M/s. SARDA METALS & ALLOYS LIMITED

EXPANSION OF FERRO ALLOY PLANT, CAPTIVE POWER PLANT AND INSTALLATION OF STEEL MELTING SHOP,

MINERAL FIBRE PLANT

At

APIIC Industrial Park, Kantakapalli (V), Kothavalasa (M), Vizianagaram (Dist.), Andhra Pradesh.

March -2022

PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sarda Metals & Alloys Limited

APIIC Industrial Park,

Kantakapalli (V), Kothavalasa (M),

Vizianagaram (Dist.),

Andhra Pradesh - 535240

B.S. Envi-Tech (P) Ltd.,

Secunderabad – 500 017

Accreditation No: NABET/EIA/1922/RA0174

NABL Certificate No: TC-5233

Report No: BSET/FEIA/2021-22/22

FINAL ENVIRONMENTAL IMPACT ASSESSMENT REPORT (BASELINE PERIOD: WINTER SEASON – 2020-21)

By

M/s. SARDA METALS & ALLOYS LIMITED


MINERAL FIBRE PLANT

At


March-2022

PROJECT PROPONENT Environmental Consultant

Sarda Metals & Alloys Limited

APIIC Industrial Park,

Kantakapalli (V), Kothavalasa (M),

Vizianagaram (Dist.),

Andhra Pradesh - 535240

B.S. Envi-Tech (P) Ltd.,

Secunderabad – 500 017

Accreditation No: NABET/EIA/1922/RA0174

NABL Certificate No: TC-5233

Report No: BSET/FEIA/2021-22/22

FINAL ENVIRONMENTAL IMPACT ASSESSMENT REPORT (BASELINE PERIOD: WINTER SEASON – 2020-21)

By


TABLE OF CONTENTS

TABLE OF CONTENTS

Para No. Content Page No.

Executive Summary i - xxiii

Chapter - 1: INTRODUCTION

1.1 Purpose of the Project 1

1.2 Identification of the Project 2

1.3 Project Proponent - Sarda Metals & Alloys Ltd. 4

1.4 Brief Description of Project 4

1.4.1 Nature and Size 4

1.4.2 Location of the Project Site 5

1.4.3 Project Cost 7

1.5 Importance to the Project 7

1.6 Scope of the Study 13

1.7 Status of Litigations 14

1.8 Compliance of Terms of Reference 14

CHAPTER – 2: PROJECT DESCRIPTION

2.1 Type of Project 31

2.2 Need for the Project 31

2.3 Advantages of the Project 32

2.4 Location of the Project 32

2.5 Size and Magnitude of Operation 34

2.6 Requirements of the Project 39

2.6.1 Raw Material 39

2.6.1.2 Mode of Transport of Raw Material 40

2.6.2 Land 40

2.6.3 Water 40

2.6.4 Power 41

2.6.5 Man Power 42

2.6.6 Schedule of Implementation 42

2.6.7 Plant Layout 42

2.6.8 Colony 44

2.7 Green Belt 44

2.8 Social Infrastructure 45

2.9 Connectivity (Traffic and Transportation Road, Rail/Metro/

Waterways etc.) 45

2.10 Manufacturing Process 45

2.10.1 Existing Plant Facilities 45

2.10.2 Ferro Alloys Plant 46

2.10.3 Steel Melting Shop with CCM and Hot Charging Rolling Mill 52

2.10.4 Briquetting Plant 56

2.10.5 Mineral Fibre Plant 58

2.10.6 Captive Power Plant 60

2.11 Mitigation Measures Incorporated in the Project to Comply with 64


Environmental Standards

2.12 Assessment of New & Untested Technology for the Risk of

Technological Failure 65

CHAPTER – 3: DESCRIPTION OF ENVIRONMENT

3.1 Study Area 66

3.1.1 Activities in Study Area 66

3.2 Study Period 66

3.3 Scoping of Baseline Study with Project Activities 66

3.4 Baseline Environment 68

3.5 Micro Meteorology 68

3.5.1 Regional Meteorology - Visakhapatnam 68

3.5.2 Study Area – Winter 2020-21 69

3.6 Ambient Air Quality 70

3.6.1 AQQ Stations Selection Criteria 70

3.6.2 Ambient Air Quality Status of the Study Area 73

3.6.3 Interpretation of Ambient Air Quality 75

3.6.4 Stack Emission Monitoring 77

3.7 Noise Environment 77

3.7.1 Noise Levels in Study Area & Plant Site 79

3.7.2 Source Noise Levels – Plant Area 79

3.8 Water Environment 80

3.8.1 Drainage Pattern 80

3.8.2 Hydro Geology and Ground Water Potential 80

3.8.3 Water Quality of The Study Area 84

3.8.4 Ground Water Quality 84

3.9 Land Environment 87

3.9.1 Physiography 87

3.9.2 Geology 87

3.9.3 Landuse Pattern of Study Area 89

3.9.4 Soils of Study Area and Soil Quality 89

3.9.5 Agriculture - Crops 94

3.10 Biological Environment 94

3.10.1 Methodology of Flora-Fauna Studies 94

3.10.2 Habitats 97

3.10.3 Presence of Sensitive Areas 98

3.10.4 Flora 98

3.10.5 Phyto - Sociological Studies 99

3.10.6 Endangered Flora 100

3.10.7 Fauna 100

3.10.8 Endangered Fauna 102

3.10.9 Schedule-I Species 102

3.11 Socio Economic Environment 103

3.11.1 Project Site 103

3.11.2 Socio Economic Profile – Nearest Village/Jurisdiction Village 103


3.11.3 Vizianagaram 104

3.11.4 Socio Economic Profile of the Study Area 105

3.11.5 Population 106

3.11.6 Sex Ratio 107

3.11.7 SC & ST Population 107

3.11.8 Literacy 108

3.11.9 Economic Pattern and Livelihood 108

3.11.10 Languages and Religion 110

3.11.11 Primary Survey 110

3.11.11.1 Sample Size 110

3.11.11.2 Field Work 110

3.11.11.3 Social Profile of Respondents 111

3.11.11.4 Economic Profile 112

3.11.11.5 Benefits and Amenities 115

3.11.11.6 Conclusion and Recommendations 119

CHAPTER – 4: ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION

MEASURES

4.0 Introduction 126

4.1 Quantification of Environmental Impacts and Mitigation

Measures 130

4.1.1 Quantification of Impacts 131

4.2 Impacts and Mitigation Measures During Construction Phase 136

4.3 Impacts and Mitigation Measures During Operation

Phase 137

4.3.1 Air Environment 138

4.3.1.1 Emission Sources 138

4.3.1.1.1 Ferro Alloy Plant 139

4.3.1.1.2 Steel Melting Shop 139

4.3.1.1.3 Rolling Mill 139

4.3.1.1.4 Mineral Fibre Plant 139

4.3.1.1.5 Captive Power Plant 140

4.3.1.2 Simulation Model for Estimation of Ground Level

Concentrations – AERMOD 141

4.3.1.3 Meteorological Data 142

4.3.1.4 Estimation of Ground Level Concentrations 142

4.3.1.5 Post Project Scenario 142

4.3.1.6 Air Pollution Control Measures 143

4.3.1.6.1 Fugitive Emission Control 148

4.3.1.6.2 Power Plant 149

4.3.1.6.3 Fugitive Dust Protection for Workers 149

4.3.2 Noise Environment 150

4.3.2.1 Noise Pollution Control Measures 150

4.3.3 Water Environment 152

4.3.3.1 Water Consumption 152


4.3.3.2 Wastewater Generation Treatment and Disposal 152

4.3.3.2.1 Waste Water Management 152

4.3.3.2.2 Waste Water Treatment Plant 155

4.3.3.3 Treatment and Utilisation of Wastewater 155

4.3.3.4 Rain Water Harvesting 155

4.3.4 Solid Waste Management 156

4.3.5 Greenbelt Development Plan 159

4.3.5.1 Miyawaki Plantation 160

4.3.6 Socio Economic Impact and Measures 163

4.3.7 Occupational Safety & Health Management 164

4.3.7.1 Occupational Health Centre 164

4.4 Energy Conservation 165

CHAPTER – 5: ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)

5.1 Selection of Alternative Technology 166

5.1.1 Selection of Technology for Mineral Fibre Plant 166

5.1.2 Selection of Technology for Flue Gas Desulphurization (FGD)

For Captive Power Plant 167

5.2 Selection of Site 169

CHAPTER – 6: ENVIRONMENTAL MONITORING PROGRAMME

6.1 Environmental Monitoring Program 170

6.2 Environmental Laboratory 171

6.3 Budget for Environmental Monitoring Program 171

CHAPTER – 7: ADDITIONAL STUDIES

7.1 Public Consultation 174

7.2 Risk Assessment, On-Site Emergency Preparedness & Disaster

Management Plan 187

7.2.1 Risk Assessment - Major Laws Relating to Occupational Safety

& Working Conditions Management 187

7.2.2 Other Related Legislations on Safety, Health and Environment 188

7.2.3 Major Hazards in Steel Plant 188

7.2.4 Main Plant 189

7.2.5 Risk Analysis of M/s. Sarda Metals & Alloys Limited 189

7.2.5.1 Hazards Consideration 189

7.2.5.2 Fire Hazard 190

7.2.5.3 Explosion Hazard 190

7.2.5.4 Bursting of Pipe Lines 190

7.2.5.5 Release of Gases / Dusts 190

7.2.6 Hazardous Materials Stored in Factory 191

7.2.7 Consequence of Major Hazards from Storage 191

7.2.8 Consequence of Major Hazardous from Processing 192

7.2.9 Description of Hazardous Operation/Process/Area/ Materials

in SMAL 192


7.3 On Site & Offsite Emergency Preparedness and Response Plan

of SMAL

220

7.4 Traffic Study – Impact Due to Transportation of Raw Materials

and Finished Products

221

CHAPTER – 8: PROJECT BENEFITS

8.1 Project Benefits 225

8.2 Social Welfare Measures 226

CHAPTER – 9: ENVIRONMENTAL COST BENEFIT ANALYSIS 234

CHAPTER – 10: ENVIRONMENAL MANAGEMENT PLAN

10.1 Environmental Management Plan 235

10.2 Organisation Structure of EHS Department 235

10.3 Environmental Policy 236

10.3.1 Transparency in the Implementation of Environmental Policy 236

10.3.2 Audit & Review 238

10.3.3 Non-Conformity, Corrective Action and Preventive Action 239

10.3.4 Management Review 239

10.4 Budget for Implementation of Environmental Management Plan 239

CHAPTER – 11: SUMMARY & CONCLUSIONS

11.1 Project Description 241

11.2 Requirements of the Project 243

11.3 Manufacturing Process 244

11.4 Description of Environment 246

11.5 Anticipated Environmental Impacts and Mitigation Measures 249

11.5.1 Air Environment 249

11.5.2 Air Pollution Control Measures 249

11.5.3 Noise Environment 254

11.5.4 Water Environment 255

11.5.5 Solid Waste Management 256

11.5.6 Greenbelt Development 258

11.6 Environmental Monitoring Programme 258

11.7 Environmental Management Plan 259

11.8 Project Benefits 260

11.9 Public Hearing 261

11.10 Conclusion 263

Chapter – 12: DISCLOSURE OF CONSULTANTS 265

LIST OF FIGURES

Fig. No. Title Page No.

Fig-1.1 Location Map of Plant Site

Fig-2.1 Key map 33

Fig-2.2 Toposheet showing all Corner Coordinates of the Plant Site 35

Fig-2.3 Toposheet showing 10 km radius 36

Fig-2.4 Photographs of the Project Site 37

Fig-2.5 Google Earth Imagery of the Project Site 38

Fig-2.6 Plant Layout 43

Fig-2.7 Process flow diagram of Ferro Alloys 53

Fig-2.8 Process flow diagram of Steel Melting Shop 57

Fig-2.9 Process flow diagram of Briquetting Plant 58

Fig-2.10 Process flow diagram of Mineral Fibre Plant 59

Fig-2.11 Process flow diagram of Captive Power Plant 63

Fig-3.1 Wind Rose – 8 Hourly Interval 71

Fig-3.2 Wind Rose – 24 Hours 72

Fig-3.3 Ambient Air Quality Monitoring Stations 74

Fig-3.4 Noise Recording Stations 78

Fig-3.5 Drainage Pattern 81

Fig-3.6 Water Sampling Locations 85

Fig-3.7 Digital Elevation Model of 10 Km Radius of Plant Site 88

Fig-3.8 Satellite Imagery of the Study Area 90

Fig-3.9 Land use and Land Cover Map of the Study Area 91

Fig-3.10 Soil Sampling Locations 92

Fig-3.11 Status of Floral Species 96

Fig-4.1 Predicted 24-Hourly Average Ground Level Concentrations of

PM10 (µg/m3

) 144


Sulphur Dioxide (µg/m3

) 145


Oxides of Nitrogen (µg/m3

) 146

Fig-4.4 ETP flow diagram of CPP 154

Fig-4.5 Plant Layout including Green Belt 161

Fig-7.1 Photographs of Public Hearing 174

Fig-8.1 Photographs Showing Implementation of CSR Measures 231

Fig-8.2 CSR Expenditure 232

Fig-10.1 EHS Organogram 235

Fig-10.2 Environmental Policy 237

LIST OF TABLES

Table No. Title Page No.

Table-1.1 Configuration of the Plant as per the approved Environment

Clearance 2

Table-1.2 Production Capacity 3

Table-1.3 Existing and Proposed Production Capacities and Expansion

Activity 5

Table-1.4 Salient Locational Features of the Plant 6

Table -1.5 Compliance of Terms of Reference 15 - 33

Table-2.1 Details about the Project 34

Table-2.2 Proposed Expansion of Ferro Alloys, Steel Melting and

Captive Power Plant 34

Table-2.3 Annual Raw Material Quantity Existing and Proposed 39

Table-2.4 Land Breakup - Area (Ha) 40

Table-2.5 Water Requirement for the Project 41

Table-2.6 Present Power Requirement 41

Table-2.7 Proposed Power Requirement 41

Table-2.8 Project Implementation Schedule & Project Cost 42

Table-2.9 Reverse Air Bag House Technical Data 51

Table-3.1 Scoping of Baseline Environmental Parameters 67

Table-3.2 Regional Meteorology – Visakhapatnam District 69

Table-3.3 Summary of Wind Pattern -Winter Season, 2020-21 70

Table-3.4 Ambient Air Quality Monitoring Stations 73

Table-3.5 98th

Percentile Values of AAQ Monitoring 73

Table-3.6 Noise Monitoring Stations 79

Table-3.7 Spot Noise Levels at Various Sources 80

Table-3.8 Ground Water Balance of The Study Area 83

Table-3.9 Water Sampling Locations 84

Table-3.10 Summary of Ground Water Quality in the Study Area 86

Table-3.11 Level–II LandUse/ LandCover Categories with in Study Area 89

Table-3.12 Soil Sampling Stations 93

Table-3.13 Summary of Soil Quality 93

Table-3.14 Sampling Locations in Project Area 95

Table-3.15 Details of Forest Areas in Study Area 97

Table-3.16 List of Mammals Observed/Reported in Study Area 100

Table-3.17 List of Reptiles and Amphibians in Study Area 101

Table-3.18 Villages in the Study Area 106

Table-3.19 Population, Household Size & Sex Ratio 106

Table-3.20 Work Participation: Male & Female 110

Table-4.1 Compliance of the CREP 127

Table-4.2 Matrix of Impacts 131

Table-4.3 Matrices of Quantification 132

Table-4.4 Emission Details 138

Table-4.5 Overall Scenario Within Study area 143

Table No. Title Page No.

