

10 Dambhaliya Umrala 57 263 144 119 0 0 106 68

11 Timba Umrala 46 248 132 116 0 0 102 56

12 Dharuka Umrala 449 2106 1051 1055 149 2 687 510

13 Ratanpar Umrala 158 887 463 424 112 0 353 265

14 Golrama Umrala 232 1116 561 555 21 0 392 284

15 Bajud Umrala 644 3152 1621 1531 240 0 1228 887

16 Devaliya Bhavnagar 154 815 414 401 0 0 250 135

17 Paliyad Bhavnagar 182 997 532 465 0 0 358 193

18 Sendurda Shior 56 266 136 130 0 0 103 63

19 Ukharla Shior 162 919 482 437 87 0 323 189




Environment


20 Paldi Shior 285 1457 749 708 152 7 550 384

21Navagam(Mota) Shior 149 753 389 364 44 0 290 186

22 Maglana Shior 87 441 231 210 0 0 167 134

23 Ghanghali Shior 835 4462 2305 2157 197 12 1494 1028

24 Bhangadh Shior 74 443 236 207 0 0 177 152

25 Nesda Shior 675 4161 2241 1920 109 8 1681 1087

26 Bholad Shior 233 1412 736 676 126 0 483 319

27 Vadiya Shior 256 1478 755 723 279 0 595 426

28 Pipaliya Shior 416 1953 1005 948 590 10 769 548

29 Nana Surka Shior 361 1683 850 833 128 0 643 489

30 Kantodiya Shior 182 942 493 449 235 0 428 385

31 Vav Shior 175 932 486 446 128 0 365 270

Total 12006 63191 32671 30520 4164 142 23792 16934

(Source: Census 2011)




Environment


Table 3.19 : Employment Pattern

S.N.

NAME OF THEVILLAGE

TALUKA

TOTAL MAINWORKERS

CULTIVA-TORS

AGRILLAB

HHINDUSTRY

OTHERWORKERS

MARGINALWORKER

NONWORKERS

M F M F M F M F M F M F M F

1 Anandpurvallabhipura 104 17 45 4 8 9 0 0 51 4 1 18 56 137

2 Rajpara (Bhal)vallabhipura 135 3 72 0 0 0 0 0 63 3 19 11 79 188

3 Pativallabhipura 148 10 48 0 66 5 0 0 34 5 4 2 144 261

4 Juna Ramparvallabhipura 325 40 69 4 106 15 0 0 150 21 6 10 279 517

5 Chamardivallabhipura 1086 83 157 3 451 42 13 0 465 38 26 224 809 1430

6 Vallabhipur (M)vallabhipura 4537 742 471 8 811 358 34 2 3221 374 237 300 3409 6627

7 Rajpipala Gadhada 690 211 179 23 325 170 5 0 181 18 9 92 510 848

8 Dhamnaka Umrala 152 14 52 3 39 9 2 0 59 2 1 1 121 235

9Chogath(Thapnath) Umrala 2222 770 382 91 726 564 81 9 1033 106 102 358 1448 2497

10 Dambhaliya Umrala 56 4 23 0 0 0 0 0 33 4 3 1 85 114

11 Timba Umrala 55 1 30 0 13 0 0 0 12 1 1 8 76 107

12 Dharuka Umrala 638 98 108 3 425 85 1 0 104 10 22 475 391 482

13 Ratanpar Umrala 253 4 62 1 141 2 0 0 50 1 11 158 199 262

14 Golrama Umrala 282 9 111 1 26 3 80 2 65 3 48 57 231 489

15 Bajud Umrala 919 280 260 62 194 114 15 6 450 98 16 68 686 1183

16 DevaliyaBhavnagar 247 26 33 0 130 22 0 0 84 4 45 207 122 168




Environment


17 PaliyadBhavnagar 318 184 59 6 166 167 0 0 93 11 7 21 207 260

18 Sendurda Shior 83 10 24 4 14 5 0 0 45 1 0 0 53 120

19 Ukharla Shior 266 78 48 2 96 62 1 1 121 13 12 9 204 350

20 Paldi Shior 377 99 26 2 58 54 1 0 292 43 4 3 368 606

21 Navagam (Mota) Shior 205 11 54 1 18 7 0 0 133 3 17 32 167 321

22 Maglana Shior 133 4 75 0 35 0 0 0 23 4 0 0 98 206

23 Ghanghali Shior 1352 557 160 107 408 289 0 1 784 160 20 321 933 127924 Bhangadh Shior 81 5 40 1 24 4 1 0 16 0 47 10 108 192

25 Nesda Shior 1157 124 284 7 305 65 25 2 543 50 14 184 1070 1612

26 Bholad Shior 425 221 58 22 54 50 1 1 312 148 39 137 272 318

27 Vadiya Shior 379 94 84 3 45 68 1 0 249 23 22 102 354 527

28 Pipaliya Shior 560 329 139 98 180 201 9 2 232 28 42 138 403 481

29 Nana Surka Shior 472 189 128 28 190 146 4 5 150 10 1 0 377 644

30 Kantodiya Shior 292 52 73 2 102 46 0 0 117 4 0 2 201 395

31 Vav Shior 267 73 102 3 60 67 5 0 100 3 0 21 219 352

Total 18216 4342 3456 489 5216 2629 279 31 9265 1193 776 2970 13679 23208Source: Census 2011



Chapter 4:Anticipated Environmental

Impacts & MitigationMeasures


CHAPTER 4:ANTICIPATED ENVIRONMENTAL IMPACTS &

MITIGATION MEASURES

4.1 IDENTIFICATION OF IMPACTS

Identification and prediction of Impacts is the most important component in the

Environmental Impact Assessment studies. The environmental impacts can be

categorized as either primary or secondary. Primary impacts are those, which are

attributed directly due to the project and secondary impacts are those, which are

indirectly induced and typically include the associated investment and changed pattern of

social and economic activities due to proposed activities.

The environmental impacts have been assessed assuming that the pollution due to the

existing activities at Village: Chamardi, Taluka:Vallabhipur, District:

Bhavnagar(Gujarat), where the project site has been identified and covered under the

present environmental scenario established by the monitored baseline data. During

construction and operation phase of proposed activities various impacts on environmental

parameter will be studied to estimate the impacts on environment and apply mitigation

measures. Several scientific techniques and methodologies are available to predict

impacts of proposed activities on physical, ecological and socio-economic environments.

Such predictions are superimposed over the baseline (Pre-project) status of environmental

quality to derive the ultimate (Post-project) scenario of environmental conditions.

The Summary of Matrix Valued Ecosystem Components of Concerns (VECs) is given in

below .






4.1.1 Issues Scoping / Pathway Analysis - Summary of Matrix Valued Ecosystem

Components of Concerns (VECs)

EnvironmentalComponents of

Concern (ECCs)

Pathway ofConcern

PossiblePathways

VEC Rationale for Inclusion / Exclusion asValued Ecosystem Component (VECs)

Yes No Yes No

Air Quality √ Construction &Operation ofPlant

√ Included as a VEC – National standardsexist for ambient air quality. Potentialimpact on air quality during construction(dust, vehicle emissions) andoperations(Sponge Iron)

Water Quality √ Construction &operation plant

√ Included as VEC – Proper sanitationarrangement for construction workers.No discharge of waste water

GroundwaterResourcesIrrigation projects

√ Nil √ Excluded as a VEC – No ground waterwill be used for construction & operationof the plant. No irrigation project in studyarea. No discharge of waste water.Recharging of ground water by adoptingrain water harvesting system.

Soil Quality / Solidwaste.

√ Constructionand operationof plant

√ Included as a VEC – Preservation ofexcavated top soil during construction forplantation purpose.Use of construction debris in roadmaking.Disposal of solid waste generated duringoperations by reusing in process andother activities.Storage of solid waste in scientificmanner.

Fauna and Flora √ Nil √ Excluded as a VEC –No project site specific impact on flora &fauna.The marginal impact on the environment,if any will be taken care off by thedevelopment of the green belt / plantationby M/s K. B. Ispat Hence no impact dueto the proposed project.

EnvironmentallySensitive Areas

√ Nil √ Excluded as a VEC – Noenvironmentally sensitive areas in studyarea of proposed project.

Ambient Noise √ ConstructionandOperations ofPlant

√ Included as VEC – Marginal impact ofnoise on surrounding areas duringconstruction and operations, vehiclemovements.






Land Use √ Nil √ Excluded as a VEC – No change inLand use.

Archaeological /Heritage Resources

√ Nil √ Excluded as a VEC – No archeologicalor heritage structures in study area ofproposed plant .

Traffic √ ConstructionandOperations ofPlant

√ Included as VEC – Marginal impactfrom construction and operations relatedtraffic on existing traffic patterns.

4.2 CONSTRUCTION PHASE

Air Environment

Impact on Air Quality

During construction phase, dust will be the main pollutant, which will be generated

from the site development activities and vehicular movement on the road. Further,

concentration of NOx and CO may also slightly increase due to increased vehicular

traffic. However, change in ambient concentrations of air quality will be insignificant

and temporary. As most of the construction equipment will be mobile, the emissions

are likely to be fugitive. The impacts will be localized in nature and the areas outside

the project boundary are not likely to have any significant adverse impact.

Air Pollution Control Measures

During dry weather conditions, it is necessary to control the dust generated by

excavation and transportation activities. This will be achieved by regular water

sprinkling. Ambient air concentrations of SO2 and NOx are expected to increase due to

operation of construction machineries such as bulldozers, pay loaders, trucks etc. These

levels are expected to be insignificant as these machines will be operated intermittently

and only day time. Most of the equipment and machineries will be mobile and hence, the

emissions will be mostly fugitive. It will be ensured that vehicles and machineries are

properly maintained to minimize smoke in the exhaust emissions. Additional air

pollution control measures include the following:






• Sprinkling of water at regular intervals preferably using truck-mounted sprinklers

along the roads and work zone areas;

• Electrical power shall be made available near to the site. Attempts to be made to

utilize the electrically powered machinery to the extent possible to minimize the

emissions of SO2 and NOx.

Noise Environment

Impact on Noise Levels

The major sources of noise during the construction phase are vehicular traffic,

construction equipment like dozers, scrapers, concrete mixers, cranes, pumps,

compressors, pneumatic tools, saws, vibrators etc. The operation of this equipment will

generate noise ranging between 85-90 dB (A) near the source. These noise levels will

be generated within the plant boundary and will be temporary in nature.

Noise Control Measures

Equipment will be maintained appropriately to keep the noise level within 85 dB(A).

Wherever possible, equipment will be provided with silencers and mufflers. Acoustic

enclosures will be provided to stationary machines like DG sets. High noise generating

construction activities will be restricted to day time only. Further, workers working in

high noise areas will be provided with necessary protective devices e.g. ear plug, ear-

muffs etc.

Water Environment

The water requirement during construction for the proposed plant will be met from

GWIL. Water will be required for construction activities, sprinkling on pavements for

dust suppression and domestic & non domestic usages. Runoffs from the construction

yards and worker’s camps during monsoon may affect the quality of water bodies in the

project area. Impact on water quality during the construction phase may arise due to non-

point discharges of sewage from the workers camp stationed at the project site.






Mitigation Measures

The earth work (cutting and filling) will be avoided during rainy season and will

be completed during the winter and summer seasons only.

Stone pitching on the slopes and construction of concrete drains for storm water

to minimize soil erosion in the area will be undertaken.

The development of green belt will be undertaken during the monsoon season.

Soil binding and fast growing vegetation will be grown within the plant

premises to arrest the soil erosion.

Septic tanks followed by soak pit will be provided.

The overall impact on water environment during construction phase of the proposed plant

will be temporary and insignificant.

Solid Waste

During installation of new structure there may be some accumulation of scrap, boulders

and solid waste at site which will be removed by building material suppliers. Additional

work force deployed at site will generate garbage. Unless suitable disposal methods are

adopted, the accumulated garbage can have adverse primary impact on land environment

through fouls smell. This may lead to secondary impacts of health hazard to the workers.

The impact due to this will be overcome by good housekeeping. Top soil removed during

construction will be utilized for the green belt development.

Socio Economic Environment

The impact of the proposed plant on socio economic conditions of the local people of the

study area are expected to be positive during construction phase.

The local population will have employment opportunities due to the proposed

project. The local people will be preferred during the construction phase. This will

help in up-liftment of local people in terms of economy and social welfare

Benefits due to the civil construction and transportation companies to the local

people

All the applicable guidelines under the relevant Acts and Rules related to labour






welfare and safety shall be implemented during the construction phase;

The construction site will be secured with fencing and will have guards at the

entry points. Facilities to be provided by the Labor Contractor

The contractor shall be asked to provide following facilities to construction work force.

A. First Aid

At work place, first aid facilities will be maintained at a readily accessible place where

necessary appliances including sterilized cotton wool, disinfectants, bandages etc. will

be available. Emergency vehicles will be kept readily available at workplace to take

injured person to the nearest hospital. Reasonably equipped dispensary will be

established for the use of workers as well as local population.

B. Potable Water

Sufficient supply of drinking water will be provided from the filtered water storage tank.

C. Sanitary Facility

Latrines and urinals will be provided at accessible place to workers. These will be

cleaned at least twice during working hours and kept in a good sanitary condition.

D. Canteen

A canteen on a moderate scale will be provided.

4.3 OPERATION PHASE

4.3.1 Impact on Air Quality

The impacts on air quality due to source of the air pollutant in the proposed facilities have

been identified.

Sources of Emissions

Emissions released from the stack during operation phase will get dispersed in the

atmosphere and finally reach the ground at a specified distance from the sources. From






the proposed activities the possible environmental impact on air quality has been

envisaged due to the following sources.

Table 4.1

Stacks & Emissions Details

No. Description Capacity Fuel &ItsQuantity

No.ofStack

StackHeight&Dia

APCM Emission Rate(g/sec.)

WithoutAPCD

WithAPCD

1 4 No(InductionFurnace)

2 X 25TPH2X12TPH

Electricity 2 H:30mD:1.77m

HoodCover,BagFilterwithExhaustBlower

PM10

=0.286PM10 =0.581

2 DG set 125KVA

Diesel40 l/h

1 H: 5 mD: 0.1 m

- Not consider formodeling since its act

as a standby4.3.1.1 Prediction of Air quality

Simulation Model for Prediction using Industrial Source Complex AERMOD View

The pollutants released into the atmosphere will disperse in the down wind direction and

finally reach the ground at farther distance from the source. The concentration of ground

level concentrations mainly depends upon the strength of the emission source and

micrometeorology of the study area.

In order to estimate the ground level concentrations due to the emission from the

proposed project, EPA approved Industrial Source Complex AERMOD View Model has

been employed.

The mathematical model used for predictions on air quality impact in the present study is

ISC-AERMOD View. It is the next generation air dispersion model, which incorporates

planetary boundary layer concepts.






The AERMOD is actually a modeling system with three separate components:

AERMOD (AERMIC Dispersion Model), AERMAP (AERMOD Terrain Preprocessor),

and AERMET (AERMOD Meteorological Preprocessor).

Special features of AERMOD include its ability to treat the vertical in homogeneity of

the planetary boundary layer special treatment of surface releases, irregularly-shaped area

sources, a plume model for the convective boundary layer, limitation of vertical mixing

in the stable boundary layer, and fixing the reflecting surface at the stack base.

The AERMET is the meteorological preprocessor for the AERMOD. Input data can come

from hourly cloud cover observations, surface meteorological observations and twice-a-

day upper air soundings. Output includes surface meteorological observations and

parameters and vertical profiles of several atmospheric parameters.

The AERMAP is a terrain preprocessor designed to simplify and standardize the input of

terrain data for the AERMOD. Input data include receptor terrain elevation data. Output

includes, for each receptor, location and height scale, which are elevations used for the

computation of airflow around hills.

Post Project Scenario

Predicted maximum ground level concentrations considering micro meteorological data

of October, November and December 2018 are superimposed on the maximum baseline

concentrations obtained during the study period to estimate the post project scenario,

which would prevail at the post operational phase.

Predicted 24 hourly Ground Level Incremental Concentrations for October, November,

and December 2018 is given in Table 4.2 and The overall scenario with predicted

concentrations over the maximum baseline concentrations is shown in the Table 4.3 and

isopleth with air pollution control and without control are given in Figures 4.1 and

Figure 4.2 respectively.






Table 4.2 : Predicted 24 hourly Ground Level Incremental Concentrations

Monitoring Period Year

Maximum IncrementalLevels (µg/m3)

Distance (km) DirectionPM10

WithAPCD

PM10

WithoutAPCD

October, November

and December 20182018-19 0.26 0.53 3.3 SW

Figure 4.1: Predicted GLC of PM10 due to Propose Plant (With APCD)






Figure 4.2: Predicted GLC of PM10 due to Propose Plant (Without APCD)






TABLE 4.3

Resultant PM10 at Monitoring Locations, µg/m3(with APCD)

Location Sample

code

Back

ground

level

(µg/m3)

PM 10

Maximum

Incremental

Levels

(µg/m3)

Resultant

Concentration

(µg/m3)

Distance

of

Village

(km)

Direction

of

Village

Project Site A-1 78 <0.05 78.05 ---- ----

Dambhaliya A-2 66 0.11 66.11 2.5 Km. W

Bhangadh A-3 58 <0.05 58.05 5.5 Km. E

Manglana A-4 78 <0.05 78.05 5.0 Km. SE

Navagam A-5 74 <0.05 74.05 4.0 Km. S

Ukharala A-6 67 0.11 67.11 4.5 Km. SW

Chamardi A-7 68 <0.05 68.05 2.5 Km. N

Chogath A-8 68 0.05 68.05 4.5 Km. NW

The predicted ground level concentrations obtained when superimposed on the baseline

concentrations are within the prescribed NAAQ Standards for residential areas.

Air Pollution Mitigation Measures

M/s. Sai Inductomelt Pvt. Ltd. shall provide dust suction system which will control

fugitive emission due to material handling. Dust suppression system will be provided in

the form of water sprinklers. All vibrating screens and weigh feeders below the hopper;

day bins etc. are totally covered to prevent leakages of dust. Dust and fume extraction

system will be provided for Induction Furnace. Dust and fumes will be collected with the

help of bag filter as air pollution control system of specified size followed by 30 m stack.

Flue gases generated will be cleaned in the Bag Filters and discharged through stack, so

that the dust concentration will be well within the prescribed standard.






Impacts Due to the Transportation of Raw Material

The major impact due to transportation of the raw material i.e. Sponge Iron, MS scrap..

All the raw material as well as the finished product will be transported through the Road.

The total material transportation includes 2,22,000 TPA input and output. Estimation of

transportation is given in Below Table 4.4

TABLE 4.4

Estimation of Transportation of the Raw Material

Mitigation Measures

• Traffic management to be done properly and parking space will be provided

within premises

• The vehicles used in transportation will comply norms as per the motor vehicle

act.

• The repair and maintains of vehicle will be taken care by transporter

• Particulate matter will be controlled below 50 mg/Nm3 by providing efficient

dust suppression system like water spray system shall be installed in the material

handling system transfer points

• Plantation along the internal roads in the plant premises will be strengthen

• All the internal roads shall be concreted / asphalted to reduce the fugitive dust

due to vehicular movement

• Water spraying will be practiced frequently

Sr.

No

Raw Material Quantity

(TPA)

Truck

Capacity

(Tonnes)

No of

Trucks/day

Total production of

Billets /Ingots

1 MS Scrap 2,20,000 30 23 2, 22, 000 TPA

2Sponge Iron 11,100 30 02






4.3.2 Noise Levels

Operation Phase

During operation, the major noise generating sources are crushing unit, auto loading

section, electric motors etc. These sources will be located far off from each other. Under

any circumstances the noise level from each of these sources will not exceed 85 dB (A).

Noise levels generated in the project site will be confined to the noise generating plant

units hence the impact of noise levels on surroundings will be insignificant

Mitigation Measures

The noise levels stipulated by Central Pollution Control Board at any point of time will

not exceed the standards. The equipment will have inbuilt noise control devices. The

measured noise level produced by any equipment will not exceed 85 dB(A) at a distance

of 1.0-m from its boundary in any direction under any load condition. The noise produced

in valves and piping associated with handling compressible and incompressible fluids

will be attenuated to 75 dB(A) at a distance of 1.0 m from the source by the use of low

noise trims, baffle plate silencers/line silencers, acoustic lagging (insulation), thick-

walled pipe work as and where necessary. The general mitigation for the attenuation of

the noise are given below:

By providing padding at various locations to avoid sharp noise due to vibration.

Encasement of noise generating equipment where otherwise noise cannot be

controlled

Providing noise proof cabins to operators where remote control for operating

noise generating equipment is feasible.

In all the design/installation precautions are taken as specified by the

manufacturers with respect to noise control will be strictly adhered to;

High noise generating sources will be insulated adequately by providing suitable






enclosures;

Use of lagging with attenuation properties on plant components / installation of

sound attenuation panels around the equipment

Other than the regular maintenance of the various equipment, ear plugs/muffs are

recommended for the personnel working close to the noise generating units;

All the openings like covers, partitions will be designed properly

Inlet and outlet mufflers will be provided which are easy to design and construct.

All rotating items will be well lubricated and provided with enclosures as far as

possible to reduce noise transmission. Extensive vibration monitoring system will

be provided to check and reduce vibrations. Vibration isolators will be provided

to reduce vibration and noise wherever possible;

The insulation provided for prevention of loss of heat and personnel safety will

also act as noise reducers.

4.3.3 Impact on Water

The total water requirement for the proposed activities is 150 KLD. There will not be any

impact on the water quality as no wastewater will be generated from the process. The

sewage generated from the toilets and bathroom of the proposed facility will be

13 m3/day which will be disposed through septic tank soak pit system. Water will be used

in concast machine for moulding of molten metal through water spray. So the water will

gets evaporated due to temperature difference. The unit will be zero discharge unit.






Table 4.5: Water Requirement and Waste water Generation

4.3.4 Solid Waste Generation

The solid waste generation in the proposed activities is given in Table 4.6

Table 4.6

Solid Waste Generation & Mitigation Measures

Waste Quantity(TPA)

Category Mitigation Measures

Slag 11,100 Non-Hazardous

Slag Crushers will be installed to recoveriron particles to be reused in InductionFurnace. Slag generated from InductionFurnace will be used for hardening ofworking area, internal road, brickmanufacturers, concreting

Usedspent

oil

0.1 Hazardous Used to lubricate rotating parts withinpremises or will be sold to registeredrecyclers

Sr.No.

Unit Total WaterRequirement

m3/day

WastewaterGeneration

m3/day

Mode of disposal of wastewater

1 Domestic 16.5 13 Domestic wastewater will bedisposed of through soak pit/septictank system

2 Gardening 5.5 - -

3 Industriala) Process Nil Nil -

b) Washing Nil Nil -c) Boiler NA - -d) Cooling 123 - Water will be used in concast

machine for moulding of moltenmetal through water spray. So thewater will gets evaporated due totemperature difference. The unit willbe zero discharge unit.

d) Others 5 - Dust Suppression within Premises

Total 150 13 -






4.3.5 Impact on Socio-Economic Environment

The impacts of the proposed project, during its operation, on demography and socio-

economic condition can be identified as follows.

Negative impacts can be depletion of natural resources like water and land,

depletion in air quality if proper mitigative measures are not taken.

Increase in employment opportunities and Reduction in migrants to outside for

employment.

Growth in service sectors.

During operation phase 325 technical and nontechnical people will be employed.

Increase in consumer prices of indigenous produce and services, land prices,

house rent rates and Labor prices.

Improvement in socio-economic environment of the study area.

Improvement in transport, communication, health and educational services.

Increase in employment due to increased business, trade commerce and service

sector.

The overall impact on the socio economic environment will be significant.

The management of M/s Sai Inductomelt Pvt Ltd has proposed to give preference to local

people for recruitment in semi-skilled and unskilled categories.

4.3.6 Prediction of Impacts and Mitigation on Occupational Health

The damage risk criteria as enforced by OSHA (Occupational Safety and Health

Administration) to reduce hearing loss, stipulates that noise level upto 85 dBA are

acceptable for 8 hour working shift per day. Plant authorities will provide ear plugs to the

employees and will be enforced to be used by the employees.

4.3.7 Prediction of Impacts on Flora and Fauna

There are no forests and eco-sensitive area in the vicinity of the site. There are no

endangered flora and fauna species in the region. The project activities are restricted to

the factory site except the transportation of raw material and products. There is no






discharge of solid or liquid wastes to the environment. Green belt and greenery will be

developed in the premises covering more than 33% of area. The plantation will comprise

of fruit bearing trees, soil improving and air pollution abatement tress.



Chapter 5:Analysis of Alternatives

(Technology & Site)


CHAPTER 5:

ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)

5.1 ALTERNATE TECHNOLOGY

The manufacturing of M.S. Billets/Ingots using Induction Furnace technology is a

globally proven technology adopted by all for medium scale industry. It is latest

technology with advantage of low capital cost, low power consumption; low slag

generation provided compared with other technology. Its installation is relatively easier

and its operation is simpler. Among other advantages, there is very little heat loss due to

rotation from the furnace as the bath is constantly covered and there is practically no

noise attending its operation. The molten metal in an induction furnace is circulated

automatically by electro-magnetic action so that when alloy additions are made, a

homogeneous product is ensured in minimum time. The major advantages of Induction

Furnace over the other furnace system are as follows:

• Optimized Consistency: Induction heating eliminates the inconsistencies and

quality issues associated with open flame, torch heating and other methods.

• Maximized Productivity: Production rates can be maximized because induction

works so quickly; heat is developed directly and instantly (>20002 F. in < 1

second) inside the part. Startup is virtually instantaneous; no warm up or cool

down cycle is required.

• Environmentally Sound: Induction heating systems do not burn traditional fossil

fuels; induction is a clean, non-polluting process which will help protect the

environment. An induction system improves working conditions for your

employees by eliminating smoke, Waste heat, noxious emissions and loud noise.

Heating is safe and efficient with no open flame to endanger the operator or

obscure the process. Non-conductive materials are not affected and can be located

in close proximity to the heating zone without damage.