Table-4.6 Water Balance (Existing + Proposed) 152

Table- 4.7 Water and Waste Water Inventory 153

Table- 4.8 Chemical Composition of Wastes 158

Table- 4.9 Hazardous Waste Generation 159

Table-6.1 Plan for Monitoring of Environmental Parameters 172

Table-6.2 Proposed Budget for Implementation of Environmental

Monitoring Program 173

Table-7.1 Summary of Public Hearing Issues and Response 175

Table-7.2 Public Hearing Commitments and Action Plan And Budget 183

Table-7.3 Hazardous Materials stored in factory 191

Table-7.4 Coal Handling Plant Operations 192

Table-7.5 Ferro Alloy Plant Operations 194

Table-7.6 Power Plant Operations 208

Table-7.7 Steel Melting Shop (SMS) 217

Table-8.1 Implementation of CSR Measures 228

Table-10.1 Proposed Budget Allocation for Environmental

Management Plan 240

LIST OF ANNEXURES

Annexure No Title Page No.

Annexure-1A Terms of Reference approved by MoEF&CC 266 - 273

Annexure-1B Earlier EC Dated 26.11.2009 274 - 280

Annexure-1C Amendment to EC Dated 04.06.2015 281 – 283

Annexure-1D Amendment to EC Dated 02.07.2018 284 – 295

Annexure-1E CFE for the Briquetting Plant 296 – 303

Annexure-1F Consent to Operate of the existing Plant 304 – 323

Annexure-1G Compliance of Consent to Operate 324 – 373

Annexure-1H Certified compliance of the EC conditions by

Integrated Regional Office, Vijayawada, A.P.

374 – 402

Annexure-2A Water Permission Letter 403

Annexure-3A Ambient Air Quality Data 404 – 412

Annexure-3B Water Quality Data 413 – 417

Annexure-3C Soil Analysis Data 418 – 425

Annexure-3D Flora & Fauna of the Study Area 426 – 433

Annexure-3E Authenticated DFO Letter 434 – 435

Annexure-3F Socio Economic Data 436 – 442

Annexure-4A Meteorological Data 443 – 457

Annexure-4B 25 High 24-Hourly Average Ground Level

Concentrations of PM10, SO2 and NO2

458 – 463

Annexure-4C

The trace metals analysis for Fly ash, Granulated

Silico Manganese Sample and GCP Dust done by

Chennai Test Laboratory Pvt. Ltd.

464 – 466

Annexure-4D The Health data of Workers 467 – 478

Annexure-7A Paper advertisements (Telugu & English) 479 – 480

Annexure-7B Proceedings of the Public Hearing 481 – 578

Annexure-7C

Speaker wise and written representations with

Management Response, Action Plan, Budget

Allotment and time of Completion

579 – 628

Annexure-7D Emergency Response plan 629 – 661

Annexure-7E Traffic Study 662 – 726

Annexure-12A NABET Accreditation of B. S. Envi-Tech (P) Limited 727

Annexure-12B NABL Accreditation 728

Annexure-12C MOEF&CC Recognition of Laboratory 729 - 731

EXECUTIVE SUMMARY


MINERAL FIBRE PLANT

At


EXECUTIVE SUMMARY

By


i

EXECUTIVE SUMMARY

1.1 PROJECT DESCRIPTION

M/s Sarda Metals & Alloys Ltd. (SMAL) is promoted by Raipur, CG based

Sarda Group. The Groups’ flagship company Sarda Energy & Minerals

Ltd. (SEML) is listed on BSE and NSE with interests in Steel, Ferro Alloys,

Power (hydro and thermal), Mining, Investments and Horticulture. SMAL

is a 100% wholly owned subsidiary of SEML.

SMAL is operating a Ferro Alloy Plant and Captive Power Plant near

Kantakapalli Village, Kothavalasa Mandal, Vizianagaram district,

Andhra Pradesh having the following units.

a) Ferro Alloys - 1,00,000 TPA

b) Captive Power Plant 1x80 MW

c) Briquetting Plant-1,05,000 TPA

SMAL proposes to undertake expansion of the facilities by adding the

following units.

❖ Ferro Alloys plant - 1,50,000 TPA,

❖ Steel Melting Shop (IF, TMT & WRM) - 3,00,000 TPA

❖ Mineral Plant – 1,50,000 TPA

❖ Captive Power Plant with PF Boiler - 1X80MW

SMAL has earlier received Environment Clearance from MoEF&CC,

Government of India vide letter no. J-11011/164/2009-IA II (I) dated

26.11.2009 and subsequently amendment to the same on 04.06.2015.

The Configuration of the Plant as per the approved Environment

Clearance is as below:

CONFIGURATION OF THE PLANT AS PER THE APPROVED ENVIRONMENT CLEARANCE

S.No Facilities Phase I Phase II Phase III

Unit 1

1 Ferro Alloys 1x 33 MVA

(75,000 TPA)

1x 33 MVA

(75,000 TPA)

---

2 Sinter Plant 1X24 M2

(1,25,000 TPA)

------ ---

Unit -II

3 Thermal Power Plant 1 x 80 MW 1 x 80 MW 1 x 80 MW

4 Coke Oven with Stamp

Charging

2,00,000 TPA -- 2,00,000 TPA

5 Sponge Iron Plant -- 2 x 500 TPD

(3,00,000 TPA)

--

6 Blast Furnace (1x350 m3) --- --- 2,50,000 TPA

ii


7 Steel Melting Shop

Induction Furnace

(5x15T)

Arc Furnace (5x 40T)

--- --- 2,50,000 TPA

2,50,000 TPA

8 Rolling Mills --- --- 4,50,000 TPA

9 Iron Ore Crushing Plant --- --- 6,00,000 TPA

10 Pellet Plant --- --- 6,00,000 TPA

11 Railway Siding --- --- --

SMAL did not implement the integrated steel plant and obtained and

amendment from MoEF&CC. MoEF&CC issued amendment dated

02.07.2018.

SMAL has implemented the following facilities and commenced the

operation in the year 2013.

S. No Facilities Configuration Amendment Capacity

1 Ferro Alloys 2x33 MVA 1,00,000 TPA

2 Thermal Power Plant 1x80 MW 1x80 MW

Briquetting Plant does not require the Environmental Clearance and is

now categorized as Green Category as per CPCB guidelines. Hence

CFE for the Briquetting Plant of capacity 1,05,000 TPA was obtained by

SMAL.

The summary of the Production capacities (Post Expansion) is given

below.

PRODUCTION CAPACITY (Post Expansion)

Sl.No Plant Unit Existing

Proposed

Total capacity

after expansion

1 Ferro Alloys

TPA

1,00,000 1,50,000 2,50,000

2 Steel Melting Shop (Induction

Furnace (IF), Continuous

Casting Machine (CCM), Re-

Heating Furnace, TMT & Wire

Rod Mill (WRM)

-- 3,00,000 3,00,000

3 Mineral Plant -- 1,50,000 1,50,000

4 Briquetting Plant 1,05,000 -- 1,05,000

5 Coal Based Captive Power

Plant

MW 1 x 80

1 x 80

2 x 80

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1.2 REQUIREMENTS OF THE PROJECT

The major raw material required for different products are Manganese

Ore, Coal, Coke, Fe, Mn Slag, Quartz, Dolomite, Coal, Scrap, DRI, Ferro

Alloys, Aluminum, Fluxes, GCP Dust, Mn Ore Dust, Binder, Additive, Coke

Fines, SiMn Slag.

The proposed activities will be within the existing project site. The total

land area for the project is 280.96 cares in village Kantakapalli. Survey

No.179/4,181,182,183/1to20,185,186,187,188/1&2,190,191,192/1to3,193,1

94,195,196, 197,198,199,200,201,202 & 203.

Present activities are covered under 54.12 Acres, Green Belt in 93.23

acres and area available for future expansion is 133.61 Acres. No

additional land is required for the expansion project.

The Present water consumption of the plant is 980 m3/day and is

supplied by Greater Visakhapatnam Municipal Corporation (GVMC).

The total water requirement after expansion will be about 2700 m3/day.

SMAL has obtained in principle permission for 2700 m3/day water drawl

Lr.No.53/2012-13/E.II (WS-M) dated 16.01.2013.

The plant has already commissioned a 220 kV GIS substation. This will

supply the grid power to the plant along with the captive generation

from the existing 1 X 80 MW CPP and the proposed 1 X 80 MW CPP.

2 X 250 kVA diesel fired DG sets was installed as standby power supply

units. These DG sets will be operated only when there is a normal power

supply failure. HSD will be used for power generation in DG Sets.

SMAL has already provided employment to about 865 people (direct

and indirect) and the proposed expansion will provide employment

about 1658 people (direct and indirect). Thus, the total direct

employment will be 2523 (direct and indirect) post expansion and

priority to local people will be given.

There is no residential area/ colony proposed in the plant area as many

of the staff come from Kothavalasa and Vizag. The company had

provided Transport facilities for two/three shift operation depending

iv

upon the Production schedule. A full-fledged canteen facility also has

been provided for the benefit of the employees and other contractual

workers.

11.3 MANUFACTURING PROCESS

FERRO ALLOYS PLANT

Two types of Manganese alloys viz. Ferro Manganese and Silico

Manganese are produced in submerged arc furnace. The type of raw

materials and consumption for producing Ferro Manganese and Silico

Manganese alloys are almost same. The difference is only in chemical

composition of alloy. To produce FeMn/SiMn Manganese ore,

reductants like Coke & Coal and fluxes like Dolomite & Quartz are

blended in suitable proportion and fed into submerged arc furnace.

The energy required for smelting is provided from electricity passing

through three Soderberg electrodes that are submerged in the raw

material charge. The Electrical energy is converted into heat energy

and smelting will take place in the furnace with a bath at the

temperature of 1600°C-1700°C.

STEEL MELTING SHOP WITH CCM AND HOT CHARGING ROLLING MILL:

Sarda Metals & Alloys Limited proposes to install 4 x 22T induction

furnaces for producing into liquid steel having production capacity of

300000 TPA.

The plant will produce steel in the form of billets & TMT Bars through (IF) -

Continuous Casting Machine (CCM) - Rolling Mill (RM) route. Steel

making will be done using induction furnaces. route. Steel making will

be done using induction furnaces.

The Process is divided into three main steps.

❖ Induction Furnace

❖ Continuous Casting

❖ Direct rolling

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BRIQUETTING PLANT

The objective of setting up the briquette plant is to fully recycle

Baghouse Dust from Ferro alloys plant and Steel Melting shop along

with Manganese ore fines & Coke fines to form hard briquettes with

some use of binders like cement, bentonite by the process of extrusion.

In this process first fine material is mixed manually on ground and fed

by payloader onto the hopper. From hopper material is conveyed

through belt conveyors to Pug mill. Binders are added before raw

material is taken into pug sealer to increase the strength and plasticity

of the extruded product.

Finally, from a mixture of -3mm ore fines and coke fines, bag house dust

and binders such as cement bentonite 20mm diameter solid briquette

is extruded. It is cured for 3-4 days in an open area after which it

becomes strong, gaining enough mechanical strength to withstand the

impact during transferring through belt conveyors to furnace.

MINERAL FIBER PLANT

Over the last 2-3 years we have collaborated with the Environmental

studies Department of Peking University, China and developed a

process to convert the Silico Manganese slag into mineral fiber. Hot

Silico Manganese slag at 1400ºC will be sent to a specialized furnace to

adjust the properties of slag.

Mineral fiber wool is a name for fiber materials that are formed by

spinning or drawing molten minerals such as SiMn slag.

CAPTIVE POWER PLANT

Sarda Metals & Alloys Ltd has a captive power plant having installed

capacity of 80MW equipped with a STG (Steam Turbine Generator)

and PC (Pulverized Coal) fired boiler of steam capacity 309 TPH at

operating pressure and temperature of 105 kg/cm2 and 540 Deg c

respectively. Steam is produced in boiler by converting chemical

energy of fuel to heat energy of the system. The heat energy of steam

converts to kinetic energy in Turbine and where it converts to Electric

energy through Electric Generator.

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The two major inputs to boiler for production of steam is coal as Prime

Fuel & DM water as makeup water. The coal used in boiler is mainly

from Indonesia / South Africa / India and fed through Coal Handling

plant of capacity 500 TPH. Raw water supplied from GVMC is treated

in the DM plant of capacity 15m3/hr and fed to the boiler for

generation of the steam.

The power generated from Captive power plant is consumed by

various units of SMAL.

The flyash and bottom Ash is disposed to local vendors.

1.4 DESCRIPTION OF ENVIRONMENT

The study area considered for baseline study covers 10 km radius of

project site of Sarda Metals & Alloys Limited (SMAL) located at APIIC

Industrial Park, Kantakapalli Village, Kothavalsa Mandal, Vizianagaram

District, Andhra Pradesh.

The various activities in the study area which reflect the baseline

environmental quality of various environmental components are given

below:

a. There are no industries in the study area except for existing plant

of the project proponent.

b. Vehicular Movement

c. Rural activities in villages

d. Agricultural Activities

Major Habitation is Alamanda at 5.3 km (NNE).

Pedda Gedda is a nalla located at a distance of 8.7 km in SE. This is

seasonal. Similarly, there are many dry tanks in the study area.

Agricultural area covers about 55.43 %. Depending on the availability

of water source, agriculture is carried out with bore wells, streams, river

and rainfed in the study area.

The study period considered is Winter Season, 2020-2021, covering the

months of December’20, January’2021 and February’2021.

Maximum temperature recorded is 36.40C in the month of February

with minimum of 11.30C in the month of December. The predominant

vii

wind direction is from NE-ENE-E Sector accounting to 33.51 % with calm

wind for 9.44 % and wind from other directions accounting to 57.05%.