• Energy Conservation: Overall energy efficiency in induction melting ranges

from 55 to 75 percent, and is significantly better than combustion processes.



Chapter 5:Analysis of Alternatives

(Technology & Site)


• Higher Yield: The absence of combustion sources reduces oxidation losses that

can be significant in production economics.

• Faster Startup: Full power from the power supply is available, instantaneously,

thus reducing the time to reach working temperature. Cold charge-to-tap times of

one to two hours are common.

• Flexibility: No molten metal is necessary to start medium frequency coreless

induction melting equipment. This facilitates repeated cold starting and frequent

alloy changes

• Cleaner Melting: No by-products of combustion mean a cleaner melting

environment and no associated products of combustion pollution control systems.

• Compact Installation: High melting rates can be obtained from small furnaces.

• Reduced Refractory: The compact size in relation to melting rate means

induction furnace require much less refractory than fuel-fired units.

In pursuance of this, the induction furnace based technology is proposed for this project

and noother alternative technology is considered.

5.1.1 DETAILS OF ALTERNATIVE SITE CONSIDERED:

No alternative site is considered.

The following are the factors in favor of selection of site:

• No Rehabilitation/Resettlement required.

• No archaeological monument, interstate boundary and defense installation.

• No notified critically polluted area.

• No nallah/water body, public roads, forests within the project site.

• Availability of Raw Material.

• Availability of Water.

• Assured Power Supply.

• Market available for finished products.

• Availability of man power.



Chapter 6:Environmental

Monitoring Program

Pollution and Ecology Control Services (PECS), Nagpur P a g e | 86

CHAPTER 6

ENVIRIONMENTAL MONITORING PROGRAM

6.1 INTRODUCTION

This chapter presents the details of environmental monitoring schedule, institutional

arrangements for pollution control and cost for environmental monitoring program for the

proposed project.

Monitoring of various environmental parameters will be carried out on a regular basis to

assess the pollutionlevel in the proposed plant and surrounding area. The main objectives

of the monitoring are as follow:

• State of pollution within the plant and in its vicinity;

• Generate data for predictive or corrective purpose in respect of pollution;

• Examine the efficacy of Pollution Control Systems installed in the complex

• To assess and monitor environmental impacts

• Evaluate the performance and effectiveness of mitigation measures proposed in the

Environment Management Plan (EMP) and suggest improvements in management

plan,if required.

6.2 ENVIRONMENTAL MONITORING PROGRAM

A detailed monitoring of emissions and effluent sources for different environmental

parameters will be carried out as per the present norms and any further notification /

direction from Gujarat Pollution Control Board (GPCB), Central Pollution Control Board

(CPCB) and MoEF & CC. Monitoring methodologies will follow standard methods

prescribed by Central Pollution Control Board (CPCB), Bureau of Indian Standards (BIS)

and USEPA.




Monitoring Program


The Environmental monitoring forthe proposed project of M.S. Billets/Ingots plant will be

conducted for following aspects

• Ambient Air Quality

• Ambient Noise level

• Stack Emission

• Surface water and Ground Water Quality,

• Soil Quality

The Monitoring schedule for the environmental parameters is suggested in Table 6.1

Table 6.1: Proposed Environmental Monitoring Schedules

Sr.No. Description of

Parameter

Location Parameters for

Monitoring

Schedule/Frequency

Monitoring

1 Ambient Air

Quality

Monitoring

Three direction of Plant

premises including

industrial and residential

area

PM10, PM2.5,

SO2NOx, and CO

Quarterly

2 Work zone

Monitoring

Process Area PM10,

Temperature

Quarterly

2 Stack Emission

Monitoring

All stacks PM and NOx Once in a month

3 Ambient Noise

level

Within Premises Noise level in dB

(A)

Quarterly

4 Drinking water

quality

- As per IS: 10500

2012 standards

Quarterly

5 CER activities Nearby village Implementation

status and need

based assessment

Annual

6 CC & A

compliance

- - Yearly

7 EC compliance - - Yearly

6.3 BUDGET ALLOCATION FOR ENVIRONMENTAL MONITORING

In order to maintain the environmental quality within the stipulated standards, regular

monitoring of various environmental components is necessary which will complied as per

conditions. Regular Monitoring of all the environmental parameters viz., air, water, noise




Monitoring Program


and soil as per the formulated program based on CPCB and MoEF&CC guidelines will

be carried out every year. The location of the monitoring stations was selected on the

basis of prevailing micro meteorological conditions of the area like; wind direction and

wind speed, relative humidity, temperature. In order to implement Environmental

Monitoring Programme, M/s Sai Inductomelt Private Limited will assign separate budget.

The details are given in Table 6.2. The budget may be increased as per the

requirement/actual condition.

Table 6.2: Proposed Budget for Environmental Monitoring Programme

Sr.No

Component Description Capital CostRs. in Lacs

Operation &Maintenance CostRs. in Lacs

1. Emission controlEngineering

Bag filter, WaterSprinkler System, Stack

50 5

2. Water & Wastewatermanagement

Septic tank, soak pitsystem

10 1

3. Solid WasteManagement

Slag Crusher, Handlingand Disposing

100 10

4. Green Beltdevelopment

Plantation 5 1.00

5. EnvironmentalMonitoring

Air Quality, WaterQuality, Noise Level,Soil Quality

10 02

6. Other aspect Rainwater harvestingand fire-fighting systemetc.

25 1.00

Total Rs. 200 Lacs Rs. 20 Lacs


Project Proponent: M/s SAI INDUCTOMELT PRIVATE LIMITEDChapter 7:

Additional Studies


CHAPTER 7

ADDITIONAL STUDIES

7.0 SOCIAL IMPACT ASSESSMENT

The proposed project to be sited at NA obtained land. No displacement of peoples will

be needed hence R& R study not required for the proposed project

7.1 RISK ASSESSMENT

Hazard analysis involves the identification and quantification of the various hazards

(unsafe conditions) that exist in the plant. On the other hand, risk analysis deals with the

identification and quantification of risks. The workers are exposed to, accidents resulting

from the hazards due to accident occur in the plant area.

Risk analysis follows an extensive hazard analysis. It involves the identification and

assessment of risks the neighbouring populations are exposed to as a result of hazards

present. This requires a thorough knowledge of failure probability, maximum credible

accident scenario, vulnerability of population etc. Consequently, the risk analysis is often

confined to maximum credible accident studies.

In the sections below, the identification of various hazards, probable risks in the proposed

plant, maximum credible accident analysis, consequence analysis are addressed which

gives a broad identification of risks involved in the plant. Based on the risk estimation for

fuel and chemical storage Disaster Management Plan (DMP) has been prepared.

7.1.1 Approaches to the Study

Risk involves the occurrence or potential occurrence of some accidents consisting of an

event or sequence of events. The risk assessment study covers the following:

• Identification of potential hazard areas.

• Identification of representative failure cases.



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• Visualization of the resulting scenarios in terms of fire (thermal radiation) and

explosion.

• Assess the overall damage potential of the identified hazardous events and the

impact zones from the accidental scenarios.

• Assess the overall suitability of the site for hazard minimization and disaster

mitigation point of view.

7.1.2 HAZARDS IDENTIFICATION

S.No.

Operation/Process

Equipment/AreaPossible Hazards

Precautionary Measure tobe Done

Taken If Occurs

01 Belt ConveyorSystems forsponge iron, slagcrusher etc., Rawmaterial HandlingPlant

a) Jamming ofconveyor Belts

b) Breakage ofConveyor Belts

c) Splash of Materialfrom ConveyorSystem

a) All conveyors belts mustbe provided with tripwire system must beremoved

b) Head & Tail end areprovided by nip guard.

c) Movement below theConveyor belt duringoperation must be banned

d) A 750mm wide walk waymust be provided on bothside for movement

e) Drives are provided withcoupling guards

f) Stop switches with Lockmust be provided forsafety

The process to bestopped immediatelyand the cause of jam.The broken conveyorbelt to be replaced orrepaired. Reason forsplash to be rectified.

02. Induction Furnace a) Blast in Furnaceb) Furnace foundation

damaged due to heavymaterial fall orextreme temperature

c) Induction wiringdamaged/burn

a) Feeding material ischecked and sorted toavoid any explosive orpressurized material tointer in furnace

b) Temperature near furnaceis monitored

c) Structural barrier to beprovided to avoid fallout.

The plant operation tobe stoppedimmediately. The areato be sealed untilcooled forreinstallation.



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S.No.

Operation/Process



Taken If Occurs

d) The temperature of thefurnace to be maintainedproperly no overheatingto be allowed.

03. Oil TransformerOil, Diesel etc.

Fire hazard may possibleif come in direct contactwith fire.

a) Fire proof system madeavailable like foalextinguishers andhydrant system etc keepaccessible.

b) Stored in MS cylindertank & kept away fromany type of fire causedthings,

Proper care is to betaken in storing andkeeping the drum ofoil. Precautions shouldbe adopted and takenas mentioned inChapter-7.

04. Control Rooms Electrical shock possibledue to leakage

a) Earth leakage Circuitbreaker is installed.

b) Shock precaution &treatment chart aredisplayed.

c) Operator should beprovided with insulatedshoes.

d) All instruments areproperly earthed

e) Electrification layout &diagram is displayed

In the event of electricleakage main supplyshould be immediatelyshut off. ShockTreatment & medicalAid shall beimmediately provided.

05. E.O.T Crane Hoist Rope Breakagepossible

a) No movement of strangepeople in crane bay willbe permitted.

b) Frequent check of therope and other loadbearing material shall bedone

c) Light indicationmovement of crane shallbe provided.

d) Prescribed load shallonly be allowed

e) Crane operator to givealarm before movement

Weak rope shall beimmediately replaced.



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S.No.

Operation/Process



Taken If Occurs

06. Welding GasOxygen LPG and/Acetylenecylinders

Fire hazards caused byflames and leakage.

a. Emergency kit is keptreadily available in storeand working place.

b. Firefighting equipment’spowder / Foam typeextinguishers on vehicleand mounting on walls arekept readily available.

c. Hydrant system providedat conspicuous place.

d. Firefighting trained man isemployed.

e. Cylinders are handledcarefully without droppingor rolling.

f. Precaution to ensure thatcylinders are not allowedto dash with each other.

g. Sand bed cushionavailable for the purposeof unloading cylinders.

h. Periodic inspection doneto avoid accident of anykind.

• Installation of inertgas Nitrogen,Carbon dioxide.Equipment’s to takecare of fire hazardsin the factory arebeing installed.

•Hydrant point willbe for gas cylindersstores and pointwhere weldingoperation is done.

07.

Electricaltransformer

Electrical power Shock proof insulated PCCPlatform.

Immediate Cut off thepower supply, treat theinjured for electricalshock



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S.No.

Operation/Process



Taken If Occurs

Fire Firefighting equipment

(i)Sand buckets.(ii)Fire extinguisher.

Immediately fight firewith availableresources, summonoutside help ifnecessary.

08. Lab Chemicals In case of bottlebreakage, causes burnsand damageto respirator systemsdue to inhalation.

a. Proper care should betaken while handling thechemicals.

b. First Aid Box should beavailable at Site with allnecessary and requiredmedicines.

c. Firefighting equipmentlike Extinguishers, sandbuckets should beavailable always.

Instruction Boards tobe displaced forknowledge of otherworkers to take care ofthe situation in theevent of occurrence.

7.1.3 Occupational health impacts on the workers

Hazards in heat treatment include burns and scalding, mechanical hazards from steel

handling, and hazards arising from the annealing gases, including nitrogen, hydrogen and

carbon monoxide. Furnace insulation wools can expose workers to hazardous fibers.

HEAT STRESS

Hazard description

In heat treating, steel products are heated and cooled in a controlled way to change their

physical or mechanical properties without changing their shapes. Heat treating is used to

relieve stresses in the metal created during cold rolling, to improve its hardness or

strength, or to change its electromagnetic properties. Some heat treating is done by

quenching, in which heated steel is plunged into a cold bath of water or oil to rapidly cool

it. The most common heat-treating process is annealing, in which the steel is slowly



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heated, maintained at temperature, then cooled. Often this takes place in a closed furnace,

using an inert gas to prevent oxidation, or a gas that conveys desired properties to the

steel.

Hazards in heat treatment include burns and scalding, mechanical hazards from steel

handling, and hazards arising from the annealing gases, including nitrogen, hydrogen and

carbon monoxide. Furnace insulation wools can expose workers to hazardous fibers.

Heat radiation around the furnace is 480C to 550C temperature near the furnace.

Mitigation Measures Proposed to Avoid the Human Health Hazards

Hazard control

The work area and the flow of material through it shall be designed so as to

minimize the possibility of worker contact with hot steel, or to scalding in the

case of quenching operations.

Inert annealing gases shall be handled in a way that prevents their build-upon

enclosed spaces other than the furnace itself, so as to prevent asphyxiation.

Annealing furnaces shall be considered to be hazardous confined spaces.

The system for handling flammable annealing gases like oxygen shall be

minimize the possibility of an explosive build-up.

The safest practicable furnace insulation shall be used. In general, this means

using insulation wools with a low content of respirable fibres, and which do not

convert to silica when heated.