Ambient air quality monitored at eight locations showed all values well

within the limits of NAAQ standards specified for Industrial, Rural,

Residential & Other areas. The overall 98th percentile values of ambient

air quality in the study area are given below:

AIR QUALITY IN THE STUDY AREA (All the values are in g/m3)

S. No Pollutant Range of values

(98th percentile)

NAAQ Standards

for Residential areas

1 PM10 43.7 – 65.6 100

2 PM2.5 25.6 – 32.3 60

3 SO2 13.4 – 16.2 80

4 NOx 15.6 – 17.4 80 Note: CO values are observed less than 1 ppm during study period.

Noise levels recorded at plant showed Day equivalent and night

equivalent noise levels of 71.8 dB (A) and 67.4 dB (A) respectively

which are within the limits of National Ambient Air Quality Standards

w.r.t Noise for industrial area.

Day equivalent and night equivalent noise levels in the villages were

recorded and found to be in the range of 51.6 - 54.3 dB (A) and 41.3 -

44.0 dB (A) respectively which are within the limits of National Ambient

Air Quality Standards w.r.t Noise for residential area. Maximum levels of

noise recorded are due to local activities in the villages and movement

of vehicles.

Water samples collected from 8 ground water samples showed all

parameters of ground water samples well within the acceptable limits

of IS 10500:2012 except for Total Dissolved Solids, but they are well

within the permissible limits of IS 10500:2012.

There are no rivers in the study area. However, there are many dry

tanks and Geddas (nalla or streams) which are not perennial. Surface

water samples could not be collected during the study period since

there was no water in tanks and Geddas.

Eight soil samples were collected from various locations within study

area and analysed to study the fertility.

viii

The fertility status of the soil samples was assessed based on NPK and

Organic carbon content along with other parameters.

❖ Soil of Plant Site, Kovvada, Bhimali, Kantakapalli, Kothavalasa

Dabala, and Alamanda villages is having good fertility

❖ Soil of Sunkarapalem and Relli, indicated medium fertility

The project area falls in Deccan biogeographic zone (6) and Deccan

plateau south (6A) biotic province. The natural vegetation in the study

area consists mainly of dry deciduous to xerophytic and scrub types

with stunted growth.

Two types of forest were observed in the study area namely Southern

Tropical Dry Deciduous Forest and Dry Deciduous Shrub Forest.

The study area is part of Vizianagaram District in Andhra Pradesh and

the list of forest areas around the project within study area is given

below.

DETAILS OF FOREST AREAS IN STUDY AREA

S.

No

Location

code Name of the location

Distance from

project site

(in km)

Direction

from project

site

1 F1 Advanapalem RF 1.3 E

2 F2 Muchcherla RF 6.9 ESE

On the basis of literature survey, from Red data books of Indian plants,

detailed list of rare and endangered plant genera of Vizianagaram

district of Andhra Pradesh reveals that there are no endangered plant

species observed or reported in the study area. There are no

endangered species in study area as per IUCN Red Listed Categories.

There are no Schedule - I species in the study area as authenticated by

DFO, Visakhapatnam.

Socio economic status of the study area is found to be moderate. The

primary survey has brought out the following issues which helps in

formulating the CSR plan.

• Low levels of literacy

• Dependence on ground water for drinking water and the

associated quality issues

• Non-availability of underground drainage facility

• Improvement of health infrastructural facilities

• Need for pucca roads

• Transportation facilities

ix

• Drainage system

• Drinking water facilities

• Skill development for women and adolescents

• Job opportunities for the youth

1.5 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

1.5.1 AIR ENVIRONMENT

Main pollutants emitted from the plant are particulate matter, sulphur

dioxide, oxides of nitrogen etc. from point sources and fugitive

emission. Air pollution emissions from all the units of proposed expansion

are quantified to estimate the impact in the study area.

The Overall Scenario with predicted concentrations over the baseline is

shown below.

OVERALL SCENARIO WITHIN STUDY AREA (g/m3)

CUMULATIVE GROUND LEVEL CONCENTRATIONS OF FERRO ALLOY PLANT AND

CAPTIVE POWER PLANT WITH FGD

24-Hourly Concentrations Particulate

Matter (PM10)

Sulphur dioxide

(SO2)

Oxides of

Nitrogen (NOx)

Baseline Scenario (max) 65.6 16.2 17.4

Predicted Ground level

Concentration (Max) 7.56 4.49 4.49

Overall Scenario 73.16{100} 20.69{80} 21.89{80}

NOTE: 1. Values in parenthesis are National Ambient Air Quality (NAAQ) standard limits specified for

Industrial, Residential, Rural and other areas.

2. The above Overall Scenario is based on post implementation of expansion without FGD

The ambient air quality values are not exceeding the stipulated

standards due to the expansion when the predicted values are

superimposed on the baseline value i.e., when the contribution of

expansion is added to the background air quality.

1.5.2 AIR POLLUTION CONTROL MEASURES

The air pollution prevention and control measures during operation

phase are described below

x

RAW MATERIAL HANDLING SYSTEM (RMHS)

1. Fugitive dust generated during raw material handling (unloading,

conveying, transporting, stacking etc), vehicular movement,

bagging and packing.

2. Unloading of trucks with material is carried out with great care by

avoiding dropping of material from height, wetting the material

by sprinkling water while unloading.

3. Asphalting or concreting the work area of the plant controls the

fugitive dust emissions.

4. The fugitive dust emissions due to iron ore fines, and dolomite fines

from the stockpile of raw materials and fines dump in the open

area will be controlled by dust suppression system by routine

water sprinkling.

5. The reductants coal storage is stored in the Coal storage shed.

The other fugitive dust emission sources such as material transfer

points, etc., will be equipped with dust extraction systems of

adequate capacity.

6. The raw material is transported through the closed conveying

system only.

DUST EXTRACTION SYSTEM

S.No Location / Shop Facilities

1

Raw material

handling area,

Material Transfer

points

Dust suppression system comprising of spray

nozzles, piping network, valves pumps,

instrumentation and controls, electrics,

water tank etc.

2 Electrical Arc Furnace

Gas Cleaning Plant

Dust extraction system comprising of

Reverse Air Bag House type bag filter,

Centrifugal fan and motor, duct work

including suction hoods, duct supports,

stack, duct hopper, rotary air lock valves,

etc

3 Ladle furnace Gas

Cleaning Plant






etc


Fugitive emissions-

Installation of

secondary de-

One bag filter proposed to install to reduce

fugitive emissions at steel melting area.

Water sprinkling will be done to suppress the

fugitive dust at raw material handling area,

xi


dusting facilities. pulverizing area, raw material feed area,

cooler discharge area and the product

processing area.

5 Captive Power Plant Dust extraction system comprising of pulse

jet type bag filter, Fly Ash Silo, Bottom Ash

handling system, Electro Static Precipitator,

centrifugal fan and motor, duct work


stack, dust hopper, rotary air lock valves,

etc.

ASH HANDLING SYSTEM

For handling of fly ash of the steam generator, dense phase,

pneumatic conveying system is provided. The ash collected in the

hoppers located in economizer, air pre-heated sections of SG and ESP

hoppers will be pneumatically conveyed and collected in a silo from

where the ash will be disposed off by road trucks for brick

manufacturing and selling to cement plants.

DRY BOTTOM ASH HANDLING SYSTEM

High dense ash from boiler furnace being transferred to clinker crusher

through belt conveyor. The same will be crushed in the clinker crusher

to reduce the size high dense ash in to small particles. These small

particles transferred to Dry bottom ash silo through post cooler chain

belt conveyor. The bottom ash is disposed to local vendors

FUGITIVE EMISSION CONTROL

Setting up of the new plant results in the increase of SPM

concentrations due to fugitive dust. Frequent water sprinkling in the

vicinity of the construction site would be undertaken and will be

continued after the completion of plant construction, as there will be

vehicular plying. It will be ensured that vehicles are properly

maintained to comply with exhaust emission requirements.

xii

Water spray arrangement is provided to spray water all-round the coal

stock piles to suppress the dust and to wet the coal while compacting

to minimize the dust nuisance and also arrest spontaneous combustion.

MEASURES TO CONTROL AIR POLLUTION DUE TO THE AIRBORNE DUST

In addition to the above control measures proposed during process

and transport operations, following steps will be taken up to prevent air

pollution due to air borne dust.

GREEN BELT DEVELOPMENT

1. Dense greenbelt in an area of 93.23 acres has been developed.

2. Tree plantation on both sides of internal roads used for

transportation in order to arrest dust

3. Miyawaki method of plantation has been done on trial basis in

an area of 0.51 acres in green belt zone. 6000 trees have been

planted in close vicinity.

WATER SPRINKLING

1. Water sprinkling along the haul road & dust generation points like

raw material handling area etc.

MAINTENANCE ACTIVITIES

1. Implementation of TPM in plant-Total Productivity Maintenance

2. Proper maintenance of Air Pollution Control Equipment

3. Regular maintenance of Vehicles and Machinery

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

5. Good housekeeping and proper maintenance.

POWER PLANT

SMAL has already implemented a Pulverized Fuel (PF) based captive

power plant of 80 MW capacity. A similar plant of 80 MW capacity will

be implemented as part of the expansion plan. MOEF & CC stipulated

has revised standards for Thermal Power Plants as per the Gazette

Notification S.O. 3305 (E) dated 07.12.2015. However, for power plant

which are being commissioned after 2017 have to comply with the

following emission standards.

xiii

ESP outlet dust concentration : 30 mg/Nm3

SOx : 100 mg/Nm3

NOx : 100 mg/Nm3

Mercury : 0.03 mg/Nm3

SMAL has prepared technoeconomic evaluation of FGD systems by

having discussions with Marsulex and Thermax. SMAL has short listed the

following technologies:

1. Dry/ semi dry scrubber flue gas desulfurization

2. Multifunctional catalyst for reduction of SOx emission. Catalyst as

oxidizing agent is being sprayed in combustion zone to reduce SOx.

For NOx control, SMAL will implement Low NOx Burners and Overfire Air

Dampers.

Adequate space for implementing the FGD system is provided in the

layout. SMAL will implement the same after finalizing the technology

option.

FUGITIVE DUST PROTECTION FOR WORKERS

Fugitive dust protection measures for workers is implemented at the

following active areas:

Name of the fugitive

dust generation

area

Dust protection

technology proposed

for workers

Dust reduction technology

proposed for workers

Raw material

unloading area,

handling area

Nose mask, face

shield, eye goggles,

ear plugs

Water sprinkling, scientific

handling of fines, and

dropping of raw materials,

wind break, sheet cover

Stock house, day

bins

Nose mask, face


ear plugs

Proper ventilation, insertable

bag filters, closed conveyors

Work shop and

other confined work

area inside plant

Nose mask, face


ear plugs

Proper ventilation, skylight,

exhaust fans, proper

illumination

Internal roads -- Concrete roads, daily

sweeping

1.5.3 NOISE ENVIRONMENT

The major source of noise pollution in the Ferro Alloy Plant and Captive

power plant is from the following:

xiv

• Rotating equipment like Fans, Blowers, Feed Water Pumps, TG

Boiler & Set, Compressors, Mill motors, etc.,

• Furnace operations, tapping, casting areas.

• Super heater safety valves.

• Steam vents in Power Plant

• Metal cutting shears in Rolling Mills.

• Noises arising from the mechanical machineries like crushers,

vibrating screens, air compressors etc. are the major sources of

noise

NOISE POLLUTION CONTROL MEASURES

The following measures are implemented to control the noise pollution.

❖ The rotating equipment is provided with acoustic enclosures /

barricades to keep the sound level of 85 to 90 dB. This includes

selection of packaged equipment with acoustic enclosures,

intake and outlet silencers, etc.

❖ The start-up vent, safety valve outlets are provided with silencers

to reduce the noise level to acceptable limits.

❖ The Hogging Ejector is provided with silencer. The turbine is

covered with acoustic enclosure. The buildings where turbines,

blowers and bare compressors are installed is provided with

soundproof walls separating the control rooms.

❖ The SMS and Rolling Mill generally produce noise level of up to

about 85 dB(A). Moreover, when the plant is running, most of the

operating people normally will be working in closed operator

cabins where noise levels get considerably reduced.

❖ The noise generated by the machinery is reduced by proper

lubrication of the machinery and equipment.

❖ Personnel protection measures like use of ear plugs/ earmuffs are

provided for people who work near the for checking / inspection

during operation.

❖ The noise levels in the workspace environment is monitored

periodically for taking corrective action as part of regular

maintenance schedule to reduce noise and vibrations in

generating sources.

❖ The green belt developed all along the boundary is helping in

reducing the noise emitted by various equipment in the plant.

xv

MEASURES TO PROTECT WORKERS FROM HIGH NOISE LEVELS

The following measures are implemented to protect the workers from

exposure to higher noise levels:

➢ Provision of protective devices like earmuffs/ear plugs

➢ Provision of soundproof chamber to workers working near high

noise generating machinery like compressors, turbine etc.

1.5.4 WATER ENVIRONMENT

The present water consumption of the plant is 980 m3/day. It is

estimated that 1720 m3/day is required for the proposed expansion.

The total water requirement post expansion will be 2700 m3/day.

The total effluent quantity expected from the proposed expansion is

estimated to be 498 m3/day.

Closed circuit water system is implemented in the existing Ferro alloys

and Captive power plant. Similarly, closed circuit water system will be

implemented for proposed Ferro alloys plant, Captive power plant,

Induction Furnaces, SMS & Rolling Mill. Hence the waste water

generation is minimal from the process. The waste water from the Ferro

Alloy Division and captive power plant will be sent to an ETP.

The treated effluent is/will be used for dust suppression and green

belt development within the premises after ensuring compliance with

CPCB/APPCB standards. Hence no treated waste water is discharged

outside the plant premises

RAIN WATER HARVESTING

SMAL has closed the existing rain water harvesting pond and is

developing a new rain water harvesting pond with a total capacity of

3,46,875 m3. The existing rain water harvesting pond is required to be

shifted to a new location in order to accommodate waste to wealth

mineral fiber plant project. The details of the new rain water harvesting

pond are given below:

xvi

Rain water Storage

Requirement L (m) B (m) D (m) AREA Acres VOLUME m3

RWH POND 185 125 15 5.71 3,46,875

SMAL will ensure containment of 100% rainwater and reuse in the plant.

1.5.5 SOLID WASTE MANAGEMENT

The following is the solid waste management plan.

FERRO ALLOY PLANT (EXISTING)

Furnace -1&2 Project Solid Waste Generation and Management (TPA)

Type of Waste Quantity, TPA Mode of Disposal

Slag from production

of Silico Manganese

1,20,000 Si Mn Slag will be provided to brick

manufacturers / Raw material for

Mineral Fiber Plant.

GCP Dust 3,000 As a raw material for Briquetting Plant

in making Briquettes.

Furnace -3, 4, 5, Project (Expansion)

Type of Waste

Quantity,

TPA Mode of Disposal

Slag from

production of Silico

Manganese

1,80,000 SiMn Slag will be provided to brick manufacturers

/ Raw material for Mineral Fiber Plant.

GCP Dust 4,500 Recycled and used as feed material for

Briquetting Plant.