Adequate drinking water arrangement shall be provided for worker

Natural ventilation and air conditioner room is available for worker.



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Control strategies

Training

Personnel handling molten metal shall have been trained in the proper procedures

to adopt, and in the relevant safety and health precautions, including use of

appropriate PPE.

Completion of training shall be documented, and training repeated as necessary.

Persons who are untrained shall not be employed in the transport of molten metal.

Work practices

Only essential personnel shall be in the vicinity of pouring operations.

Moulds and tundishes shall not be damp, nor should there be any means whereby

water could enter the melt because of the risk of explosion.

The area shall be cordoned off prior to the transport of molten metal if there is a

possibility of spillage.

Safety inspection of ladles

A competent person shall regularly inspect ladle buckets and their supporting,

locking and tipping mechanisms.

Before each filling, the pouring of, or transport of slag ladles and their related

appliances should be visually inspected.

Test results, including remedies for cracks and other defects, shall be recorded.

Corrective repair measures that are recommended shall be planned and

implemented on a timely basis.



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There shall be a system for checking and ensuring that the corrective measures

have been completed.

Personal protective equipment

1. Appropriate PPE, such as helmets, gloves, aprons and boots shall be provided and

used. Where appropriate, molten metal resistant clothing should be provided and

used.

First aid

Injuries caused by molten metal, dross or slag or exposure to alkaline dust shall

receive immediate medical attention.

Ventilation

Proper ventilation will be provide.

Thermometer for work zone temperature monitoring will be place at appropriate

location

Drinking water

Water cooler will be provided.

Purified water will be made available.

General

Job rotation will be done for worker

Glucose and head relief drink will be made available for worker

Bath shower and hand wash will be provided at appropriate location

Air conditioning room will be provide for heat relief.



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7.1.4 Do’s & Don’ts of preventive maintenance

CLEANING THE FLOOR

Do’s

1. While Cleaning Use the mildest cleaning agent that does the job effectively.

2. Follow the polishing lines when using abrasive cleaners.

3. Rinse thoroughly after every cleaning operation.

4. Wipe dry to avoid water marks

5. Handle with clean gloves/cloths to guard against stains/finger print

Don’t

1. Do not use an ordinary steel scraper or knife to remove dirt.

2. Do not allow chemicals or bleaching agents to remain in prolonged contact¬

with stainless steel.

3. Avoid cleaning with chloride containing detergents/solvents.¬

4. Do not allow steel tools, containers or implements to lie on stainless¬ surfaces.

EOT CRANE

Do

1. Ensure that only authorized slingers/signaler attached or detached load, or

signal the crane operator

2. Discuss operation with the crane operator(special operation)

3. Ensure that the capacity of the crane is sufficient

4. Seek expert advice when using eye bolts, plate clam etc.

5. Use tag line always

Don’t

1. Don’t Wrap tag line around hand of body



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2. Don’t leave a suspended load unattached

3. Don’t Pass load over people

4. Don’t ride of climb on suspended load

5. Don’t stand or walk beneath the loads

6. Don’t use pipe to support for landing the load

WORKING AT HEIGHT

Do

1. Do as much as work as possible from ground

2. Ensure worker can get safety to and from where they work at height

3. Ensure equipment is suitable , stable and strong enough for the job.

Maintained and checked regularly

4. Take precautions when working near hot surface

5. Provide protection from falling object

6. Consider emergency evacuation and rescue procedure

Don’t

1. Don’t overload the equipment or materials workers are carrying before

working at height. Check the pictogram or label on the lubber for information.

2. Don’t overreach on ladder or stepladders

TOOL BOX

Do

1. Use specific tool for specific work

2. Maintain proper tool box

3. Arrange tool in proper order

4. Keep tool in tool box after use



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Don’t

1. Don’t leave tool box at work place

2. Don’t hammer with by tools

3. Don’t play with tools

4. Don’t carry tool in pockets or in hand

PERSONAL PROTECTIVE EQUIPMENT

Do

1. Use proper PPE

2. Al ways weal helmet in working premises

3. Use cotton cloth while working near furnace

4. Always follow the safety instruction

5. Take permission for use of PPE

Don’t

1. Don’t use other of PPE

2. Don’t place jock while working

3. Don’t wear polyester cloth while working near hot area.

7.1.5 Personal Protective Equipment and Periodic Medical Examination

LIST OF PPE

Protection Type Quantity

Head Helmet 350

Hand Gloves Asbestos 350 pair

Leather 350pair

Foot Safety Shoe 350Pair

Aluminized Heat

Protection

Fire Suit 1

Respirator 10



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Hearing Protection Ear plug 350Pair

Ear muff 50 Pair

Safety Belts 150

Eye Goggles 325

Face shield 50

Medical First aid box 05

Body Protection Aprons 325

PLAN FOR PERIODIC EXAMINATION

1. Pre-employment medical examination will be done.

2. Post-employment medical examination plan is one in every year from government

authorized medical institute/ fractioned.

3. Every six month medical examination of worker working in suspicious condition.

4. Bronchitis and chest diagnostic of worker working near furnace, EOT crane

operator and smoky environment after every six month.

7.2 DISASTER MANAGEMENT PLAN

Installation of 2 x 25TPH and 2 x 12 Induction Furnace to manufacture 2,22,000TPA

Billets/Ingots.

The word 'disaster' is synonymous with 'emergency' as defined by the Ministry of

Environment and Forests & CC. An emergency occurring in proposed Installation of 2 x

25TPH and 2 x 12 Induction Furnace to manufacture 2,22,000TPA Billets/Ingots is one

that may affect several sections within it and/or may cause serious injuries, loss of lives,

extensive damage to environment or property or serious disruption outside the plant. It

will require the best use of internal resources and the use of outside resources to handle it

effectively. It may happen usually as the result of a malfunction of the normal operating

procedures.



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The project is in its formative stage and detail engineering is yet to be done, so the DMP

are based on the following concepts.

Capabilities of DMP

The emergency plan envisaged will be designed to intercept full range of hazards specific

'to proposed plant such as fire, explosion, major spill etc. In particular, the DMP will be

designed and conducted to mitigate those losses of containment situations, which have

potentials to escalate into major perils.

Another measure of the DMP's capability will be to combat small and large fires due to

ignition, of flammable materials either from storage or from process streams and

evacuate people from the affected areas speedily to safe locations to prevent irreversible

injury.

Emergency medical aids to those who might be affected by incident heat radiation flux,

shock wave overpressures and toxic exposure will be inherent in the basic capabilities.

The most important capability of this DMP will be the required speed of response to

intercept a developing emergency in good time so that disasters such as explosion, major

fire etc. are never allowed to happen.

Disaster Control Philosophy

The principal strategy of DMP is "Prevention" of identified major hazards. The

"Identification" of the hazards will employ one or more of the techniques [e.g. Hazard

and Operability Study (HAZOP), accident consequence analysis etc.]. Since these

hazards can occur only in the event of loss of containment, one of the key objectives of

technology selection, project engineering, construction, commissioning and operation is

"Total and Consistent Quality Assurance". The Project Authority will be committed to

this strategy right from the conceptual stage of the plant so that the objective of

prevention can have ample opportunities to mature and be realized in practice.

The DMP or Emergency Preparedness Plan (EPP) will consist of:



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On-site Emergency Plan

Off-site Emergency Plan

Disaster Management Plan preparation under the headlines of On-site Emergency Plan

and Off-site Emergency Plan is in consonance with the guidelines laid by the Ministry of

Environment and Forests (MoEF) which states that the "Occupier" of the facility is

responsible for the development of the On-site Emergency Plan.

The off-site Emergency Plan should be developed by the Government (District

Authorities).

7.2.1 On-Site Emergency Plan

Objectives

The objective of the On-site Emergency Plan should be to make maximum use of the

combined resources of the plant and the outside services to

• Effect the rescue and treatment of casualties

• Safeguard other personnel in the premises

• Minimize damage to property and environment

• Initially contain and ultimately bring the incident under control

• Identify any dead

• Provide for the needs of relatives

• Provide authoritative information to the news media

• Secure the safe rehabilitation of affected areas

• Preserve relevant records and equipment for the subsequent enquiry into the

cause and circumstances of emergency

Action Plans

The Action Plan should consist of:

• Identification of Key Personnel

• Defining Responsibilities of Key Personnel



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• Designating Emergency Control Centers and Assembly Points

• Declaration of Emergency

• Sending All Clear Signal

• Defining actions to be taken by non-key personnel during Emergency.

Key Personnel

The actions necessary in an emergency will clearly depend upon the prevailing

circumstances. Nevertheless, it is imperative that the required actions are initiated and

directed by nominated people, each having specified responsibilities as part of co-

ordinated plan. Such nominated personnel are known as Key Personnel.

The Key Personnel are:

• Site Controller (SC)

• Incidental Controller (IC)

• Liaison and Communication Officer (LCO)

• Fire and Security Officer (FSO)

• Team Leaders (TL)

Site Controller (SC)

In the emergency situation, decisions have to be taken which may affect the whole or a

substantial part of the plant and surrounding area. Many of these decisions will be taken

in collaboration with the other officers at the plant and the staff. It is essential that the

authority to make decision be invested in one individual. In this plan, he is referred to as

the 'Site Controller'. The Plant Manager (however called) or his nominated deputy will

assume responsibility as SC.

Incident Controller (IC)

In the emergency situation, someone has to direct the operations in the plant area and co-

ordinate the actions of outside emergency services at the scene of incident. The one who

will shoulder this responsibility is known as 'Incident Controller' in this plan.



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A Senior Operations Officer or an officer of similar rank of the unit may be nominated to

act as the IC.

Liaison and Communication Officer (LCO)

Operations Officer or any other officer of deputy rank will work as LCO and will be

stationed at the main entrance during emergency to handle Police, Press and other

enquiries. He will maintain communication with the IC

Fire and Safety officer (FSO)

The Fire and Safety Officer will be responsible for fire fighting. On hearing the fire alarm

he shall contact the fire station immediately and advise the security staff in the plant and

cancel the alarm. He will also announce on PAS (public Address System) or convey

through telephones or messengers to the SC, IC and LCO about the incident zone. He

will open the gates nearest to the incident and stand by to direct the emergency services.

He will also be responsible for isolation of equipment from the affected zone.

Team Leaders (TL)

A number of special activities may have to be carried out by specified personnel to

control as well as minimize the damage and loss. For this purpose designated teams

would be available. Each team will be headed by a Team Leader (TL).

Following teams are suggested:

• Repair Team

• Fire Fighting Team

• Communication Team

• Security Team

• Safety Team

• Medical Team

Responsibilities of Key Personnel

Site Controller (SC)



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• On getting information about emergency, proceed to Main Control Centre

• Call in outside emergency services

• Take control of areas outside the plant, which are affected

• Maintain continuous communication, review situation and assess possible

course of events

• Direct evacuation of nearby settlements, if necessary

• Ensure that casualties are getting enough help

• Arrange for additional medical help and inform relatives

• Liaison with Fire and Police Services and Provide advice on possible effects on

outside areas

• Arrange for chronological recording of the emergency

• Where emergency is prolonged, arrange for relieving personnel, their catering

needs etc.

• Inform higher officials in head office

• Ensure preservation of evidence

• Direct rehabilitation work on termination of emergency

Incident Controller (IC)

• On getting emergency information, proceed to Main Control Centre

• Activate emergency procedure such as calling in various teams

• Direct all operations within plant with following priorities:

a) Control and contain emergency

b) Secure safety of personnel

c) Minimize damage to plant, property and the environment

d) Minimize loss of material

• Direct rescue and repair activities

• Guide fire-fighting teams

• Arrange to search affected area and rescue trapped persons



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• Arrange to evacuate non-essential personnel to safe area/assembly point

• Set up communications network and establish communication with SC

• Arrange for additional help/equipment to key personnel of various teams

• Consider need for preserving all records, information for subsequent enquiries

Liaison and Communications Officer

• To ensure that casualties receive adequate attention, arrange additional help if

required and inform relatives

• To control traffic movements into the plant and ensure that alternative

transport is available when need arises

• When emergency is prolonged, arrange for the relief of personnel and organize

refreshments/catering facility

• Advise the Site Controller of the situation, recommending (if necessary)

evacuation of staff from assembly points

• Recruit suitable staff to act as runners between the Incident Controller and

himself if the telephone and other system of communication fail. -Maintain

contact with congregation points

• Maintain prior agreed inventory in the Control Room

• Maintain a log of the incident on tape

• In case of a prolonged emergency involving risk to outside areas by windblown

materials - contact local meteorological office to receive early notification of

changes in weather conditions.

Fire and Safety Officer

• Announce over the PAS in which zone the incident has occurred and on the

advice of the Shift Officer informs the staff to evacuate the assembly

• Inform the Shift Officer In-charge, if there is any large escape of products

• Call out in the following order:

1) Incident Controller or his nominated deputy



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2) Maintenance Officer

3) Personnel and Administrative Officer

4) Departmental Head in whose area the incident occurred

5) Team Leaders (TL)

Emergency Control Centre

The Emergency Control Centre will be the focal point in case of an emergency from

where the operations to handle the emergency are directed and coordinated. It will control

site activities.

Emergency management measures in this case have been proposed to be carried from

single control Centre designated as Main Control Centre (MCC)

MCC is the place from which messages to outside agencies will be sent and mutual aids

and other helps for the management of emergency will be arranged. It will be located in

the safe area. It will be equipped with every facility for external and internal

communication, with relevant data, personal protective equipments to assist hose

manning the centre to enable them to co-ordinate emergency control activities. CC will

be attended by SC.

Following facilities would be available in the MCC:

• P&T phones, mobile phones, intercoms, and wireless

• Emergency manuals

• Blown up area maps

• District telephone directories

• Emergency lights

• Wind direction and speed indicator

• Requisite sets of personal protective equipment such as gloves, gumboots and

aprons



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MCC will be furnished with call out list of key persons, fire, safety, first aid, medical,

security, police and district administrative authorities. MCC will also contain safety data

pertaining to all hazardous materials likely to cause emergency and well-defined

procedures of firefighting, rescue operations, first aid etc.

Assembly Point

In an emergency, it will certainly be necessary to evacuate personnel from affected areas

and as precautionary measure, to further evacuate non-essential workers, in the first

instance, from areas likely to be affected, should the emergency escalate. The evacuation

will be effected on getting necessary message from i.e. on evacuation; employees would

be directed to a predetermined safe place called Assembly Point.

Proposed Location: Area opposite to service building will be the Assembly Point where

all non-key personnel would assemble on getting direction over Public-Address System.

Outdoor assembly points, predetermined and pre-marked, will also be provided to

accommodate evacuees from affected plant area(s). Roll call of personnel collected at

these assembly points, indoor and outdoor will be carried out by roll call crew of safety

team to account for any missing person(s) and to initiate search and rescue operations if

necessary.

Declaration of Emergency

An emergency may arise in the plant due to major leakage of oil or major outbreak of

fire/explosion. In case of major leak or major outbreak of fire the state of emergency has

to be declared by the concerned by sounding Emergency Siren.

Upon manual or sensor detection of a major loss of containment of volatile hazardous

substance, the DMP is activated by raising an audible and visual alarm through a network

of geographically dispersed gas/vapour and heat detectors and also "break glass" type fire

alarm call points with telephone handsets to inform the Central Control Room.



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A separate siren audible to a distance of 5 km range will be available for this purpose.

The alarm is coded such that the nature of emergency can be distinguished as a leakage or

major fire.

The Control Centre and Assembly point will be located at an area of the minimum risk or

vulnerability in the premises concerned, taking into account the wind direction, areas

which might be affected by fire/explosion, leakage etc.

After cessation of emergency, FSO will communicate to IC. After verification of status,

IC will communicate with SC and then announce

Alarms would be followed by an announcement over Public Address System (PAS).In

case of failure of alarm system, communication would be' by telephone operator who will

make announcement in the complex through PAS. Walkie-talkie system is very useful for

communication during emergency with predetermined codes of communication. If

everything fails, a messenger could be used for sending the information. To 5 km, range

variable pitch electric sirens (one in service and the other standby)will generate the main

alarm for the entire site as well as for the district fire brigade. The alarm is coded such

that the nature of emergency can be distinguished as a leakage or major fire. Fire and Gas

alarm matrices are provided at the Central Control room, security gate, on-site fire station

and main administrative office corridor to indicate location of the site of emergency and

its nature.

Mutual Aid

Procedure

All factories may not be equipped with an exhaustive stock of equipment/materials

required during an emergency. Further, there may be a need to augment supplies if an

emergency is prolonged.

It would be ideal to pool all resources available in the and nearby outside agencies

especially factories during an emergency, for which a formal Mutual Aid scheme should

be made among industries in the region.



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Essential Elements

Essential elements of this scheme are given below:

• Mutual aid must be a written document, signed by Location In-charge of all the

industries concerned

• It should specify available quantity of materials/ equipment that can be spared (not that

which is in stock)

• Mode of requisition during an emergency.

• It should authorize the shift-in-charge to quickly deploy available material/equipment

without waiting for formalities like gate pass etc.

• It should spell out mode of payment/replacement of material given during an emergency

• It should specify key personnel who are authorized to requisition materials from other

industries or who can send materials to other industries

• It should state clearly mode of receipt of materials at the affected unit without waiting

for quantity/quality verification etc.

• Revision number and validity of agreement should be mentioned.

• This may be updated from time to time based on experience gained.

Emergency Management Training

• The Key Personnel would undergo special courses on disaster management. This

may preferably be in-plant training. The Managers, Senior Officers and Staff

would undergo a course on the use of personal protective equipment.

• The Key Personnel belonging to various Teams would undergo special courses

as per their expected nature of work at the time of emergency.

• The plant management should conduct special courses to outside agencies like

district fire services to make them familiar with the plant layout and other

aspects, which will be helpful to them during an emergency.



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Mock Drills

It is imperative that the procedures laid in this Plan are put to the test by conducting

Mock Drills. To avoid any lethality, the emergency response time would be clocked

below 2 minutes during the mock drill.

• 1st Step: Test the effectiveness of communication system

• 2nd Step: Test the speed of mobilization of the plant emergency teams

• 3rd Step: Test the effectiveness of search, rescue and treatment of casualties

• 4th Step: Test emergency isolation and shut down and remedial measures taken

on the system

• 5th Step: Conduct a full rehearsal of all the actions to be taken during an

emergency

The Disaster Management Plan would be periodically revised based on experiences gained from

the mock drills.

Proposed Communication System

The instrument and control system will take care of the following operating philosophy

of the plant.

• The project will be provided with a control system located in a central control room.

• The shift engineer will operate the plant from his console panel.

• All operations will be represented in a graphic panel on the console and every operation

will be depicted as operating sequences.

• All operating parameters will be displayed in digital format.

• Alarms will be provided for all parameters, when they exceed set values.

• High-High/Low-Low alarms and trip functions will be provided to trip.

• Pumps/compressors to bring the entire system to a safe shutdown.

• Alarm signal code is set for process description.

Proposed Fire Fighting System



Additional Studies


Elaborate firefighting system will be available for fighting fires in any corner of

the plant. A comprehensive fire detection and protection system is envisaged.

Underground Fire and Service water storage tanks of 650 KL will be provided.

Fire water pump house containing combination of diesel and electrically driven pumps.

Hydrant system complete with suitable size piping, valves, instrumentation, hoses,

nozzles, hose boxes/stations, monitors etc.

Foam injection system for fuel oil/storage tanks consisting of foam concentrate tanks,

foam pumps, in-line inductors, valves, piping and instrumentation etc.

Automatic high velocity water spray system consisting of detectors, deluge valves

projectors, valves, piping and instrumentation.

Automatic medium velocity water spray system consisting of QB.

Detectors/smoke detectors, linear heat sensing cable detectors, deluge valves, isolation

valves, nozzles, piping, instrumentation etc.

Portable and mobile extinguishers, such as pressurized water type, carbon dioxide type,

foam type, dry chemical powder (DCP) type located at strategic locations throughout the

plant.

Fire tenders/engines of water type, DCP type/foam type, trailer pump with fire jeep etc.

provided in the fire station.

Complete instrumentation and control system for the entire fire detection and protection

system for safe operation of the complete system.

Other safety Measures

Considering that fire and explosion is the most likely hazard in such installations, the

plant is being provided with systems to guard against such hazards. Salient among these

are:

A proper layout to prevent and minimize the effects of any hazardous situation

Design of storage vessels and all components to codes and standards to withstand the

rigorous duty

Provision of operating systems to conduct the process through well-established safe

operating procedures

A control system, which monitors all, plant parameters and give alarms



Additional Studies


Control system, which has trip provisions to prevent hazard conditions escalating

A gas detection system which will provide early warning of any leaks

Provision of a fire protection system to control fire

Provision of flame-proof lighting system in the fire prone areas

First Aid and Medical Facilities

Mutual agreement with local hospital for emergency medical treatment has been done. It

will be fully equipped with emergency facilities. It will be open round the clock. A

Medical Officer with Compounder will always be available in the center. Emergency cars

will be available in all the shifts. Adequate number of first aid boxes will be kept at

strategic locations. Required stock of first aid medicines will be maintained. Trained first

aiders will be available in all departments.

Facilities to be kept in the Medical Room along with others will include: Oxygen

Cylinders, Injection Coramine, Glucose Saline, LV. Sets, Syringes, Injection Needles,

Stretchers and medicines.

Emergency Power Supply

Strategic areas will be provided with emergency lights fed through stationed battery

system. Portable emergency lamps will be also available at required points. A Diesel

Driven Generator of 125 KVA capacity is available to keep the operations running in

case of power failure. Diesel Engine operated fire pumps will be available.

7.2.2 Disaster Management Plan for Sai Inductomelt Pvt Ltd.

The main objectives of this disaster management plan are to:

• To identify type of major disaster which may occur in the plant

• To prepare an action plan to handle disaster.

Severity of accidents have been categorized as Category I - Operator Level and

Category II - Local / Community Level

Category—I



Additional Studies


In category-I, disasters may occur due to fire, explosion, oil spillage, mall function of the

machines and spontaneous ignition of inflammable materials. The severity of this

category depends upon the disaster type and nature of it. It may affect the work force

health that involves the operation at that facility and even may be on the facilities of the

plant.

Category—II

In case of complete failure of all automatic control / warning systems of the different

units then it may leads to disaster which may have the high severity on inside work force

and facilities of its own and even may effects on the others facilities surrounding plant.

Probability of these disasters occurrences will be very less because of the plant

alternative systems and well qualified and trained work force which will be placed in

respective areas.

Disaster Preventive Measures

Design, construction of all facilities and machineries will be as per national and

international codes as applicable in specific cases and lay down by statutory

authorities

The operations of the plant will be as per applicable standards laid by the statutory

authorities

Provision of adequate access ways for the movement of equipment and work

force will provide

Minimum two numbers of gates for escape during disaster will take place

All the storage facilities will be marked properly and protected by providing the

fencing around to the storage systems

Water spraying in coal storage facility

Well established firefighting system



Additional Studies


Safety and Training

In the plant all the workforce will be provided with necessary safety protective

equipments. Instrument the like safety valves, safety controls system. Safety department

will look after the safety awareness programs by different means like posters, messages

on the notice boards, etc and safety trainings in the plant as per requirement of the

criticality. Safety training and practical demos to the selected individuals in each

department will provided.

Functions of Disaster Controller

To declare “ Disaster Emergency ” after consulting the Sr. Officer available and

inform Fire Station Control Room to sound the sirens accordingly and arrange to

convey the message in public addresses system

To report to DCR immediately

To receive message from the communication centre

To take decision in consultation with the commanding Officer of different

services and convey them to the disaster point

To be responsible for planning and provision of assistance from township and

from local authorities

Decision of the Disaster Controller on any matter will be final to met the

objective of disaster control plan .

To assist Disaster Controller for provision of material and man power concerning

his services

To convey message to his services team through communication centre after

consulting Disaster Controller

To consult between themselves on matters related to more than one services and

to decide on the action to be taken

Repair Services

This section will look after mainly for the following areas after disaster takes place.



Additional Studies


To take up quick repairs of the damaged machinery

To take up repair of damaged building roads and culverts.

To maintain essential public utility services viz. water, electricity and sewages

system.

Traffic Control

During the disaster, the movement of the safety vehicles and fire fighting vehicles will be

monitored and make the emergency ways to be free from vehicles to attend the disaster

works by the security of the plant. Persons arriving by motor transport at the location of

fire / emergency must not park their vehicle within 100 meters of fire, near fire hydrants,

at road junction and at access roads. The ignition key should be left in the vehicles.

Security Services

In the plant security department will be responsible for the plant security by keeping

security checks at different locations based on the sensitivity of the area. During the

disasters the functions of security will be follows:

Alert the all workforce about the disaster and its location

Update the developments and status of the disaster to the higher officials to take

necessary actions

Co-ordinate the disaster status to the local authorities to get necessary support from

them

Control the vehicular traffic inside the plant to get way to the safety and fire

fighting vehicles to attend the disaster works immediately

Assist the different divisions like fire fighting, safety, local authorities etc. to make

the process easy to handle the disaster works



Chapter 8:Project Benefits


CHAPTER 8

PROJECT BENEFITS

8.1 IMPROVEMENT IN THE PHYSICAL INFRASTRUCTURE

The beneficial impact of the proposed project on the public amenities will be significant

after the commencement of the project activities. The basic requirement of the

community needs will be strengthened by extending healthcare facilities to the

community, building/strengthening of existing roads and drinking water facility in the

area which will help in uplifting the living standards of local communities. Iron is the

most important metal to the mankind, which is widely used for domestic, agricultural,

industrial and defense purposes. Steel consumption is a major indicator of economic

status of any country. The growth of the steel industry significantly contributes to

economic growth as it generates employment both directly and also due to development

of the industries.

8.2 EMPLOYMENT POTENTIAL

Employment opportunities are moderate and not growing in accordance with growth of

education. Employment scenario of the study area is largely dependent on the agriculture

and Industrialization of the area. The major benefit due to the proposed project will be in

the sphere of generating employment for people of that area. The present proposed

project has employment generation potential by way of recruiting local people directly

for different activities of the project. The manpower requirements for the operational

phase after the proposed project will be about 325 people. In addition, there will be an

indirect employment for skilled/ semi-skilled people during project life. All attempts will

be made to employ suitable, locally available, skilled personnel from the nearby area.