STEEL MELTING SHOP (EXPANSION)

Slag from Induction

Furnace Quantity (TPA) Mode of Disposal

Dust Laden fumes from IF

Primary FES

3,640 Reused as feed material for

Briquetting Plant.


Secondary FES


Briquetting Plant.

Mill Scale from CCM &

rolling Mill

3,000 Reused as a raw material in the Ferro

Alloys plant

Slag from Induction

Furnace

31,880 Will be used as road Ballast/Road fill

material.

CAPTIVE POWER PLANT

Present capacity 1*80 MW


Ash from Power Plant 90,000 Being disposed to brick

Manufacturers.

xvii

Proposed capacity 1*80 MW


Ash from Power Plant 90,000 Will be disposed to brick

Manufacturers.

There is no waste generation from the proposed Mineral Fiber Plant or

the Briquetting Plant.

MINERAL FIBER PLANT

The SiMn slag will be used to create s used as an insulation material

called Slag wool. SMAL had collaborated with Environment Studies

Department of Peking University, China and developed a process to

convert the Silico Manganese Slag into mineral fiber.

The hot Silico manganese slag is fed into specialized furnace to

maintain the properties of the slag at 14000C through which a stream of

air is blown in to specialized furnaces. The molten material falls into the

fiberization devices which are in form of rotors and distributed in a thin

film on the surfaces by centrifugal force and form into Fiber.

BRIQUETTING PLANT

Dust from Ferro alloy plant & Steel melting shop along with Mn Ore fines

& Coke fines are recycled at briquetting plant to manufacture hard

briquette by mixing with binders & additives. In this process the waste

material generated in the entire plant is being recycled in the

briquetting plant and used as a feed material for Ferro Alloy Plant.

HAZARDOUS WASTE GENERATION AND UTILISATION

SMAL have been granted Hazardous wastes authorization for Used Oil.

Used Oil is being used for lubrication purposes in plant premises and

balance, is being sold to authorized agency as per APPCB.

HAZARDOUS WASTE GENERATION

S.

No.

Type of Hazardous

Waste

Hazardous

Waste Category

Quantity Disposal

1. Waste Oil/Spent Oil 5.1 224 ltrs/Month Stored in covered HDPE

Drums, used for

lubrication purpose &

will be given to APPCB

approved vendors.

xviii

1.5.6 GREENBELT DEVELOPMENT

The total plot area of the industry is 280.96 acres. As per CPCB guideline,

every industry should develop minimum 33% of total plot area as

greenbelt area. SMAL has already developed greenbelt on 93.23 Acres

or 3,77,288 Sq.m i.e., 33.18 %. Green belt shall be enhanced further on

continuous basis by planting additional trees to existing green belt.

17000 nos. trees have been planted and maintained by SMAL in

existing plant. Proposed green belt has been developed comprising

rows of varying height of trees of native species with thick foliage,

along the periphery as well as within the unit.

Trees like Neem, Bael tree, Bottle Brush, Golden showers, Kapok,

Mango, Sapota/Chiku, Nilgiri, Ashok, Umbrella tree, Indian Tulip Tree

etc., and varieties of local shrubs have been planted.

1.6 ENVIRONMENTAL MONITORING PROGRAMME

SMAL has budgeted an amount of Rs. 20.0 lakhs per annum for carrying

out regularly the monitoring of environmental parameters by a reputed

third party NABL Accredited Laboratory.

PROPOSED BUDGET FOR IMPLEMENTATION OF ENVIRONMENTAL MONITORING

PROGRAM (COST IN Rs. LAKHS)

S. No Parameters Recurring Cost

1 Ambient Air Quality Monitoring 2.0

Stack Emissions monitoring 2.0

Water quality 2.0

Waste water quality monitoring 1.0

Soil Quality 0.5

Noise Levels 0.5

Solid and Hazardous Waste Quality 2.0

2 Occupational Health and Safety

Provision of PPE and Medical Examination

10

TOTAL 20.0

1.7 ENVIRONMENTAL MANAGEMENT PLAN

The total capital cost of Environmental Management Plan which will be

phase wise incurred for the expansion of Ferro Alloy Plant and Captive

Power Plant is estimated to be about Rs. 17047 Lakhs (170.47 Crores)

with annual recurring cost of Rs. 1719.4 Lakhs (17.19 Crores). The budget

has been formulated in the following table:

xix

PROPOSED BUDGET ALLOCATION FOR ENVIRONMENTAL MANAGEMENT

PLAN (Rs. In Lakhs)

S.No Plant Capital Recurring

Per Annum

1 Furnace-3, 4 & 5 (Bag House, FD cooler,

Chimney) 8880 884

2

Mineral fibre plant-1 & 2 (Fume

extraction system - 2Nos, Chimney) 537 54

3

MFB-3 Nos (Fume extraction system-

2Nos) 1260 126

4 Steel Melting Shop (SMS) (Dust

extraction System, Bag Filter) 2938 294

5 Power plant (ESP, Chimney, Ash

Handling System, Dust Extraction

System, Dust Suppression System, FGD#)

3002 300

6 Continuous Stack Emission Analyser for

Furnace – 3, 4 & 5 120 12


CPP 40 4


SMS 40 4

10 Continuous Ambient Air Quality Station,

(1 No). $ 60 6

11 Environmental Monitoring Program and

Occupational Health Survey 0 20

12 Miyawaki Plantation (Greenbelt) 20 2

13 Rain Water Harvesting Ponds (1 & 2) 60 5

14 Storm Water Management 30 3

15 Effluent Treatment Plant 30 3

16 Three Modular Sewage Treatment Plant 30 2.4

Total 17047 1719.4 Note: $- SMAL has already implemented three Continuous Ambient Air Quality Monitoring Stations

(CAAQMS) at Main Gate, DM Plant and Coal Handling Plant. Budget has been provided to

implement one more CAAQMS during the proposed expansion.

#SMAL is evaluating the various FGD technologies. Suitable Budget for implementation of FGD

and NOx control will be provided in the implementation.

1.8 PROJECT BENEFITS

The project will have the following benefits:

ENVIRONMENTAL

❖ The project has implemented Briquetting Plant. Dust from Ferro alloy

plant along with Mn Ore fines & Coke fines are currently being

recycled at briquetting plant to manufacture hard briquette by

mixing with binders & additives. In this process the waste material

xx

generated in the entire plant is being recycled in the briquetting

plant and used as a feed material for Ferro Alloy Plant. After

commissioning of the SMS the fugitive dust collected will also be

recycled into the Briquetting Plant.

❖ Slag from Ferro Alloy Plant will be used as raw material in Mineral

Fibre plant. The Gas Cleaning Plant (GCP) dust will be sent to

briquetting Plant.

❖ The dust from SMS will be sent to Briquetting Plant. Mill Scales will be

sent to Ferro Alloy Plant for recycling. The slag will be used for road

construction.

❖ Solid waste like waste cottons, empty bags, rejected gaskets, empty

bottles band Jerry canes, steel structures and rejected spares of

process equipment etc, generated may have scrap value and shall

be disposed of with price realization.

❖ Used oil will be disposed to authorized reprocessing units having

valid authorization from APPCB.

❖ The project is implementing the Mineral fiber plant which will convert

the slag to value added product- mineral wool. The technology for

the same is being sourced from Peking University, China.

❖ The project will implement the Flue Gas Desulphurization systems for

both the Captive power plants as per the notification from

CPCB/APPCB based on norms for stack emissions.

❖ The Power Plants are based on Air Cooled condensation systems

and Dry Bottom Ash handling system to minimize water

consumption.

SOCIAL

❖ Project will provide employment to 2523 persons.

❖ By establishment of the plant will give indirect employment to

many more people in the form of contractual jobs, business

opportunities, service facilities etc.

❖ CSR activities will be taken up in the following areas of rural

infrastructure, health, education and skill development etc., of

the nearby villages.

FINANCIAL

❖ Increased revenue to the state by way of taxes and duties.

❖ SMAL is also exporting finished products and earning foreign

exchange

xxi

SMAL has implemented the CSR activities aimed at strengthening the

bond between the project authorities and the local population in the

vicinity of project area.

1.9 PUBLIC HEARING

Public hearing advertisement for the expansion proposal was published

on 07.11.2021 in “Times of India” (English News Paper) and Sakshi

(Telugu News Paper). Paper advertisements are Enclosed as Annexure

– 7A.

Venue of the Public hearing was fixed near to the existing industry

premises of SMAL at APIIC Industrial Park, Kantakapalli (V), Kothavalsa

(M), Vizianagaram (Dist.), A.P.

Public Hearing was conducted on 10.12.2021 by Andhra Pradesh State

Pollution Control Board. Summary of public hearing issues are given

below:

❖ Compensation to the land losers

❖ Compensation to the farmers whose mango garden was

disturbed during laying the power line through

Kothasunkarapalem village

❖ Impact on black dust pollution on mango and cashew

plantation from the industry

❖ Option to reduce coal consumption to meet COPS guideline for

reducing CO2 emissions

❖ Water pollution to Marrigedda

❖ Impact of rainwater being discharged from the plant site and

joining the narasapalli Tank.

❖ Avenue plantation on internal roads

❖ Plantation of Fruit bearing and medicinal Plants

❖ Jobs to local and surrounding villages

❖ 75 to 80 % employment should be given for locals

❖ Provide the employment to the people who lost the land

❖ Priority to local and unemployed youth

❖ Preference to local people for petty contracts like earth works,

civil works etc.,

❖ Monitoring the heat near furnace

❖ PPE to all the workers

xxii

❖ Rainwater Harvesting

❖ Comply with emission standards and follow the rules and

regulation of MoEFCC / APPCB

❖ Charging for RO water

❖ Medical camps, Issue of Health Cards and supply of medicines

❖ CSR amount is not spent in the nearby villages

❖ CSR amount should be 5% of the net profit

❖ Formation of Coordination committee with Govt. officials, PCB

Officials and Local Villagers

❖ Construction of Hospital

❖ Construction of burning shed in grave yard of Kantakapalli

❖ Construction of Community Hall

❖ Construction of additional overhead tank in kantakapalli,

Sunkurapalem

❖ Construction Of Ro Plant In Sambhayyapalem, Sunkurapalem

And Supply Ro Water Free Of Cost.

❖ Development of roads, nallas and other Infrastructure needs of

the village under CSR activities

❖ Skill Development Programs

❖ Support to rural primary education for weaker sections

SMAL has allotted Rs 78.835 Crores, towards the Public Hearing

demands. The District Collector, Vizianagaram during the public

hearing has advised the govt. official to constitute a committee

comprising of all the relevant Govt. officials and local sarpanches and

SMAL representatives. This committee will be responsible to identify the

projects and advise SMAL to implement the same under CSR budget.

SMAL has provided Rs. 2.0 Crores for this purpose excluding the budget

provided for various commitments of the public hearing.

1.10 CONCLUSION

The proposed expansion will have significant benefits on the

environmental, social and financial aspects.




xxiii



SMAL has developed greenbelt in an area of 93.23 acres which is

33.18% of the total plot area.

SMAL has implemented air cooled condenser system in the existing

power plant to save water and the same will be planned for new

power plant

An area of 5.71 acres will be developed to harvest the entire rain

water.

The treated wastewater from the plant will be utilized within the project.

The solid waste from Ferro Alloy Plant, SMS is converted to briquettes in

the briquetting plant and reused.

SMAL is implementing the value addition project for utilization of SiMn

slag in the Mineral Fibre Plant to produce slag wool which is used for

insulation purposes.

Saving in operation cost due to sharing of existing infrastructures

No additional Land acquisition is required for the proposed expansion,

since adequate vacant land is available in the existing project site.

A budget of Rs. 170.47 Crores towards capital cost and 17.19 Crores

towards recurring cost is planned for implementation of Environmental

Management Plan.

SMAL is carrying out various CSR activities in the areas of health, rural

infrastructure, education, skill development and tree plantation. A total

10685 persons have benefited due to conduct of periodical medical

camps since 2016.

With the implementation of pollution control equipment, greenbelt,

rainwater harvesting and CSR activities will have positive impact on the

surroundings of project site with respect to Environment and Social

Welfare after expansion.

CHAPTER - 1

INTRODUCTION

Expansion of Ferro Alloy Plant, CPP & Installation of SMS, MFP- M/s. Sarda Metals & Alloys Ltd.

APIIC Industrial Park, Kantakapalli (V), Kothavalasa (M), Vizianagaram (Dist.), A.P.

Final EIA

Report

1 B.S. Envi-Tech (P) Ltd., Sec’bad

CHAPTER – 1 INTRODUCTION

1.1 PURPOSE OF THE PROJECT

M/s Sarda Metals & Alloys Ltd. (SMAL) is promoted by Raipur, CG based Sarda

Group. The Groups’ flagship company Sarda Energy & Minerals Ltd. (SEML) is

listed on BSE and NSE with interests in Steel, Ferro Alloys, Power (hydro and

thermal), Mining, Investments and Horticulture. SMAL is a 100% wholly owned

subsidiary of SEML.

SMAL is operating a Ferro Alloy Plant and Captive Power Plant in an area of

280.96 acres at APIIC Industrial Park, Kantakapalli, Kothavalasa Mandal,

Vizianagaram District, Andhra Pradesh having the following units.

❖ Ferro Alloys - 1,00,000 TPA

❖ Captive Power Plant 1x80 MW

❖ Briquetting Plant- 1,05,000TPA

SMAL proposes to undertake expansion of the facilities by adding the following

units.



❖ Mineral Fibre Plant – 1,50,000 TPA


The proposed activity comes under Category – ‘A’ project as per Environmental

Impact Assessment (EIA) Notification SO 1533, of14-9-2006 and subsequent

amendments. It necessitates obtaining the Prior Environmental Clearance from

Ministry of Environment and Forests & Climate Change (MoEF&CC).

As per the requirement of EIA notification, necessary application to MoEFCC

was submitted by SMAL for approval of Terms of Reference (TOR). System

generated Terms of Reference was issued vide Lr. No. J-11011/164/2009-IA.

II (I) dated 22nd

, April 2020 for carrying out the Environmental Impact

Assessment study and is enclosed as Annexure – 1A.

Public Hearing was conducted on 10.12.2021 by Andhra Pradesh Pollution

Control Board. Final EIA report incorporating the minutes of the Public Hearing

and Response Statement is presented in subsequent chapters.



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1.2 IDENTIFICATION OF THE PROJECT



26.11.2009 (Annexure – 1B), and subsequently amendment to the same on

04.06.2015 (Annexure – 1C). The Configuration of the Plant as per the

approved Environment Clearance is as below:

TABLE -1.1: CONFIGURATION OF THE PLANT AS PER THE APPROVED

ENVIRONMENT CLEARANCE


Unit 1


(75,000 TPA)

1x 33 MVA

(75,000 TPA)

---

2 Sinter Plant 1X24M2

(1,25,000 TPA)

------ ---

Unit 1I



Charging

2,00,000 TPA -- 2,00,000 TPA

5 Sponge Iron Plant -- 2 x 500 TPD

(3,00,000 TPA)

--

6 Blast Furnace (1x350 m3

) --- --- 2,50,000 TPA


Induction Furnace (5x15T)


--- --- 2,50,000 TPA

2,50,000 TPA



10 Pellet Plant --- --- 6,00,000 TPA



amendment from MoEF&CC. Later, SMAL obtained amendment (Annexure –

1D) vide dated 02.07.2018 to the project comprising expansion of Ferro Alloy

Plant, Power Plant, Sinter Plant etc., However, SMAL did not implement the

same.

SMAL has implemented the following facilities and commenced the operation

in the year 2013.

S.

No

Facilities Configuration Capacity



3 Briquetting Plant* - 1,05,000 TPA

* Briquetting Plant does not require the Environmental Clearance and is now categorized as Green

Category as per CPCB guidelines. Hence CFE for the Briquetting Plant of capacity 1,05,000 TPA was

obtained by SMAL (Annexure – 1E).



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All Consent to Operate for the existing Plant since inception are enclosed as

Annexure-1F and compliance for CFO are enclosed as Annexure-1G.

Certified compliance of the EC conditions by Integrated Regional Office,

Vijayawada, A.P. is enclosed as Annexure-1H.

PROPOSED EXPANSION

SMAL proposes to undertake expansion of the Ferro Alloy Plant and Captive

Power Plant by adding the following units.

❖ Ferro Alloys plant - 1,50,000 TPA (Addition of 3 Furnaces)

❖ Steel Melting Shop (Induction Furnace (IF), Continuous Casting Machine

(CCM), Re-Heating Furnace, TMT & Wire Rod Mill (WRM)) - 3,00,000

TPA

❖ Captive power plant with Pulverized Fuel Boiler - 1X80MW

❖ Mineral fibre plant – 1,50,000 TPA

The summary of the Production capacities (Post Expansion) is given below:

TABLE -1.2: PRODUCTION CAPACITY (Post Expansion)


Proposed

Total capacity after

expansion

1 Ferro Alloys

TPA

1,00,000 1,50,000 2,50,000


(Induction Furnace (IF),

Continuous Casting

Machine (CCM), Re-

Heating Furnace, TMT &

Wire Rod Mill (WRM)

-- 3,00,000 3,00,000

3 Mineral Fibre Plant -- 1,50,000 1,50,000


5 Coal Based Captive

Power Plant

MW 1 x 80

1 x 80

2 x 80

Note: SMAL started construction of Furnace no.3 in 2018 (Kindly refer EC &

CFE dtd.2nd

July’2018 & 26th

September’2018, bearing order no. Order No.

200/APPCB/CFE/RO-VZM/HO/2018). Substantial civil and structural works

were undertaken, however SMAL had to stop the project mid-way due to

adverse market conditions and lack of funding tie-up from institutions due to

stress in the financial system.



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1.3 PROJECT PROPONENT- SARDA METALS & ALLOYS LTD.

Sarda Energy & Minerals Ltd. (SEML) is promoted by Raipur, Chhattisgarh

based Sarda Group. The Groups’ flagship company Sarda Energy & Minerals

Ltd. is listed on BSE and NSE with interests in Steel, Ferro Alloys, Power (hydro

and thermal), Mining, Investments and Horticulture.

The Group today has become the largest producer of manganese-based

Ferroalloys with a total manufacturing capacity of over 200,000 MT at Raipur

and Visakhapatnam. It is one of the largest exporters of Ferro alloys from India

and has been granted Star Export House Status from the Government of India

as well as Government of Chhattisgarh. SEML has also been ranked in Top

500 Private Sector Indian Companies by Business Today for two consecutive

years and enjoys a CRISIL credit rating of A+ for long term and CRISIL A1 for

short term (please visit the website).

SMAL, a 100% wholly owned subsidiary of SEML, has put up a green field

Ferro Alloys plant along with captive thermal power generation facility in

Vizianagaram District of Andhra Pradesh near Visakhapatnam.

1.4 BRIEF DESCRIPTION OF PROJECT

1.4.1 NATURE AND SIZE

The proposed project is an expansion project. The project is classified as

“Category-A” by MoEF&CC, New Delhi as per the EIA Notification dated on

14th

September 2006.

The proposed activities will be within the existing area of SMAL. The total land

area for the project is 280.96 acres and the same was procured from Andhra

Pradesh Industrial Infrastructure Corporation Land (APIIC). The existing project

is in the designated Kantakapalli Industrial Park of APIIC. Present activities are

covered under 54.12 Acres, Green Belt in 93.23 acres and area available for

future expansion is 133.61 Acres.

The configuration of the existing plant and proposed expansion is given in

Table1.3.



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TABLE 1.3: EXISTING AND PROPOSED PRODUCTION CAPACITIES

AND EXPANSION ACTIVITY

Plant Present

Capacity

Proposed

Expansion

Capacity

After

Expansion

Proposed activities

Ferro Alloys 1,00,000

2 x 33 MVA

1,00,000

TPA

1,50,000

3 x36 MVA

1,50,000

TPA

2,50,000

5 x 36 MVA

2,50,000 TPA

Nomenclature of existing Ferro

Alloys 2X33 MVA to be changed

to 2X36MVA. Production capacity

of existing unit to remain at

100000 MTPA.

3 New Units of 3 x 36 MVA

furnaces will be added.

Captive Power

Plant

1 x 80 MW

CPP

1 x 80 MW

CPP

2 x 80 MW

CPP

Addition of one unit 1 x 80 MW

CPP based on PF Boiler

technology.

Steel Melting

Shop

- 3,00,000

TPA

4x22 MT IF

3,00,000 TPA

4x22 MT IF

New unit comprising (Induction

Furnace (IF), Continuous Casting

Machine (CCM), Re-Heating

Furnace, TMT & Wire Rod Mill

(WRM) to Produce TMT bars and

Wire Rods

Mineral Fiber

Plant, TPA

- 150,000

5 Lines

150,000

5 Lines

New Unit Mineral Fiber Plant- 5

Lines - 150,000 TPA

Briquetting

Plant, TPA

1,05,000 - 1,05,000 To Recycle the Bag House Dust

and Manganese Ore Fines

1.4.2 LOCATION OF THE PROJECT SITE

SMAL is located at APIIC Industrial Park with Sy No - 179/4, 181, 182, 183/1

to 20, 185, 186, 187, 188/1&2, 189/1&2, 190, 191, 192/1 to 3, 193, 194,

195, 196, 197, 198, 199, 200, 201, 202 & 203, Kantakapalli Village,

Kothavalasa Mandal, Vizianagaram District, Andhra Pradesh.

The Project Site is a part of the Survey of India Toposheet No. 65/O/1. The

average altitude of the project site is 102 m above MSL and the coordinates

are given below:

S.No Latitude Longitude Direction

A 17°56'47.70"N 83°13'4.60"E NORTH

B 17°56'12.89"N 83°13'31.44"E SOUTH

C 17°56'39.92"N 83°12'46.32"E WEST

D 17°56'31.16"N 83°13'47.88"E EAST

The location of the project is shown in Fig – 1.1 and salient locational features

of the project site are given in Table – 1.4.



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ANDHRA PRADESH

LOCATION MAP

Chittoor

SPSR Nellore

Prakasam

GunturKrishna

Kurnool

Anantapur

YSR Kadapa

West Godavari

East Godavari

Vishakhapatnam

Vizianagaram

Srikakulam

FIG - 1.1

INDIA

PROJECT SITE

VIZIANAGARAM DISTRICT

Bhodragiri

Mondemkhallu

Kurupam

Komarada

Merangi

NaguruBelagam

Parvatipuram

Duggeru

Makkuva

Bobbili

RamabhadrapuramSalur

Pachipenta

Maradam

Andra

Mentada

Uttaravilli

Garbham

Bondapalle JagannadharajuChattram

Gajapatinagaram

Chipurupalle

NelimariaGantyada

Kottam

Jami

Bhogapuram

DenkadaKonada

Pusapatirega

VIZIANAGARAM

5

43

LEGEND

RAILWAY TRACK

RIVER

ROAD

DISTRICT BOUNDARY

STATE HIGHWAY

TALUK HEADQUARTER

DISTRICT HEADQUARTER

TOWN

STREAMS

NATIONAL HIGHWAY

PROJECT SITE

5

Note:- Not to Scale



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TABLE – 1.4: SALIENT LOCATIONAL FEATURES OF THE PLANT

Feature Details

Altitude 102 m above msl

Village, Tehsil, District, State Kantakapalli Village, Vizianagaram District, A.P.

Temp. 0

C 15.8 – 42.0

Relative Humidity % 65 – 80

Annual rainfall 1071mm

IMD Station Vishakhapatnam – 21.37 - S

Nearest water bodies Nearest water tank – 0.32 km - W

Pedda Gedda – 5.55 km – SE

Mehadri Gedda – 3.45 km – SW

Vagu passing at a distance of 7.1 km - NE

Nearest Highway National Highway (NH-5 name change to NH-16) -

Visakhapatnam – Srikakulam - 16.50 km - ESE,

The State Highway (SH-39) - Araku - Visakhapatnam - 3.17

km in W,

Major Road connecting Kothavalasa - Vizianagaram - 0.02

km in W,

Nearest Railway station Kantakapalle RS - 1.11 km – NW

Nearest Industries Vishakapatnam Steel Plant – 33.63 km - S

Inter State Boundary Andhra Pradesh – Odisha – 50.25 km - NW

Nearest National Parks Kondakarla Bird Sanctuary – 43.02 km - SW

Nearest Villages Kantakapalli – 0.46 km – N

Pata Sunkarapalem – 1.06 km – SW

Kotta Sunkarapalem – 0.55 km – WSW

Datti – 1.19 km – WSW

Nearest Town/City Vizianagaram – 23.01 km – NE

Visakhapatnam – 21.37 km – S

Nearest Air Port Visakhapatnam Airport – 22.87 km – S

Nearest Port Visakhapatnam – 25.26 km – S

Gangavaram – 30.90 km – S

Nearest Forest Advanapalem RF – 1.3 km – SE

Muchcherla RF - 7.2 km – ESE

Historical places None within 10 km radius

* All distances mentioned in the above table are aerial distances.



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1.4.3 PROJECT COST

The estimated capital cost of the proposed expansion is about Rs. 1242 Crores

and will be implemented as per the implementation schedule given below:

PROPOSED UNITS NO OF

UNIITS

PROJECT COST

(IN CRORES)

IMPLEMENTATION

SCHEDULE

Furnace 3 Of Ferro Alloy Plant 01 211 2021-2023

Mineral Fiber Plants (2nos) 02

Furnace 4 & 5 Of Ferro Alloy Plant 02 321 2023-2025

Mineral Fiber Plants 03

Steel Melting Shop 01 710

2025-2027 1x80 Mw Coal Based Captive Power

Plant Based on PF Boiler Technology

01

TOTAL PROJECT COST FOR EXPANSION 1242

1.5 IMPORTANCE OF THE PROJECT

GLOBAL SCENARIO

❖ In CY 2019, the world crude steel production reached 1869 million

tonnes (MT) and showed a growth of 3% over CY 2018.

❖ China remained world’s largest crude steel producer in 2019 (996 MT)

followed by India (111 MT), Japan (99 MT) and the USA (88 MT), based

on rankings released by the World Steel Association.

❖ Per capita finished steel consumption in 2019 was 229.3 kg for world

and 663 kg for China. The same for India was 74.3 kg in 2019

(Source: JPC). The per capita consumption of total finished steel in India

during 2019-20 was 74.7 kg (Source: JPC).

Source: World Steel Association report (Provisional data)

DOMESTIC SCENARIO

❖ The Indian steel industry has entered a new development stage, post de-

regulation, riding high on the resurgent economy and rising demand for

steel.

❖ Rapid rise in production has resulted in India becoming the 2nd

largest

producer of crude steel during 2018 and 2019, from its 3rd

largest status

in 2017. The country was also the largest producer of Sponge Iron or

DRI in the world and the 2nd

largest finished steel consumer in the world

after China & USA in 2019, based on rankings released by the World

Steel Association.

❖ In a de-regulated, liberalized economic/market scenario like India the

Government’s role is that of a facilitator which lays down the policy



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guidelines and establishes the institutional mechanism/structure for

creating conducive environment for improving efficiency and

performance of the steel sector.

❖ In this role, the Government has released the National Steel Policy

2017, which has laid down the broad roadmap for encouraging long

term growth for the Indian steel industry, both on demand and supply

sides, by 2030-31. The Government has also announced a policy for

providing preference to domestically manufactured Iron & Steel products

in Government procurement.

PRODUCTION

❖ Steel industry was de-licensed and de-controlled in 1991 & 1992

respectively.

❖ India was the 2nd

largest producer of crude steel in the world in 2019.

❖ In 2019-20, production of total finished steel (alloy/stainless + non-

alloy) was 102.62 million tonnes (MT).

❖ Production of Pig Iron in 2019-20 was 5.42 MT, a decline of 15.5%

over last year.

❖ India was the largest producer of Sponge Iron in the world in 2019. The

coal- based route accounted for 82% of total Sponge Iron production

(37.10 MT) in the country in 2019-20.

❖ Data on production of Pig Iron, Sponge Iron and Total Finished Steel

(alloy/stainless + non-alloy) are given below for last five years:

Source: Joint Plant Committee (JPC)

PIG IRON: India is also an important producer of pig iron. Post-liberalization,

with setting up several units in the private sector, not only imports have

drastically reduced but also India has turned out to be a net exporter of pig

iron. The private sector accounted for 89% of total production of pig iron (5.42

MT) in the country in 2019-20.



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SPONGE IRON: India, world’s largest producer of sponge iron, has a host of

coal- based units located in the mineral-rich states of the country. Over the

years, the coal- based route has emerged as a key contributor and accounted

for 82% of total Sponge Iron production in the country during 2019-20.

Production of Sponge Iron making too has increased over the years and stood

at 37.10 MT (2019-20).

Source: https://steel.gov.in/

FERRO ALLOYS MARKET

GLOBAL OUTLOOK

Ferro alloys are basically iron-based alloys that include elements like

manganese, chromium, silicon, and others with high proportions. The Ferro

alloys are extensively used in iron and steel production because of the

increasing demand of the iron and steel industries.

In the year 2018, the largest ferro alloys market share has been generated by

the Asia Pacific region, and this region is predicted to continue the same

growth in the upcoming years. This region is generating more ferro alloys

market share due to the disposable income growth among the consumers and

the construction industry growth in the region.