Manpower for unloading of raw materials, loading of finished goods, plant cleaning,

hiring of vehicles, road maintenance, plant security, gardening / green belt development

etc. will be locally contracted out. Local people will be given the opportunity of

employment as per their capability and expertise. Priority will be given to scheduled tribe





families and women. This will enhance the present socio economic status of the local

people.

8.3 IMPOVEMENT IN INFRASTRUCTURE

M/s Sai Inductomelt Private Limited will provide the following infrastructure in the study

area of 10 km radius:

• Road Transport: There will be improved road communication due to the

proposed project and maintenance will also be done time to time.

• Market for product: Need for the proposed products are based on the demand

and supply gap in the current market. With increasing utilization of the current

products in future, to cater the requirement of all the products, it is essential to

have the proposed manufacturing unit.

• Market for Consumer Goods: With the implementation of the project and

development of the locality, existing demand pattern is likely to continue which

indicates more importance on consumer goods and quality products. This will

affect the local consumer goods market will grow, thus creating more income

opportunities to the local people. The proposed project is going to have positive

income effect and consequently, the multiplier effect is expected to lead to an

overall increase in average consumption of the people of the study area.

• Infrastructure: Creation of community assets (infrastructure) like Installation/

Repair of Hand Pumps/ Bore wells Gram Panchayat dug well de‐siltation and

deepening, as a part of corporate social responsibility.

8.4 EDUCATION

The local peoples’ interest towards education will increase due to the expectation of

getting jobs, especially from non-agricultural sources such as the industries in the vicinity

of M/s Sai Inductomelt Private Limited. Educational institutions will also come-up and

will lead to improvement of educational status of the people in the area. The general

awareness towards the importance of education is expected to increase as a result of the





proposed project. The project will have positive impact on the level of education of the

people.

8.5 GREEN BELT DEVELOPMENT

The plantation and green belt development will also be taken care in the plant and the

space reserved for plantation will be more than 33% of the total plant area. Adequate

plantation will substantially abate the dust pollution, filter the polluted air, reduce the

noise and ameliorate the plant environment.

8.6 SOCIAL INFRASTRUCTURE

With the implementation of the proposed plant, the increasing industrial activity will

boostup the commercial and economic status of the locality, to some extent the socio

economic status of the local people will improve substantially. The required skilled and

unskilled laborers will be utilized maximum from the local area. The land rates in the

area will improve in the nearby areas due to the proposed activity. This will help in

upliftment of the social status of the people in the area. Primary health the medical

facilities will certainly improve due to the proposed project.

8.7 OTHER TANGIBLE BENEFITS

This project is essential in-view of production of high value downstream products. The

present project is likely to accelerate such industrialization the study area. M/s Sai

Inductomelt Private Limited is equally conscious for the all-round socio-economic

development and is committed to raise the quality of life and social well-being of

communities where it operates. The activities under CER will be local need basis with

focus on Health, Education, Infrastructure Development, Drinking water, Sanitation and

Environment Conservation.





8.8 CORPORATE ENVIRONMENT RESPONSIBILITY PLAN (CER)

As per the Notification dated 1.05.2018 issued by MOEF&CC, it is mandatory to prepare

Corporate Environment Responsibility Plan (CER) to spend 2 % (project cost≤ 100

Crores, Greenfield project) of total capital cost of the project on social, economical and

peripheral development activities. Hence, a detailed socio-economic analysis of pre-

project status of 10 km buffer zone villages is required so as to establish a bench mark for

measuring changes due to project’s CSR interventions over a period of time. As per the

above mentioned new office memorandum CER dated 1.05.2018, 2 % of total project

cost i.e Rs. 1.2 Crores will be allocated for CER based on public hearing issues (Total

cost of project is (60 crores). The CER for the proposed expansion is as follows.

S.N Task

Annual Capital Cost(in Lakh)

Year-1

Year-2Year-

3Year-

4Year-

5Total

1 Educational Activities/Facilities 4.0 4.0 4.0 4.0 4.0 20.02 Public health (Annual health check up of

local people)3.0 3.0 3.0 3.0 3.0

15.03 Facility of Drinking water in nearby

villages3.5 3.5 3.5 3.5 3.5

17.54 Donation for Grampanchyat

Development3.0 3.0 3.0 3.0 3.0

15.05 Toilets Facility 3.0 3.0 3.0 3.0 3.0 15.06 Internal road development and repairing

of village roads2.0 2.0 2.0 2.0 2.0

10.07 Facility of solar light along the village

roads2.0 2.0 2.0 2.0 2.0

10.08 Woman Empowerment & children

Development Activities1.0 1.0 1.0 1.0 1.0

5.09 Miscellaneous as per the demand of

surrounding villages2.5 2.5 2.5 2.5 2.5

12.5Total 24.0 24.0 24.0 24.0 24.0 120.0



Chapter 9:Environmental Cost

Benefit Analysis


CHAPTER 9

ENVIRIONMENTAL COST BENEEFIT ANALYSIS

The chapter on “Environmental Cost Benefit Analysis” is applicable only, if the same is

recommended at the Scoping Stage (As per EIA Notification dated 14th September, 2006

as amended from time to time). However, as per the TORs issued by SEAC the

Environmental Cost Benefit Analysis is not asked for hence the same has not been

required.




Management Plan


CHAPTER 10

ENVIRONMENTAL MANAGEMENT PLAN

10.0 INTRODUCTION

Any industrial development is associated with certain positive impacts as well as some

negative impacts on the environment. However, the negative or adverse impacts cannot

possibly rule out scientific development. At the same time adverse impacts cannot be

neglected. An Environmental Management Plan shall be formulated for mitigation of the

adverse impacts and is based on the present environmental conditions and the

environmental impact appraisal. This plan helps in formulation, implementationand

monitoring of the environmental parameters during and after commissioning of the

project. The Environmental Management Plan describes in brief, the management plan

for proper and adequate implementation of treatment and control system for air and liquid

pollutants and for maintaining the environment. It also includes the development of green

belts in and around the plant, proper safety of the workers, noise control, fire protection

systems and measures.

10.1 PURPOSE OF ENVIRONMENTAL MANAGEMENT PLAN

The environment management plan is prepared with a view to facilitate effective

environment management of the project, in general and implementation of the mitigation

measures in particular. The EMP provides a delivery mechanism to address potential

adverse impacts and to introduce standards of good practice to be adopted for all project

works. For each stage of the program, the EMP lists all the requirements to ensure

effective mitigation of every potential biophysical and socio-economic impact identified

in the EIA. For each operation, which could otherwise give rise to impact, the following

information is presented:

• To treat and dispose-off all the pollutants viz. liquid, gaseous and solid waste so

as to meet statutory requirements (Relevant Pollution Control Acts) with

appropriate technology.




Management Plan


• To support and implement work to achieve environmental standards and to

improve the methods of environmental management.

• To promote green-belt development

• To encourage good working conditions for employees.

• To reduce fire and accident hazards.

• Budgeting and allocation of funds for environment management system.

• To adopt cleaner production technology and waste minimization program

10.2 OVERVIEW OF THE POLLUTION CONTROL MANAGEMENT

10.2.1 CONSTRUCTION PHASE

(a) Air Environment

The construction activities will result in the increase of PM10, PM2.5 due to fugitive

emissions of dust. Frequent water sprinkling in the vicinity of the construction sites will

be undertaken. It will be ensured that both gasoline and diesel powered vehicles are

properly maintained to comply with exhaust emission requirements.

(b) Noise Environment

There will be marginal increase in noise levels during construction phase, which is

temporary. To control the noise levels during construction phase, the silencer of the

vehicles will be maintained properly. Noise generating equipment’s with moving part

will be lubricated which will result in reduction of noise levels. Noise prone activities

will be restricted to the day time only. On site workers working in noise prone areas

would be provided with ear muffs & plugs. Noise prone activities will be restricted to day

time only.

(c) Water Environment

Provision for infrastructural services including water supply, sewage and drainage

facilities shall be made. Sewage from construction worker site will be collected in septic

tank followed by soak pit.




Management Plan


(d) Land Environment

The tree plantation will be undertaken during the construction phase so as these plants

will grow in considerable height by the time the proposed activities are in operational

stage. Excavated top soil from site will be used for tree plantation.

(e ) Socio-economic Environment

Management of M/s Sai Inductomelt Private Limited shall give preference to local people

through both direct and indirect employment.

(f) Occupational Health and Safety

Health hazards are due to dust generation, gas cutting, welding, noise and high

temperature and micro ambient conditions, which may be due to heat generated. The

precautionary measures which will be followed to reduce the risk due to dust to the

workers engaged in and around the material handling areas are:

Continuous water supply in the water spraying system will be maintained to

suppress the dust generated during construction activities.

Almost all material handling systems will be automatic thereby reducing the

manpower. The workers engaged in material handling area will be provided

with personal protective equipment like dust masks, respirators, helmets, face

shields etc.

All workers engaged in material handling system will be regularly examined

through PFT (Pulmonary Function Test) tests for lung diseases.

Any worker found positive symptoms of dust related disease will be given

medical treatment immediately.

Thermal insulation will be provided wherever necessary to minimize heat

radiation from the equipment, piping, etc. to ensure protection of workers.

Insulation thickness will be such that the covering jacket surface temperature

does not exceed the surrounding ambient temperature.




Management Plan


The safety department will supervise the safe working of the contractor and their

employees. Work place will be maintained clean, with optimum lighting and

enough ventilation to eliminate dust/fumes.

Action plan for protecting the workers from the occurrence of hazardous will be

taken by safety department.

10.2.2 OPERATION PHASE

a) AIR MANAGEMENT

The major sources of pollutants are vehicular movement, material handling, crushing,

grinding and the emission from induction furnace operation. During the ambient air

quality monitoring, it is observed that the baseline concentration of air pollutants,

namely PM10, PM2.5, NO2, SO2, and CO is well below the National Ambient Air

Quality Standards (NAAQS), 2009. It is anticipated that the plant activity will not

cause any adverse effect on the existing baseline status. Fugitive emissions will be

controlled with the following recommended measures:

• Development of green belt in the plant area.

• Use of water sprinkling system in haulage roads for dust suppression.

• Over loading shall be avoided during crushing and grinding of Scrap.

• Proper maintenance of haulage roads, which are being used for transportation

of material

• Dust mask will be provided to all workers working in dust generating area.

• Spread of dust from grinding mill will be controlled with the help of

enclosures and dust collectors.

• Overloading of trucks will be avoided.

• Utmost care and regular inspection schedule will be carried out to prevent any

fugitive emission of dust during manufacturing process and transportation of

material from one place to another.




Management Plan


Air Pollution Control Equipment

There will be two major source of air pollution in the plant, fugitive emissions from

various material handling and transfer points and flue gases generated from induction

furnace. Dust and fume extraction system will be provided for Induction Furnace.

Dust and fumes will be collected with the help of bag filter as air pollution control

system of specified size followed by 30 m stack. Flue gases generated will be cleaned

in the Bag Filters and discharged through stack, so that the dust concentration will be

well within the prescribed standard.

Height of the all the flue gas discharge facilities will be designed as per CPCB norms.

The various places where the flue gases will be discharge are shown in the Table.

AIR POLLUTION CONTROL SYSTEM

S.No Process Air Pollution Control System Stack

Height

1 Induction Furnace Bag filters air pollution control

system of specified size.

30 Mtrs.

b) WATER ENVIRONMENT

There will be no industrial wastewater generation and the domestic wastewater generated

will be treated in septic tank and soak pit system.

c) RAIN WATER HARVESTING SYSTEM

Rainwater harvesting is a mechanism involved in collecting, storing and putting rainwater to use

when it is most needed. A rainwater harvesting system comprises of various stages -

transporting rainwater through pipes or drains, filtration, and storage in tanks for reuse or

recharge.

Rain water harvesting can be done by three ways;

• Recharge through Roof Top




Management Plan


• Rain water storage Tank

• Recharge through surface run-off

There are five components in a rainwater harvesting system namely

catchment, conveyance, filtration, storage and recharge.

Advantages of Rain Water Harvesting

There are various advantages of Rain Water Harvesting from which some of them are

listed below:

• Outsourcing is reduced as it allows use of rainwater in case of scarcity.

• Solution to water problems.

• Effective rise in Ground Water levels.

• Inexpensive and simple technology.

• It’s economical & energy saving as it prevents extraction of water

from depleting Ground Water Table.

• Provides high quality water, having low mineral content.

• Easy operation & maintenance.

• Reduces soil erosion.

Design of Rain Water Harvesting

Quantity of Rain water collected depends upon:

• Average Rainfall Intensity.

Catchment area.