Across the regions, the ferro alloys market is providing higher durability and

more tensile strength. Hence, the automotive, transportation, automobile

industries have been attracted towards the Ferro alloys products. Moreover,

many manufacturers are adopting the Ferro alloys like ferronickel and

ferromanganese for the better production of low-carbon steel, jaws of rock

crushers, and high-speed cutting tools at a high temperature. Along with that,

Ferro alloys like ferro-chrome are extensively used to produce radiator grills,

car fittings, ball bearings, and plating bumpers in the automobile industry.

Also, ferro-chrome is widely used in the manufacturing process of stainless

steel. Hence, the ferro alloys market is increasing its public demand and

growing its supply chain.

Thus, the continuous ferro alloys market growth is showing the high

performance and high reliability of the ferro alloys product in all the regions.

The ferro alloys market analysis report explains that the global market has

adopted some of the major trends where new product developments have been

considered in the aircraft and automobile applications. Along with that, the

ferro alloys industries are investing in advanced and new technologies. The

https://steel.gov.in/



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market is showing environmental concerns, which is attracting many audiences

and generating higher ferro alloys market demand across various counties.

https://www.marketresearchfuture.com/

DOMESTIC SCENARIO

Ferroalloys are one of the important inputs in the manufacture of alloys and

special steel. They are used as deoxidizers and alloy additives in the steel

manufacturing process. They impart special properties to steel. The alloys

provide increased resistance to corrosion, improve hardness & tensile strength

at high temperature, impart wear and abrasion resistance and increases creep

strength etc.

The growth of Ferroalloys Industry is, thus, linked with the development of the

Iron and Steel Industry, Foundry Industry and to some extent Chemicals and

Electronic/EV Industry. The principal ferroalloys are chromium, manganese and

silicon. The product series consists mainly of ferromanganese,

silicomanganese, ferrosilicon and ferrochrome.

Ferroalloys are classified into two main categories, viz, bulk ferroalloys and

noble ferro alloys. Bulk ferroalloys are majorly used in stainless steel & carbon

steel. Most of the noble ferroalloys are made from rare-earth minerals and are

expensive to produce as compared to bulk ferroalloys.

Owing to high cost of power, Ferroalloys Industry has not been operating to its

full capacity in India. Ferroalloys Industry spends 40 to 70% production cost on

power consumption. The power consumption per ton of ferroalloys production

in the country varied from 3,000 to 12,000 kWh. At present, major portion of

the ferroalloys produced is exported.

As per Indian Ferroalloys Producers' Association (IFAPA), the total installed

capacity of bulk Ferroalloys Industry in India is estimated at 5.10 million tonnes

per annum and for noble ferroalloys it is 50,000 tonnes per annum. The

products covered are Manganese alloys (HC, MC & LC ferro chrome, silico

chrome and charge chrome) and Nobel ferroalloys (ferromolybdenum,

ferrovanadium, ferrotungsten, ferrosilicon magnesium, ferroboron,

ferrotitanium etc.).

https://www.marketresearchfuture.com/



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The Ferroalloys Industry was established as an ancillary industry to cater to the

growing needs of the domestic Steel Industry and is spread all over the country.

Most of the ferroalloys units have been set up in Andhra Pradesh,

Chhattisgarh, Jharkhand, Karnataka, Madhya Pradesh, Maharashtra, Odisha

and West Bengal because of availability of the raw material as well as

uninterrupted electricity supply.

Recently, the Industry has further spread to the North-Eastern Region of India.

In Meghalaya several small units producing ferrosilicon and ferro

silicomanganese have come up.

The ferroalloy units have incorporated the latest technology to use non-

metallurgical grade ores, both lumps and fines, after necessary beneficiation

and agglomeration. The units have also incorporated an effective pollution

control measures in the form of gas cleaning, deoxidizing and waste heat

recovery.

BULK FERROALLOY- Bulk ferroalloys consist of principal alloys, viz,

ferromanganese, silicomanganese, ferrochrome, charge chrome and

ferrosilicon.

FERROMANGANESE/SILICOMANGANESE - Ferromanganese is produced as

high carbon ferromanganese with 72-82% Mn, 6-8% C and 1.5% Si; medium-

carbon ferromanganese with 74-82% Mn, 1-3% C and 1.5% Si; and low-

carbon ferromanganese with 80-85% Mn, 0.1-0.7% C and 1-2% Si.

Silicomanganese on the other hand is a combination of 60-70% Mn, 10-20%

silicon and about 1 - 2% carbon.

FERROCHROME/CHARGE CHROME - Ferrochrome when added to steel

imparts hardness, strength and augments its stainless characteristics. For every

ton of stainless steel (depending on the grade), there is 17-23% of chrome

content is required. Hence, if the stainless-steel Industry grows, the ferrochrome

Industry also grows. Carbon content classifies the ferrochrome alloy into high-

carbon (6-8%), medium-carbon (3-4%) and low-carbon (1.5-3%), although

chromium content in all the three grades is around 60-70%.

Around 2.5 tonnes chrome ore with an estimated power consumption of 4,500

kWh is required to produce one ton of ferrochrome. Ferrochrome is produced

by electric carbothermic reduction of chromite.



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FERROSILICON – Ferrosilicon is produced by reduction of silica or sand with

coke in the presence of iron. Typical sources of iron are scrap iron or millscale.

Ferrosilicons with higher silicon content are made in electric arc furnaces. The

usual formulations on the market are ferrosilicons with 15%, 45%, 75%, and

90% silicon. The remainder is iron, with about 2% consisting of other elements

like aluminium and calcium.

A very high consumption of power, i.e., 9,000 to 10,000 kWh is required to

produce one ton of ferrosilicon. It is a powerful deoxidizing agent, and its

major applications are in electrical steel used for transformers and dynamos,

alloy steel for tools & automobile valves and in iron casting and mineral

dressing. Ferrosilicon is used by the military to quickly produce hydrogen for

balloons. For this, chemical reaction of sodium hydroxide, ferrosilicon and

water is utilized.

NOBLE FERROALLOYS - Noble ferroalloys are one of the vital additive inputs

required especially in production of alloy and special steel. Noble ferroalloys

also refer to alloys used in small quantities and are relatively. expensive

compared to bulk ferroalloys. These are used in the production of steel as

deoxidant and alloying agents. These high temperature alloys impart strength,

resistance and stability within a temperature range from 260 to 1,200 o

C.

These alloys are used generally in turbine engines, power plants, furnaces, and

all pollution control equipment. Noble ferroalloys include ferrovanadium,

ferrotitanium, ferronickel, ferromolybdenum, ferrotungsten and ferroniobium.

In India, noble ferro-alloys are mostly manufactured through alumino-thermic

process

https://ibm.gov.in/writereaddata/files/08012020124231Ferroalloys2019.pdf

CONCLUSION

Thus, with the increase in Steel consumption, the growth of Ferro Alloys

industry is positive both in terms of domestic consumption and exports. This

justifies the proposed expansion of Ferro Alloys production along with captive

power plant.

The production of various ferroalloys is detailed in the following Table:

https://ibm.gov.in/writereaddata/files/08012020124231Ferroalloys2019.pdf



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PRODUCTION OF FERRO ALLOYS- (IN TONNES)

1.6 SCOPE OF THE STUDY

Environmental Impact Assessment study has been carried out within an area of

10 km radius around the SMAL plant as per the Terms of Reference issued by

Ministry of Environment & Forests and Climate change. The various steps

involved in Environmental Impact Assessment study of the project site are

divided into the following phases:

1. Identification of significant environmental parameters and assessing the

existing status within the impact zone with respect to air, water, noise,

soil and socioeconomic components of environment.

2. Study of various activities of the proposed expansion to identify the area

leading to impact/change in environmental quality.

3. Quantification/prediction of impact for the identified activities and to

study the level of impact on various environmental components.

4. Evaluation of impacts after superimposing the predicted/quantified

scenario over the baseline scenario.

5. Formulation of Environmental Management Plan for implementation in

the proposed expansion.

Baseline data was collected during Winter Season 2020-21 covering the

months of December 2020, January-2021 and February-2021 to assess the

existing environmental status of various environmental parameters within the

10 km radius of study area. The report presents the baseline scenario,

prediction of impacts for the total plant at expanded capacity along with a

detailed Environmental Management Plan, which is/will be implemented by

Sarda Metals & Alloys Ltd in post expansion phase.



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1.7 STATUS OF LITIGATIONS

The details of the litigations filed by Proponent against the statutory bodies is

given below. However, these are not related to Environment or Pollution

Control.

Name of the Court Case no Details of the Case

AP High Court,

Vijayawada

WP 46355/2016 Case against revenue department, VZM

against levy of conversion charges @10% on

the land cost - Land Purchased from APIIC

AP High Court,

Vijayawada

WP 25480/2013 Levy of royalty by Mines and Geology

department, AP with regard to levelling of

land inside the plant premises for starting

construction work.

1.8 COMPLIANCE OF TERMS OF REFERENCE

MoEFCC issued system generated standard Terms of Reference, specific Terms

of Reference for EIA Studies for Metallurgical Industries (Ferrous & Non-

Ferrous) and Additional Terms of Reference vide letter no. F. No. J-

11011/164/2009-IA. II (I) Dated: 22nd

April 2020. Table 1.5 gives the

compliance of Terms of Reference (TOR) for the Proposed Project.

TABLE-1.5: TOR COMPLIANCE, F.No. J-11011/164/2009-IA. II (I) Dt: 22.04.2020

S.

No

TOR POINT COMPLIANCE REFERENCE IN EIA

1 Executive Summary Enclosed Page No. –

2 Introduction

i. Details of the EIA Consultant

including NABET accreditation

B.S. Envi – Tech Pvt. Ltd, Secunderabad

is a NABET, QCI Accredited

Organisation since year 2010 –

Category – A

NABET Accreditation No:

NABET/EIA/1922/RA 0174

NABET Validity – 16.11.2022

Chapter – 12

Page No. – 265

Annexure – 12A

Page No. - 727

ii. Information about the project

proponent

Sarda Metals & Alloys Ltd. (SMAL), a

100% wholly owned subsidiary of

SEML, has put up a green field Ferro

Alloys plant along with captive thermal

power generation facility near

Visakhapatnam in Andhra Pradesh.

Chapter – 1

Para – 1.3

Page No. – 4

iii. Importance and benefits of

the project

The proposed project will cater to the

domestic steel industry and exports

Chapter – 1

Para – 1.5

Page No. – 7



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S.

No


3 Project Description

i. Cost of project and time of

completion.

Cost of Expansion: Rs. 1242 Crores.

The proposed expansion will be carried

out as per construction schedule the

details are furnished.

Chapter – 1

Para – 1.4.3

Page No. – 7

Chapter – 2

Para – 2.6.6

Page No. – 42

ii. Products with capacities for

the proposed project

• Ferro Alloys – 1,00,000 TPA to

2,50,000 TPA.

• SMS (TMT bars & Wire Rod Mill) –

3,00,000 TPA

• Mineral Fibre Plant – 1,50,000 TPA

• Captive Power Plant (MW) – 1x80

MW to 2x80 MW.

Chapter – 2

Para – 2.5

Page No. – 34

iii. If expansion project, details

of existing products with

capacities and whether

adequate land is available

for expansion, reference of

earlier EC if any.

Existing Products are

• Ferro Alloys – 1,00,000 TPA

• Captive Power Plant (MW) – 1x80

MW

• Briquetting Plant – 1,05,000 TPA

The total land available is 280.96 Acres

Area covered under Present

Activities:54.12 Acres

Green Belt:93.23 acres area available

for future expansion :133.61 Acres.

Chapter – 2

Para – 2.5

Page No. – 34

Chapter – 2

Para – 2.7

Page No. – 44

iv. List of raw materials required

and their source along with

mode of transportation.

Details of raw material along with

source and mode of transportation has

been incorporated.

Chapter – 2

Para – 2.6.1

Page No. – 39

v. Other chemicals and

materials required with

quantities and storage

capacities

Space is provided for the material

storage as per requirement at various

stages of production for ensuring

sufficient buffer stocks for continuous

operation of the plant.

Chapter – 2

Para – 2.6.1

Page No. – 39

vi. Details of Emission, effluents,

hazardous waste generation

and their management.

The Emission and effluents from various

sources along with management are

detailed.

Solid waste and Hazardous waste

generation along with details of their

disposal are furnished.

Chapter – 4

Para – 4.3.3.3

Page No. – 155

Chapter – 4

Para – 4.3.4

Page No. – 156



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vii. Requirement of water, power,

with source of supply, status

of approval, water balance

diagram, man-power

requirement (regular and

contract)

Present Water Consumption: 980

m3

/day

Total Water requirement after

expansion: 2700 m3

/day

Source: Greater Visakha Municipal

Corporation

Permission for drawl upto 2700 m3

/day

is already obtained through GVMC

Vide Lr.No.53/2012-13/E. II (WS-M)

dated 16.01.2013.

Power requirement is met from Captive

power plant

Present Manpower: 865

Additional Manpower: 1658

Chapter – 4

Para – 4.3.3

Page No. – 152

viii. Process description along with

major equipments and

machineries, process flow

sheet (quantative) from raw

material to products to be

provided

Process description and details of major

equipments along with flow sheet with

material balance is provided.

Chapter – 2

Fig – 2.7 to 2.11

Page No. – 53,

57, 58, 59, 63

ix. Hazard identification and

details of proposed safety

systems

Hazard identification and emergency

situations are identified and safety

measures proposed are detailed in the

report.

Chapter – 7

Para – 7.2.3 and

subsequent paras

Page No. – 188

x. Expansion/Modernization Proposals

a. Copy of all the Environmental

Clearance(s) including

Amendments thereto obtained

for the project from

MOEF/SEIAA shall be attached

as an Annexure. A certified

copy of the latest Monitoring

Report of the Regional Office

of the Ministry of Environment

and Forests as per circular

dated 30th May, 2012 on the

status of compliance of

conditions stipulated in all the

existing environmental

clearances including

Amendments shall be

provided. In addition, status of

compliance of Consent to

Operate for the ongoing

existing operation of the

project from SPCB shall be

attached with the EIA-EMP

report.

Certified Compliance of EC is under

process.

CFO and Its Compliance details are

furnished in EIA

Chapter – 1

Para – 1.2

Page No. – 2

Annexure - 1F &

1G

Page No. – 304 to

323 & 324 - 373



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b. In case the existing project has

not obtained environmental

clearance, reasons for not

taking EC under the provisions

of the EIA Notification 1994

and/or EIA Notification 2006

shall be provided. Copies of

Consent to Establish/No

Objection Certificate and

Consent to Operate (in case of

units operating prior to EIA

Notification 2006, CTE and

CTO of FY 2005-2006)

obtained from the SPCB shall

be submitted. Further,

compliance report to the

conditions of consents from

the SPCB shall be submitted.

Not applicable as the project has

obtained EC.

Chapter -1

Annexure – 1B,

1C & 1D

Page No. – 274 –

280, 281 – 283 &

284 - 295

4 Site Details

i. Location of the project site

covering village,

Taluka/Tehsil, District and

State, Justification for selecting

the site, whether other sites

were considered.

The project is located within APIIC

Industrial Park at Village Kantakapalli,

Vizianagaram District, Andhra Pradesh.

The proposed expansion is planned

within the existing Ferro Alloy Plant and

Captive Power Plant complex utilising

the additional available area and

infrastructure. Hence no alternative sites

were studied.

Chapter – 2

Para – 2.4

Page No. – 32

Chapter – 5

Para – 5.2

Page No. – 169

ii. A toposheet of the study area

of radius of 10km and site

location on

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

an A3/A2 sheet. (including all

eco-sensitive areas and

environmentally sensitive

places)

The site falls within Survey of India

Toposheet no. 65/0/1 [1:50000 scale].

10 km of study area along with

topographical features in the area is

enclosed.

Chapter – 2

Fig – 2.3

Page No. – 36

iii. Details w.r.t. option analysis

for selection of site

Not applicable since the proposed

expansion is planned within the existing

Project Site. No additional Land is

required for the Project.

Chapter – 5

Para – 5.2

Page No. – 169

iv. Co-ordinates (lat-long) of all

four corners of the site.

The site falls between 17°56'12.89"N to

17°56'47.70"N Latitude and

83°12'46.32"E to 83°13'47.88"E

Longitude Map showing the corner

coordinates is enclosed.

Chapter – 2

Fig – 2.2

Page No. – 35

v. Google map-Earth

downloaded of the project

site.

Plant site marked on the Google Earth

Map is enclosed.

Chapter – 2

Fig – 2.5

Page No. – 38



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vi. Layout maps indicating

existing unit as well as

proposed unit indicating

storage area, plant area,

greenbelt area, utilities etc. If

located within an Industrial

area/Estate/Complex, layout

of Industrial Area indicating

location of unit within the

Industrial area/Estate.

Layout map with existing and proposed

units along with greenbelt marking is

enclosed.

Chapter – 2

Fig – 2.6

Page No. – 43

vii. Photographs of the proposed

and existing (if applicable)

plant site. If existing, show

photographs of

plantation/greenbelt, in

particular.

Photographs of existing plant site

along with greenbelt and proposed

area considered for expansion is

furnished

Chapter – 2

Fig – 2.4

Page No. – 37

viii. Land use break-up of total

land of the project site

(identified and acquired),

government/private -

agricultural, forest,

wasteland, water bodies,

settlements, etc shall be

included, (not required for

industrial area)

The total area of 280.96 acres falls

under existing Kantakapalli Industrial

Area of APIIC

Chapter – 1

Para – 1.4.2

Page No. – 5

Chapter – 2

Para – 2.4.

Page No. – 32

Table No. – 2.1

Page No. – 34

ix. A list of major industries with

name and type within study

area (10km radius) shall be

incorporated. Land use

details of the study area

Land use pattern of the study area has

been assessed through Remote Sensing

methodology using IRS-P6, LISS-III

geocoded images. Details are

furnished.

Chapter – 3

Para – 3.9.3

Fig-3.8 & 3.9

Page No. – 89, 90

& 91

x. Geological features and Geo-

hydrological status of the

study area shall be included.

The study area is undulating terrain

with hillocks varying RL over 86 m to

162 m RL over a stretch of 10 km

radius.

The study area geologically belongs to

Archaean group. The study area is

characterized by Eastern Ghat mobile

belt.

Chapter – 3

Para – 3.9.1

Page No. – 87



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xi. Details of Drainage of the

project upto 5km radius of

study area. If the site is within

1 km radius of any major

river, peak and lean season

river discharge as well as

flood occurrence frequency

based on peak rainfall data

of the past 30 years. Details

of Flood Level of the project

site and maximum Flood

Level of the river shall also be

provided, (mega green field

projects)

Drainage pattern of the project and 5

km radius of study area is enclosed

Chapter – 3

Para – 3.8.1

Fig-3.6

Page No. – 80 &

85

xii. Status of acquisition of land.

If acquisition is not complete,

stage of the acquisition

process and expected time of

complete possession of the

land.

No additional land is required for

implementing the proposed expansion.

Chapter – 2

Para – 2.6.2

Page No. – 40

Chapter – 4

Para – 4.3.6

Page No. – 163

xiii. R&R details in respect of land

in line with state Government

policy

No R & R is involved. The proposed

expansion project will be located within

the existing plant complex.

Chapter – 4

Para – 4.3.6

Page No. – 163

5 Forest and wildlife related issues (if applicable):

i. Permission and approval for

the use of forest land (forestry

clearance), if any, and

recommendations of the State

Forest Department, (if

applicable).

No Forest land is involved in the project

site.

Chapter – 2

Para – 2.6.2

Page No. – 40

ii. Land use map based on High

resolution satellite imagery

(GPS) of the proposed site

delineating the forestland (in

case of projects involving

forest land more than 40 ha).

Not Applicable as no forest land is

involved

Chapter – 2

Para – 2.6.2

Page No. – 40

iii. Status of Application

submitted for obtaining the

stage I forestry clearance

along with latest status shall

be submitted.

Not Applicable as no forest land is

involved

Chapter – 2

Para – 2.6.2

Page No. – 40



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iv. The projects to be located

within 10 km of the National

Parks, Sanctuaries, Biosphere

Reserves, Migratory Corridors

of Wild Animals, the project

proponent shall submit the

map duly authenticated by

Chief Wildlife Warden showing

these features vis-a-vis the

project location and the

recommendations or

comments of the Chief Wildlife

Warden-thereon.

There are no wildlife sanctuaries,

national parks,

elephant/tiger/Biosphere reserves,

Migratory Corridors of Wild Animals,

within 10km radius of the study area.

Chapter – 3

Para – 3.10.3

Page No. – 98

v. Wildlife Conservation Plan- duly

authenticated by the Chief

Wildlife Warden of the State

Government for conservation of

Schedule 1 fauna, if any exists

in the study area.

Not Applicable, no schedule – 1

Species are available in the study area.

Chapter – 3

Para – 3.10.9

Page No. – 102

Annexure – 3E

Page No. – 434 -

435

vi. Copy of application submitted

for clearance under the Wildlife

(Protection) Act, 1972, to the

Standing Committee of the

National Board for Wildlife

Not Applicable, no schedule – 1

Species are available in the study area.

Chapter – 3

Para – 3.10.9

Page No. – 102

Annexure – 3E

Page No. 434 -

435

6 Environmental Status

i. Determination of atmospheric

inversion level at the project site

and site- specific micro-

meteorological data using

temperature, relative humidity,

hourly wind speed and direction

and rainfall.

Site specific meteorological data in the

form of Wind rose is enclosed

Hourly meteorological data is furnished

Chapter – 3

Para – 3.5.2

Fig-3.1 & 3.2

Page No. – 69, 71

& 72

Annexure-4A

Page No. – 443 -

457

ii. AAQ data (except monsoon) at

8 locations for PM10, PM2.5, SO2,

NOx, CO and other parameters

relevant to the project shall be

collected. The monitoring

stations shall be based CPCB

guidelines and consider the

predominant wind direction,

population zone and sensitive

receptors including reserved

forests.

Environmental Impact Assessment

study, baseline environmental

monitoring was carried out for Winter

Season 2020-2021, covering the

months of December, 2020 to

February, 2021.

Details are presented.

Chapter – 3

Para – 3.6.2

Page No. – 73

Annexure-3A

Page No. – 404 -

412



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iii. Raw data of all AAQ

measurement for 12 weeks of

all stations as per frequency

given in the NAQQM

Notification of Nov. 2009

along with - min., max.,

average and 98% values for

each of the AAQ parameters

from data of all AAQ stations

should be provided as an

annexure to the EIA Report.

Date wise AAQ data at eight locations

is enclosed

Chapter – 3

Para – 3.6.2

Page No. – 73

Annexure-3A

Page No. – 404 -

412

iv. Surface water quality of nearby

River (100m upstream and

downstream of discharge

point) and other surface drains

at eight locations as per

CPCB/MoEFCC guidelines.

Eight surface water samples were

collected from various locations within

the study area.

Water quality of the above locations are

furnished.

Chapter – 3

Para – 3.8.3

Page No. – 84

Annexure-3B

Page No. – 413 -

417

v. Whether the site falls near to

polluted stretch of river

identified by the

CPCB/MoEF&CC, if yes give

details.

Not Applicable, the project site does not

fall near the polluted stretch of river

identified by the CPCB/MoEF&CC

Chapter – 2

Para – 2.4

Page No. – 32

vi. Ground water monitoring at

minimum at 8 locations shall

be included.

Water samples collected from 8

locations. All the samples showed

compliance of all parameters with the

drinking water standard of IS:10500.

Chapter – 3

Para – 3.8.3 &

3.8.4

Page No. – 84

Annexure-3B

Page No. – 413 -

417

vii. Noise levels monitoring at 8

locations within the study area.

Noise levels recorded at plant showed

Day equivalent and night equivalent

noise levels of 71.8 dB (A) and 67.4 dB

(A) respectively and are within the

limits.

Day equivalent and night equivalent

noise levels in the villages were

recorded and found to be in the range

of 51.6 - 54.3 dB (A) and 41.3 - 44.0

dB (A) respectively.

Chapter – 3

Para – 3.7

Page No. – 77

Chapter – 3

Para – 3.7.1

Page No. – 79

viii. Soil Characteristic as per CPCB

guidelines.

Eight soil samples were collected and

analysed as per CPCB guidelines.

Chapter – 3

Para – 3.9.4

Page No. – 89

Annexure-3C

Page No. – 418 -

425



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ix. Traffic study of the area, type

of vehicles, frequency of

vehicles for transportation of

materials, additional traffic due

to proposed project, parking

arrangement etc.

A traffic impact assessment study has

been conducted. Details are furnished

in the EIA.

Chapter – 7

Para – 7.4

Page No. – 221

x. Detailed description of Flora

and fauna (terrestrial and

aquatic) existing in the study

area shall be given with special

reference to rare, endemic and

endangered species. If

Schedule-1 fauna are found

within the study area, a Wildlife

Conservation Plan shall be

prepared and furnished.

Detailed description of Flora and fauna

existing in the study area is furnished.

Chapter – 3

Para – 3.10.1

Page No. – 94

xi. Socio-economic status of the

study area.

Socio-economic status of the study area

has been studied. The primary survey

was conducted in the villages within 5

km radius.

Chapter – 3

Para – 3.11

Page No. – 103

7 Impact Assessment and Environment Management Plan

i. Assessment of ground level

concentration of pollutants

from the stack emission based

on site-specific meteorological

features. In case the project is

located on a hilly terrain, the

AQIP Modelling shall be done

using inputs of the specific

terrain characteristics for

determining the potential

impacts of the project on the

AAQ. Cumulative impact of all

sources of emissions (including

transportation) on the AAQ of

the area shall be well assessed.

Details of the model used and

the input data used for

modelling shall also be

provided. The air quality

contours shall be plotted on a

location map showing the

location of project site,

habitation nearby, sensitive

receptors, if any.

Ground level concentrations are

computed taking into consideration

emissions from all units of Ferro Alloy

Plant and Captive Power Plant at its

existing and expanded capacity.

The meteorological conditions of the

study area during winter season 2020-

21 have been considered.

The air quality modelling has been

carried out considering the area as

undulated terrain as well as plain

terrain and combination of both.

EPA recommended Modelling has been

employed for estimation of ground level

concentrations.

Chapter – 4

Para – 4.3.1.4

Page No. – 142

Chapter – 3

Para – 3.5

Page No. – 68

Chapter – 4

Para – 4.3.1.2

Page No. – 139



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ii. Water Quality modelling - in

case, if the effluent is proposed

to be discharged in to the local

drain, then Water Quality

Modelling study should be

conducted for the drain water

taking into consideration the

upstream and downstream

quality of water of the drain.

No wastewater discharge from plant to

surface water bodies/drains. The entire

waste water is treated and reused with

the plant.

Chapter – 4

Para – 4.3.3.2.1

Page No. – 152

iii. Impact of the transport of the

raw materials and end

products on the surrounding

environment shall be assessed

and provided. In this regard,

options for transport of raw

materials and finished products

and wastes (large quantities) by

rail or rail-cum road transport

or conveyor-cum-rail transport

shall be examined.

The traffic impact assessment study was

conducted and details are furnished in

EIA

Chapter – 7

Para – 7.4

Page No. – 221

iv. A note on treatment of

wastewater from different plant

operations, extent recycled and

reused for different purposes

shall be included. Complete

scheme of effluent treatment.

Characteristics of untreated

and treated effluent to meet the

prescribed standards of

discharge under E(P) Rules.

An effluent management plan has

been implemented with collection,

treatment, recirculation and disposal

of effluents. The details of treatment of

waste water are furnished in the EIA.

Chapter – 4

Para – 4.3.3.2

Page No. – 152

v. Details of stack emission and

action plan for control of

emissions to meet standards.

Stack emission details are provided.

Air pollution control measures are

detailed.

Chapter – 4

Para – 4.3.1

Table-4.8

Page No. – 138 &

158

Chapter – 4

Para – 4.3.1.6

Page No. – 143

vi. Measures for fugitive emission

control

Fugitive emission control measures are

provided.

Chapter – 4

Para – 4.3.1.6.1

Page No. – 148



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vii. Details of hazardous waste

generation and their storage,

utilization and disposal. Copies

of MOU regarding utilization

of solid and hazardous waste

shall also be included. EMP

shall include the concept of

waste-minimization,

recycle/reuse/recover

techniques. Energy

conservation and natural

resource conservation.

Details regarding hazardous waste and

solid waste provided. The entire solid

waste is recycled to the process. The

implementation of briquetting plant and

mineral fibre plant will ensure that

entire solid waste is utilised.

Chapter – 4

Para – 4.3.4

Page No. – 156

viii. Proper utilization of fly ash

shall be ensured as per Fly Ash

Notification, 2009. A detailed

plan of action shall be

provided.

The entire fly ash and bottom ash is

being disposed to brick manufacturers.

Similarly, arrangement will be made

when the 2nd

CPP is implemented.

Chapter – 4

Para – 4.3.4

Page No. – 156

ix. Action plan for the green belt

development plan in 33 % area

i.e. land with not less than

1,500 trees per ha. Giving

details of species, width of

plantation, planning schedule

etc. shall be included. The

green belt shall be around the

project boundary and a

scheme for greening of the

roads used for the project shall

also be incorporated.

The greenbelt in an area of 93.99

acres has been developed. Almost

17000 trees have been planted in the

entire project area. This constitutes

about 33.18 %. The Miyawaki method

of developing greenbelt is planned in

an area of 1.63 acres out of which

0.51 acres has already developed.

About 6000 saplings has already been

planted under this method.