• Run-off coefficient

Co-efficient and Factor Adopted:

Runoff Co-efficient

Surface Type Run off Co efficient

Roof top area of building/sheds 0.85

Road and Paved area 0.5

Green belt area 0.2

(Source: Concepts & Practices for Rain Water Harvesting CPCB)




Management Plan


Retention Time in Recharge Well

(10 - 15) min per hour

Volume of Harvesting Pit

Q * Retention Time

Where,

Q = Catchment Area x Harvesting Factor x Rainfall intensity (mm/ hour)

Rainwater harvesting Quantity

Factory roof, offices building, all remaining civil constructions rain water is collected in

underground water storage tank through pipeline. Collected water will be used for

gardening and domestic purpose. Total rain water harvesting in year is given a below.

S.N.

Type ofStructure/

Surface

Area [A]Sq. m

Run offCoefficient [C]

Filterefficienc

y

Averagerainfall

(m/year)

Discharge (Run off) [Q=CIAF] (m3/year)

TotalDischarge[Q](m3/y)

a)

Roof toparea of

building/sheds

23408.7 0.85 0.8 0.438 23408.7x0.85x0.8x0.438 6972.04

b)

Road andPaved areaand open

space

8468.140.5 0.8 0.438 8468.14x0.5x0.8x0.438 1483.61

c)

Green beltarea

17877.8 0.2 0.8 0.438 17877.8x0.2x0.8x0.438 1252.87

Total - - 9708.54

d) NOISE ABATEMENT

Noises from fans, centrifugal pumps, electrical motors etc. will be kept in control so that

the ambient noise level shall not exceed 75dBA during daytime and 70dBA during

nighttime. Noise pollution control measures will be provided in respective departments

by way of providing silencers soundproofs cubicles/ covers and proper selection of less

noise prone machinery and by development of green belt.Ear muffs, ear plugs, etc. will

be provided to workers when the noise levels exceed 85 dB (A). Regular maintenance

will be carried out for equipment and various machines.




Management Plan


e) ENVIRONMENTAL MONITORING

Necessary provisions for routine monitoring of stack emissions, ambient air quality, noise

level, water quality as required by the regulations will also be provided.

f) SOLID WASTE MANAGEMENT/DISPOSAL

The solid waste generated will be in the form of slag. The total quantity of proposed slag

generation will be approx. 11,100 TPA. Slag crushers will be installed to recover iron

particles to be reused in Induction Furnace. Slag generated from Induction Furnace will

be used for hardening of working area, internal road, brick manufacturers and concreting.

The used machine oil of 0.1 TPA will be sell to registered oil vendors only.

g) GREENBELT DEVELOPMENT

Development of a greenbelt around the proposed facility mitigates to a certain extent the

potential negative impact on the environment due to dust, air emissions, fugitive emission

and noise. A green cover itself acts as containment for dust. Presence of a green belt, will

lead to micro-climate and soil quality balancing, by retaining soil moisture, recharge of

ground water as well as self-control of micro- climate of that area. It also improves the

aesthetic value of the area, later on it becomes the natural habitat of various bird species.

Development of a green belt around the proposed project site will also help to contain

noise generated during construction and operational phases.

In view of this, plantation and green belt development will be taken care in the plant and

the space reserved for plantation will be more than 33% of the total plant area. Plantation

will be made accordingly. For development of green belt Rs50,000 per Ha will be

allotted. The selection of plant species will be based on the local soil conditions. Post

plantation care like watering and protection from grazing will be done. The plant species

recommended for strengthening the existing plantation are presented in Table. However




Management Plan


the selection of the species will be finalized in consultation with the local Forest

Department.

PLANT SPECIES SUGGESTED FOR GREEN BELT DEVELOPMENT

Sr.No

Botanical name of theplant

Size of thegrown up tree

Type and suitable site, where the plants are to beplotted

1 acacia auriculiformis Medium Semi-evergreen fragrant white flowers suitablein green belts and on road sides

2 Adina corodifolia Large Deciduous, a light demander, suitable on open areas andnear flares

3 Aeglemarmelos Medium Deciduous, good for green belts.4 Anogeissuslatifolia Medium Deciduous, Suitable for green belts5 Artabotryshexapetalus Small Evergreen shrub with fragrant flowers good for gardens

and inside boundary wall and long canals7 Azadirachtaindica Large Evergreen, suitable in green belts along the boundary and

outside office & sensitive buildings like hospitals.8 Bauhinia variegate Medium Deciduous, good in green belts in garden and as a second

row avenue tree9 Borassusflabellifer Large A tall deciduous palm can be used as wind break when of

different age.10 Boswelliaserrata Medium Deciduous suitable on green belt on willow soils11 Caesalpiniapulcherrima Small A large shrub, suitable for gardens outside offices and

along channels12 Callistemon lanceolatus Medium Deciduous for some time, ornamental plant in garden

13 CareyaArborea Large Deciduous, good in green belts14 Cassia fistula Medium Deciduous, good ornamental tree in green belts.15 Cassia siamea Large Evergreen, good as an avenue tree.16 Ficusreligiosa Large Deciduous, widely spaced avenue tree also as a single tree

in isolated sites.17 Maducaindica Medium Deciduous, good in green belts.18 Peltophoruminerme Medium Semi evergreen, suitable on road sides, in gardens and

outside office buildings.19 Saracaindica Medium

Evergreen tree good on road sides within campus

20 Tamarindusindica LargeEvergreen tree good along boundary and road sides.

21 Terminaliacatappa Large Deciduous tree

22 Terminaliaarjuna LargeEvergreen tree for road sides and in green belts

23 Zanthoxylumalatum Medium Deciduous in green belts

h) OCCUPATIONAL HEALTH AND SAFETY

Project proponent will provide all necessary provisions under Factory Act. In addition a

Safety committee will be formed and manned by equal participants from Management

and Workers.Besides the above, the operating and maintenance personnel will be




Management Plan


provided with all the necessary safety equipment such as hand gloves, gum boots, aprons,

helmets, protective glasses, ear muffs etc.

Workers training will focus on reduction of wastes, utilization of wastes and generally

maintaining a clean and healthy environment.Company under its safety policy issues

Helmets, safety shoes, Safety goggles and location specific personal protective equipment

twice a year and has the policy to penalize the person not using the PPE in work area. All

the Internal roads are concrete trimix with speed breakers where ever required. Company

conduct annual medical health checkup for all employees and keep the record for future.

Pre-employment medical checkup is carried out by authorized medical officer

10.3 ENVIRONMENT MANAGEMENT POLICY & ENVIRONMENT COMMITTEE

The Company is very much oblivious of its responsibility in protecting the Environment.

Thus various mitigation measures as given in the report shall be taken-up and effort will

be made to nullify the effect of the Project, on the Environment, if any. Any action or

effort remains incomplete, if it is not monitored properly at regular intervals and

corrective measures taken, wherever necessary. Regular monitoring has thus, been

provided. The Company has a well-defined policy to keep the Environment clean. The

management has decided that all effective steps shall be taken to prevent deterioration of

the existing Environment. They have formed an Environment Committee committed for

this cause. The Committee will consist of following persons as given in Figure 10.1




Management Plan


Figure 10.1 Organizational Set-up for Environmental Committee

SOP in case of any Violation is observed

• The cases of violations/non-compliances of Environment or Forest Laws, if any,

shall be reported to the Board of Directors through EHS Manager and shall

identify designate responsible person for ensuring compliance with the

Environmental Laws and Regulations.

• Comply with all relevant environmental laws and regulations to minimize risks to

health, safety and the environment.

DIRECTOR (OPERATIONS)

General Manager(Environment)

Head (EHS)

Staff




Management Plan


• Work with local government, regulatory authorities and communities to ensure

safe handling, use and disposal of all materials, resources and products.

The main aims under the said Policy are to:

• Effectively manage, monitor, improve and communicate the environmental

performance.

• Take all reasonable steps to prevent pollution.

• Set realistic and measurable objectives and targets for continual improvement of

the environmental performance.

• Ensure that all employees and contractors are trained to understand their

environmental responsibilities and create an environment that adheres to the

Company’s Policies, procedures and applicable regulations.

• Hold leadership accountable for good environment performance of our operations

and projects. Inherent in that accountability will be the commitment of

management to provide resources and successfully create an appropriate

environment



Chapter 11:Summary & Conclusion


CHAPTER 11: SUMMARY & CONCLUSION

11.1 PROJECT DESCRIPTION

11.1.1 Introduction



Ahmedabad. Sai Inductomelt Pvt. Limited Corporate Identification Number is (CIN)



India.

M/s Sai Inductomelt Pvt. Ltd has proposed a project for manufacturing of Billets/Ingots

@ 2, 22,000TPA by installation of new induction furnace of capacity 2 x 25TPH and 2 x

12TPH The proposed project to be sited atSurvey no: 1020& 1021/1,Bhavnagar -

Vallabhipur Highway, Village:Chamardi, Taluka: Vallabhipur,District:Bhavnagar

(Gujarat). The total 13.29 Acreland has acquired for the proposed project.

11.1.2 Project Location & Environment Sensitivity

Sr No Particulars Details

1 Project Site Survey no: 1020 & 1021/1,Bhavnagar - VallabhipurHighwayVillage:Chamardi, Talluka :Vallabhipur,District:Bhavnagar

2 Latitude Latitude : 210 48’ 30.29” N

3 Longitude Longitude : 710 54’ 07.37 E

4 Elevation above MSL 12 m

5 Topo sheet NF 42 - 12

6 Present landuse Vaccant land, NA is obtain

7 Nearest NationalHighway/State Highway

SH 36:1.3 km in East Direction

8 Nearest Airport/ Air Strip Bhavnagar 30.Km (ESE)

9 Nearest Village/Habitates Chamardi 2.5 kms South direction

10 Forest Blackbuck National Park 30 km in NE direction





11.1.3 Size or Magnitude of Operation

The proposed project will installed four induction furnace having capacity of 2 x 25 TPH

and 2 x 12 TPH. The total production capacity of M.S.Billtes /Ingots will be 2,

22,000TPA.

Sr. No Name of Product Quantity (TPA)

1 M.S.Billets/Ingots 2, 22,000

11.2 DESCRIPTION OF ENVIRONMENT

Air Environment

The baseline environmental quality for the October to December – 2018 was assessed in

an area of 10 km radius around the proposed project site.

During the study period, average wind speed measured on site is 1.45 m/s. The

wind rose diagram indicates predominant wind direction is from NE with 7.25 % calm

condition

The ambient air quality monitored at 8 locations selected based on predominant wind

direction, indicated the following ranges;

PM10 - 47-84 µg/m3.

PM2.5 - 18-39 µg/m3

SO2 - 9-23 μg/m3

NO2 - 11-26 μg/m3

CO - 0.2-0.91 mg/m3

11Ecologically SensitiveZones like wild lifesanctuaries, national parksand biospheres

Archaeological structures, Historical places, Sanctuariesand Biosphere are not present within 10 km

12 Water Bodies Rangholi River 0.6Km South directionKalubar River 1.5Km NE directionGautameshwar Dam 13 Km SE DirectionGulf of Khambhat 36.0Km in East DirectionGhelo River 7.8 Km in North Direction





NATIONAL AMBIENT AIR QUALITY STANDARDS

PollutantTime weighted

Average

Concentration in air

IndustrialAreas, residential rural &

other areas

PM10 24 hours 100.0 µg/m3

PM2.5 24 hours 60.0 µg/m3

Nitrogen Dioxide (NOx) 24 hours 80.0 µg/m3

Sulphur dioxide (SO2) 24 hours 80.0 µg/m3

Carbon Monoxide (CO0 8 hours 2.0 mg/m3

The concentrations of PM10, PM2.5, SO2 NO2 and CO were found within the National

Ambient Air Quality Standards (NAAQ).

Water Environment

A total 10 samples including four surface & six ground water samples were collected and

analyzed. The water samples were analyzed as per Standard Methods for Analysis of

Water and Wastewater, American Public Health Association (APHA) Publication.

The data indicates that the ground water as well as the surface water quality is below the

stipulated standard for drinking water (IS 10500 of 2012).

Noise Environment

Noise levels measured at eight stations. Noise level is quietly exceed than prescribed

limit of 55.0 dB (A) for Residential Area. However noise level in industrial area is within

limit of 75.0 dB (A) for Industrial Area as given in MoEF Gazette notification for

National Ambient Noise Level Standard.





Area Code Category of AreaLimits in dB(A) Leq

Day time Night time

A Industrial Area 75 70

B Commercial Area 65 55

C Residential Area 55 45

D Silence Zone** 50 40

**Silence zone is defined as area up to 100 meters around premises of hospitals, educational institutions and courts. Use of

vehicle horns, loud speakers and bursting of crackers are banned in these zones

11.3 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATIONMEASURES

Air Environment

The impacts on air quality due to source of the air pollutant in the proposed facilities have

been identified.

Sources of Emissions

Emissions released from the stack during operation phase will get dispersed in the

atmosphere and finally reach the ground at a specified distance from the sources. From

the proposed activities the possible environmental impact on air quality has been

envisaged due to the following sources.

Raw Material Handling / Transport System

The possible pollutants are fugitive dust emissions from raw materials handling areas viz.

loading / unloading, etc.

Mitigation Measures

M/s. Sai Inductomelt Pvt.Ltd. will provide dust suction system which will control

fugitive emission due to material handling. Dust suppression system will be provided in

the form of water sprinklers. The entire length of conveyors is covered to prevent dust





pollution. All bins are totally packed and covered so that there is no chance of dust

leakage. All material transfer points are connected with dust suppression water nozzles to

avoid air pollution.

Manufacturing of M.S billets/Ingots

Bag filter will be provided for the extraction of dust particles. The continuous casting

operation is selected for the production of billets/Ingots in induction furnace, where there

is less attack on refractory lining, the changing need drastically comes down by 87%.

This process results in the low gases emission.

Mitigation Measures

Installation of Bag filter followed by Stack height as per GPCB norms.

The particulate matters and air borne metallic particles are generated from the

transfer of molten steel to the mold and from the cutting of the product by oxy-

fuel torches during continuous casting.

Exhaust should be fitted to filters and other relevant abatement equipment,

especially in the casting and finishing shops, wherever it is applicable.

11.4 ENVIRONMENT MONITORING PROGRAMME

The environmental monitoring is important to assess performance of pollution control

equipment installed in the expansion project of M/s Sai Inductomelt Pvt Ltd. The

sampling and analysis of environmental attributes including monitoring locations will be

as per the guidelines of the Central Pollution Control Board/ State Pollution Control

Board.

Environmental monitoring will be conducted on regular basis by M/s Sai Inductomelt

Pvt Ltd. to assess the pollution level in the proposed plant as well in the surrounding area.

Therefore, regular monitoring program of the environmental parameters is essential to

take into account the environmental pollutant of the study area. The objective of

monitoring is:

To verify the result of the impact assessment study in particular with regards to

new developments;





To follow the trend of parameters which have been identified as critical;

To check or assess the efficiency of the controlling measures;

To ensure that new parameters, other than those identified in the impact

assessment study, do not become critical due to the commissioning of proposed

facilities;

To check assumptions made with regard to the development and to detect

deviations in order to initiate necessary measures;

To establish a database for future Impact Assessment Studies for new projects.

The attributes, which needs regular monitoring, are specified below:

Air quality

Water and wastewater quality;

Noise levels;

Soil quality;

Ecological preservation and afforestation

Socio Economic aspects and community development

11.5 ENVIRONMENT MANAGEMENT PLAN

Overview of Pollution Control Management during Operational Phase

SOURCE POLLUTANTS CONTROL MEASURES

Air pollution from inductionfurnace due to melting of hotmetal

PM Dust and fumes will be collected withthe help of bag filter with fume hoodfollowed by 30 m stack

Solid waste Slag frominduction 11,100

TPA

Slag Crushers will be installed torecover iron particles to be reused inInduction Furnace. Slag generatedfrom Induction Furnace will be usedfor hardening of working area, internalroad, brick manufacturers, concreting.





Air Environment

The sources of air pollution are raw material handling system, materials transportation,

raw materials feeding to the operating equipments. The automatic process equipments

will be employed for the raw material feeding system. Stacks height as per GPCB norms

is proposed for proper dispersion of flue gases.

Action Plan to Control and Monitor Secondary Fugitive Emissions from all the

Sources.

The primary fume pick up from Induction Furnace will be by a canopy hood placed over

the furnace and to convey the same single walled MS ducting will be employed.

Bag filter followed by a stack will be installed.

Fugitive emission from material unloading operations, material transfer points

will be controlled fully with total enclosure.

Fugitive as well ambient air quality monitoring shall be carried out on regular

basis to ensure the compliance with National Ambient Air Quality Standards

(NAAQS). The ambient air quality within the factory premises shall not exceed

the standards (PM10 100µg/m3, PM2.5 60µg/m3 SO2 80µg/m3, NO2 80µg/m3 and

CO 04µg/m3) prescribed by CPCB.

The monitoring frequency of air quality shall be as per the consent issued by State

Pollution Control Board and reports shall be submitted as part of compliance. The

records will be maintained.

Regular Stack Monitoring will be done. All the emissions from the plant will be

controlled to meet the relevant standard set by CPCB/State Pollution Control

Board.

Details regarding volumetric flow, temperature and emission rate of pollutants

from different stacks shall be collected and compiled regularly.

Effective steps shall be taken to control fugitive emission inside the plant. All

internal roads will be Tar Roads. Efficient arrangements will be provided to

control fugitive dust emission during handling/transportation of Raw materials /

finished product etc.





The emission from induction furnace area will be extracted and treated in a fume

extraction system.

Fumes will be evacuated directly from induction furnaces through hoods with

swirling mechanism and ducting.

Avenue plantation will be strengthening further to control fugitive emissions &

gaseous pollutants to keep clean and healthy environment.

During induction melting of steel scrap, lot of sparks gets generated. For the

purpose of arresting sparks & flame, it is necessary to have an arrestor which

arrests sparks. The device provided will be a centrifugal cyclone, which removes

sparks and also collects coarser particles. The collected dust in the cyclone hopper

can be drained periodically into a drum when the system is shut or a continuous

motorized rotary air lock valve can be provided.

Impact on Transportation

The road (State Highway) connected with our project is SH 36 (Bhavnagar

Ahmadabad Road) Traffic intensity due to existing and proposed expansion is

worked out as below.

Sr. No. Name of Material(RM and Product)

Mode of Transportation No. of trucks/day

1 MS Scrap By Road 23

2 Sponge Iron By Road 02Total No. of Trucks/Day 25 Trucks/Day

All raw material and finished good shall be transported by road. The finished

product i.e. M.S. Billets/Ingots will be transported by the truck carrying raw

material. The plant is having good road connectivity and can be approached from

both Bhavnagar and Ahmadabad is strong to handle the traffic due to proposed

project. National highway 8E is also 6.5 km at south direction of plant site.

The additional transportation will have negligible impact on surroundings. There

is no habitation on approach road to the project site. The parking of the vehicles

will be in the project area.





Water Environment

During plant operation no waste water will be generated from M.S. Billets/Ingots as the

water is being used for cooling the products which will be evaporated and condensed,

water if generated will be recycled. Provision for oil/grease separators will be made to

skim oil / grease, if any in the waste water. After skimming of the oil water will be stored

in guard pond. Domestic waste will be disposed through Septic Tanks along with soak

pits.

Noise Environment:

The industry will take care while procuring major noise generating

machines/equipment to ensure that the manufactures have taken adequate

measures to minimize generation of noise.

The areas where noise levels are high will be partitioned off, noise levels will be

minimized at the source, and noise reflection and transmission will be minimized.

The workers working in the high noise areas will be provided with ear muffs/ear

plugs.

Acoustic laggings and silencers will be provided in equipment wherever

necessary. Ventilation fans shall be installed in enclosed premises.

Supply ducts and grills on the ventilation and air conditioning system will be

suitably sized for minimum noise level.

The silencers and mufflers of the individual machines shall be regularly checked

The noise level shall not exceed the limit 75 dB (A) during the day time 70 dB

(A) night time within the plant premises.

Provision of insulating caps and lids at the exit of noise source and providing

polystyrene, etc. as noise insulation material will be adopted. All the openings

will be covered and partitions will be acoustically sealed.

Avenue plantation around the plant area will reduce the noise level further.

Training of personnel is recommended to generate awareness about damaging

effects of high noise levels.





Land Environment

The main objective of the green belt is to provide a buffer between the sources of pollution

and the surrounding areas. More than 33 % of the plot area will be developed as green belt

of mixed tree species (local varieties).

The green belt helps to capture the fugitive emissions and attenuate the noise apart from

improving the aesthetics quality of the region. Dense greenbelt will be developed along the

periphery of the plant. Avenue plantation will also be developed as per the standard norms.

The general guidelines for development of greenbelt will be as follows:

Trees growing up to 5 m or more will be planted along the plant premises and

along the road sides.

Planting of trees will be undertaken in rows.

Open areas inside the plant boundary will be covered with grass lawns.

Planting of trees in each row will be in staggered orientation.

Shrubs and trees will be planted in encircling rows around the project site.

The short trees (<10 m height) will be planted in the first two rows (towards plant

side) of the green belt. The tall trees (>10 m height) will be planted in the outer

three rows (away from plant side).

Management Plan of Solid waste

Process needs refractory lining and is being changed every month.

Total Solid waste of slag generation will be about 11100 TPA after Expansion

project.

Solid waste is nonhazardous and non-toxic in nature.

Solid waste will be used for land filled, in own premises, concreting /hardening of

work area.





SOCIO-ECONOMIC ENVIRONMENT

The project proponent would aid in the overall social and economic development of the

region. The manpower requirements for the operational phase of the proposed project

will be about 325 people. In addition, there will be an indirect employment for skilled/

semi-skilled people during project life. All attempts will be made to employ suitable,

locally available, skilled personnel from the nearby area. In order to mitigate the adverse

impacts likely to arise in the proposed project activities and also to minimize the

apprehensions to the local people, it is necessary to formulate an affective EMP for

smooth initiation and functioning of the project. The suggestions are given below:

Communication with the local people will be established regular basis by project

authority to provide an opportunity for local youth.

Project authorities will undertake regular environmental awareness program on

environmental management.

Job opportunities are the most demanding factor, the local people as per their

education will be employed.

For social welfare activities to be undertaken by the project authorities,

collaboration should be sought with the local administration, gram panchayat,

block development office etc for better coordination.

Occupational Safety & Health Management

Project proponent will provide all necessary provisions under Factory Act. In addition a

Safety committee will be formed and manned by equal participants from Management

and Workers. All personal protect equipments like Safety shoes, helmet & uniform will

be issued to each employee based on the nature of job involved. In case a person inhales

CO, he should be removed to fresh air and given mediated oxygen through a mask for 30

minutes and if required cardiopulmonary resuscitation should be performed.





11.6 CONCLUSION

Based on the study it is concluded that-

• There will be no major impact on water environment as generated

• Domestic wastewater will be disposed in the septic tank followed by soak pit.

• Electrically operated induction furnace is used and it will be equipped with

suction hood, followed by bag filter.

• To prevent fugitive emission, from material unloading operations regular

sprinkling of water will be done.

• For noise control, unit will provide necessary PPEs like earplugs or earmuffs to

all workers

• Entire quantity of hazardous waste will be handled and disposed as per Hazardous

& Other Waste (Management & Trans-boundary Movement) Rules, 2016.

• Direct and indirect employment opportunities will have positive impact

EIA/EMP OF SARDA ENERGY AND MINERALS LIMITEDDISCLOSURE OF CONSULTANTS ENGAGED

PECS, Nagpur 146

CHAPTER 12

DISCLOSURE OF CONSULTANTS ENGAGED

12.0 INTRODUCTION

The EIA/EMP report for “Sai Inductomelt Pvt.Ltd” at Village Mandhar, Raipur

Chhattisgarh”, has been prepared by Pollution and Ecology Control services (PECS),

Nagpur accredited by QCI/NABET for preparing EIA/EMP reports in 10 major sectors,

including “Metallurgical industries (ferrous & non-ferrous) – both primary and

secondary” vide certificate no. NABET/EIA/1720/RA 0101 dated 07.09.2018. This

certificate is valid up to 15.11.2020. The details of sectors accorded to PECS under the

QCI-NABET scheme for accreditation of EIA consultant organization is given below:

Table 12.1 Details of sectors accorded to PECS under the QCI-NABET scheme for

accreditation of EIA consultant organization


PECS, Nagpur 147

12.1 PROFILE OF EIA/EMP CONSULTANT

PECS established and NABET accredited Environmental Consultant and Engineers based

in Nagpur and working since last 28 years. We are having tie up with well-equipped

laboratory for field studies as well as for testing and monitoring of Air, Water, Noise,

Soil and other related activities of Environment of Mines and Industries.

PECS is having a qualified and experience staff comprising of trained professionals in

their respective fields. PECS is backed by the services of retired scientists form National

Environmental Engineering Research Institute (NEERI) and retired Engineers of Thermal

Power Stations and Coal India Ltd. A team of experience Geologists is with us for

various surveys. PECS is also having a computers and software facility for modeling

purposes.

PECS is specialized in Environmental Services as mentioned below:-

o Environmental Impact Assessment (EIA)

o Environmental Risk Analysis and Assessment.

o Monitoring of Air, Water, Noise and Soil.

o Preparation of Documents for Clearance of Forest Land.

o Environmental Management Plan.

o Environment Audit Statement.

o Disaster Management Plan.

o Study and Treatment of Industrial Effluents.

o Design, Engineering and Commissioning of Effluent Treatment Plant, SewageTreatment Plant and Water Treatment Plant.

o Designing, Engineering and Commissioning of Air Pollution Control Devices.

o Dust Suppression.

o Dealing with Solid Waste Management.


PECS, Nagpur 148

o Planning on Waste Recycle, Reuse and Control

o Follow up with Explosive Department and IBM, HQ, Nagpur.

o Preparation of “ON SITE” and “OFF SITE” emergency plans and health survey.

o Geo Hydrological, Ground and Surface Water Survey and Transit Survey.

o Rain water harvesting including design and execution.

o Clearing of Project form Ministry of Environment and Forest, New Delhi(MOEF),) and State Pollution Control Board (SPCB)/SEIAA.

PECS has completed more than 50 projects in EIA sector successfully since its

incorporation.


PECS, Nagpur 149

Fig. 12.1: NABET Accreditation Certificate