Chapter – 4

Para – 4.3.5

Page No. – 159

x. Action plan for rainwater

harvesting measures at plant

site shall be submitted to

harvest rainwater from the roof

tops and storm water drains to

recharge the ground water and

also to use for the various

activities at the project site to

conserve fresh water and

reduce the water requirement

from other sources.

The total rainwater potential is

estimated 3,37,920.67 m3

per year.

It is planned to implement the RWH

pond in an area of 5.71 acres having

capacity 3,46,875 m3

storage. This is

done in East direction of the plant site

Chapter – 4

Para – 4.3.3.4

Page No. – 155

xi. Total capital cost and recurring

cost/annum for environmental

pollution control measures

shall be included.

EMP capital Cost: Rs170.47 Cr.

EMP Recurring Cost: Rs. 17.20 Cr.

Chapter – 10

Para – 10.4

Table-10.1

Page No. – 239 &

240

xii. Action plan for post-project

environmental monitoring shall

be submitted.

Post Project Monitoring programme

covering all environmental components

in the expansion phase is incorporated

Chapter – 6

Para – 6.1

Page No. – 170



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xiii. Onsite and Offsite Disaster

(natural and Man-made)

Preparedness and Emergency

Management Plan including

Risk Assessment and damage

control. Disaster management

plan should be linked with

District Disaster Management

Plan.

Onsite and Offsite Disaster Preparedness

and Emergency Management Plan is

detailed. The company has already

implemented in an onsite & offsite

emergency and Disaster response plan.

The same will be updated and for the

expansion. Details are furnished.

Chapter – 7

Para –7.3

Page No. – 220

8 Occupational health

i. Plan and fund allocation to

ensure the occupational health

& safety of all contract and

casual workers

Details are furnished in EIA Chapter – 4

Para – 4.3.7

Page No. – 164

ii. Details of exposure specific

health status evaluation of

worker. If the workers' health is

being evaluated by pre-

designed format, chest x rays,

Audiometry, Spirometry, Vision

testing (Far & Near vision,

colour vision and any other

ocular defect) ECG, during

preplacement and periodical

examinations give the details of

the same. Details regarding

last month analysed data of

above-mentioned parameters

as per age, sex, duration of

exposure and department wise.

Details of the various tests conducted

for the workers as part of the

occupational health monitoring

furnished in EIA

Chapter – 4

Para – 4.3.7

Page No. – 164

iii. Details of existing

Occupational & Safety

Hazards. What are the

exposure levels of hazards and

whether they are within

Permissible Exposure level

(PEL). If these are not within

PEL, what measures the

company has adopted to keep

them within PEL so that health

of the workers can be

preserved,

After the unit is commissioned,

Workplace monitoring will be carried

out as per Factories Act, to arrive at

exposure values. The measures will be

taken care to protect the health. Details

are furnished in EIA

Chapter – 4

Para – 4.3.7

Page No. – 164

iv. Annual report of health status

of workers with special

reference to Occupational

Health and Safety.

The details of health check-up reports

are furnished in EIA

Chapter – 4

Para – 4.3.7

Page No. – 164

Annexure-4C

Page No. – 464 -

466

9 Corporate Environment Policy



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i. Does the company have a well

laid down Environment Policy

approved by its Board of

Directors? If so, it may be

detailed in the EIA report.

Yes. Environmental policy framed

considering conservation and

protection of environment

Environmental Policy is furnished in the

Report

Chapter – 10

Para – 10.3

Page No. – 236

ii. Does the Environment Policy

prescribe for standard

operating process / procedures

to bring into focus any

infringement / deviation /

violation of the environmental

or forest norms / conditions? If

so, it may be detailed in the

EIA.

All non-conformances are reported in

the specified format, the analysis for the

cause of the non-conformance carried

out to decide corrective action required

to eliminate the causes and potential

non-conformities and is implemented.

Chapter – 10

Para – 10.3.3

Page No. – 239

iii. What is the hierarchical system

or Administrative order of the

company to deal with the

environmental issues and for

ensuring compliance with the

environmental clearance

conditions? Details of this

system may be given.

Environment Officer will be reporting to

Manager. Hierarchical system to look

into the environmental issues for

ensuring compliance with the

environmental clearance conditions is

detailed.

Chapter – 10

Para – 10.2

Page No. – 235

iv. Does the company have system

of reporting of non-

compliances / violations of

environmental norms to the

Board of Directors of the

company and / or

shareholders or stakeholders at

large? This reporting

mechanism shall be detailed in

the EIA report

Yes. the company has the reporting

system for non-compliances / violations

of environmental norms to the Board of

Directors of the company and / or

shareholders

Chapter – 10

Para – 10.3.3

Page No. – 239

10 Details regarding infrastructure

facilities such as sanitation, fuel,

restroom etc. to be provided to the

labour force during construction

as well as to the casual workers

including truck drivers during

operation phase.

All the infrastructural facilities such as

Rest shelter, fuel, canteen and

sanitation facilities are made available

for the labour during the construction

and casual workers including truck

drivers during operation phase.

Chapter – 2

Para – 2.8

Page No. – 45

11 Enterprise Social Commitment (ESC)



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i. Adequate funds (at least 2.5 %

of the project cost) shall be

earmarked towards the

Enterprise Social Commitment

based on Public Hearing

issues and item-wise details

along with time bound action

plan shall be included. Socio-

economic development

activities need to be

elaborated upon.

As per MOEFCC Office Memorandum

F.NO 22-65/2017-IA.III dated 30th

September, 2020, an amount of Rs

78.835 Crores is allotted towards the

Public Hearing demands.

Item wise details along with Physical

quantities and time bound action plan

was included.

Socio economic development activities

were elaborated upon in the EIA report.

Chapter – 7

Para – 7.1

Page No. – 174

Chapter – 8

Para – 8.2

Page No. – 226

12 Any litigation pending against the

project and/or any direction/order

passed by any Court of Law

against the project, if so, details

thereof shall also be included. Has

the unit received any notice under

the Section 5 of Environment

(Protection) Act, 1986 or relevant

Sections of Air and Water Acts If

so, details thereof and

compliance/ATR to the notice(s)

and present status of the case.

No litigation case is pending against

the project with respect to environment

or pollution control.

Chapter – 1

Para – 1.7

Page No. – 14

13 A tabular chart with index for

point wise compliance of above

TORs.

Point wise TOR compliance is provided Chapter – 1

Para – 1.8

Page No. – 14

B. SPECIFIC TERMS OF REFERENCE FOR EIA STUDIES FOR METALLURGICAL INDUSTRIES (FERROUS &

NON-FERROUS)

1. Complete process flow diagram

describing each unit, its processes

and operations, along with

material and energy inputs &

outputs (material and energy

balance).

Complete process flow diagram of

each unit along with material balance

have been furnished.

Chapter – 2

Para – 2.10.2

Fig-2.7

Page No. – 46 &

53

2. Details on blast furnace/ open

hearth furnace/ basic oxygen

furnace/ladle refining, casting and

rolling plants etc.

Not Applicable -

3. Details on installation/activation of

opacity meters with recording with

proper calibration system

SMAL will provide CEMS for CPP in

expansion phase.

Chapter – 6

Para – 6.1

Page No. – 170

4. Details on toxic metals including

mercury, arsenic and fluoride

emissions

Not Applicable -

5. Details on stack height

requirement for steel

Not Applicable -

6. Details on ash disposal and

management -Non-ferrous metal

Not Applicable -



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S.

No


7. Complete process flow diagram

describing production of

lead/zinc/copper/ aluminium, etc.

Not Applicable -

8. Raw materials substitution or

elimination

Not Applicable -

9. Details on smelting, thermal

refining, melting, slag fuming,

and Waelz kiln operation

Not Applicable -

10. Details on Holding and de-

gassing of molten metal from

primary and secondary aluminum,

materials pre-treatment, and from

melting and smelting of secondary

aluminium

Not Applicable -

11. Details on solvent recycling Not Applicable -

12. Details on precious metals

recovery

Not Applicable -

13. Details on composition,

generation and utilization of

waste/fuel gases from coke oven

plant and their utilization.

Not Applicable -

14. Details on toxic metal content in

the waste material and its

composition and end use

(particularly of

slag).

The trace metal analysis for Fly ash,

Granulated Silico Manganese Sample

and GCP Dust done by Chennai Test

Laboratory Pvt. Ltd.

Chapter – 4

Para – 4.3.4

Page No. – 156

Annexure – 4C

Page No. – 464 -

466

15. Trace metals Mercury, arsenic and

fluoride emissions in the raw

material

16. Trace metals in waste material

especially slag.

17. Plan for trace metal recovery There is no trace metal recovery.

However, the waste material is recycled

in the briquetting plant and the slag is

converted to slag wool in the Mineral

Fibre Plant

-

18. Trace metals in water Not Applicable -

C ADDITIONAL TOR FOR STEEL PLANT

1. Iron ore/coal linkage documents

along with the status of

environmental clearance of iron

ore and coal mines

Not Applicable, the coal for the power

plant is imported.

-

2. Quantum of production of coal

and iron ore from coal & iron ore

mines and the projects they cater

to. Mode of transportation to the

plant and its impact

Not Applicable -



Final EIA

Report


S.

No


3. For Large ISPs, a 3-D view i.e.

DEM (Digital Elevation Model) for

the area in 10 km radius from the

proposal site. MRL details of

project site and RL of nearby

sources of water shall be

indicated.

DEM (Digital Elevation Model) of the

area in 10 km radius from the Plant

site is shown.

Chapter – 3

Para – 3.91

Fig-3.7

Page No. – 87 &

88

4. Recent land-use map based on

satellite imagery. High-resolution

satellite image data having 1m-

5m spatial resolution like

quickbird, Ikonos, IRS P-6 pan

sharpened etc. for the 10 Km

radius area from proposed site.

The same shall be used for land

used/land-cover mapping of the

area.

Land use pattern of the study area has

been assessed through Remote Sensing

methodology using IRS-P6, LISS-III

geocoded images dated 21.06.2021.

Details are furnished.

Chapter – 3

Para – 3.9.3

Page No. – 89

5. Respirable Suspended particulate

matter (RSPM) present in the

ambient air must be analysed for

source analysis - natural

dust/RSPM generated from plant

operations (trace elements). The

RSPM shall also be analysed for

presence of poly-aromatic

hydrocarbons (PAH), i.e. Benzene

soluble fraction, where applicable.

Chemical characterization of

RSPM and incorporating of RSPM

data.

PM10, PM2.5, SO2, and NOx during

Winter Season’ 2020-2021 with respect

to study area are furnished.

Chapter – 3

Para – 3.6

Page No. – 73

6. All stockpiles will have to be on

top of a stable liner to avoid

leaching of materials to ground

water.

The raw materials storage is on a layer

of concrete floor. The coal storage is

now covered to minimize fugitive dust

emissions.

Chapter – 2

Para – 2.6.1

Page No. – 39

7. Plan for the implementation of the

recommendations made for the

steel plants in the CREP

guidelines.

Not Applicable, since the present

expansion is regarding Ferro Alloy Plant

SMS and CPP. Details are given in EIA

Chapter – 4

Table – 4.1

Page No. – 125

8. Plan for slag utilization The Si Mn slag will be converted to slag

wool in the Mineral Fibre Plant.

Chapter – 2

Para– 2.10.5

Page No. – 58

9. Plan for utilization of energy in off

gases. (coke oven, blast furnace)

Not Applicable as no Coke oven or

Blast furnace is planned in the project.

-

10. System of coke quenching

adopted with justification.

Not Applicable -

CHAPTER - 2

PROJECT DESCRIPTION



Final EIA

Report


CHAPTER – 2 PROJECT DESCRIPTION

2.1 TYPE OF THE PROJECT

Sarda Metals & Alloys Ltd. (SMAL) has implemented a green field Ferro

Alloys plant along with Captive Power Plant at APIIC Industrial Park,

Kantakapalli (V), Kothavalasa (M), Vizianagaram (Dist.), Andhra

Pradesh.

The project proponent has commissioned in 2013 Ferro Alloy Plant

having 2 submerged Arc Furnaces of 33 MVA with a total capacity of

1,00,000 TPA and a coal based captive power plant of 80 MW

capacity. A Briquetting plant of 1,05,000 TPA capacity has been

recently commissioned.

SMAL proposes to undertake the expansion by implementing the

following additional facilities within the existing project site.

a) Ferro Alloys plant (3x36 MVA capacity Submerged Arc

Furnaces) - 1,50,000 TPA

b) Steel Melting Shop (SMS) ((Induction Furnace (IF), Continuous

Casting Machine (CCM), Re-Heating Furnace, TMT & Wire Rod

Mill (WRM)): - 3,00,000 TPA

c) Mineral Fibre Plant – 150,000 TPA

d) Captive Power Plant with PF fired boiler - 1x 80MW

2.2 NEED FOR THE PROJECT

India at present ranks as the third largest producer of Steel in the world

led by China and Japan. Being a developing country, despite the

adverse global economic situation, Indian economy is managing to

grow between 6-7% becoming the largest growing economy globally.

The growth of steel industry in the country stands at a healthy figure of

7.4%, which is quite remarkable against 1.2% growth in China and

about 0.8% growth in the world production.

The biggest positive factor for the continual sustained growth of the

Indian Steel Industry is the very low per capita steel consumption which

at present is about 75.7 Kg as against a world average of 224.5 Kg.

Thus, there is great potential of growth and vast domestic demand. The



Final EIA

Report


per capita consumption is likely to increase to 95 Kg by 2020 and 150

Kg by 2030. The Government of India's National Steel Policy 2017

envisages India's goal at 300 million tonnes steel production by the year

2030. This is a challenging task set forth by the Country considering

large investment planned in the Construction Sector, Auto Sector,

Railways, Capital goods production, Consumer durable industry etc.

Domestic market with real estate, infrastructure projects, industrial

projects are available for purchase of steel which is estimated about 73

Million Tonnes /Annum by the year 2030. In view of this, it is required to

make advance planning for creating the facility and infrastructure to

meet this demand. Thus, the proposed project has potential to meet

domestic market in the future.

The Project already provided employment to 865 people. The

proposed expansion will provide direct employment to 1658 people.

Post expansion the total employment will be 2523.

2.3 ADVANTAGES OF THE PROJECT

➢ Value addition project by gainful utilization of wastes and

converting intermediate products into end-use product.

➢ Improved productivity by higher plant load factor of existing

1X80MW CPP and Economies of scale in Ferro Alloys Production.

➢ Reduced operation cost due to sharing of infrastructures and

manpower with existing unit reducing overheads by almost 30%

➢ Since the materials handling will be similar to existing operation,

synergy of activities will bring economies to the unit. The current

Coal handling plant for 1X80MW CPP is sufficient to feed the

proposed additional 1X80MW unit Thereby having no increase of

fugitive emissions in the raw material handling section.

➢ Dedicated and experienced workforce is available.

➢ Technology is not new and has already been successfully tried in

existing plant.

2.4 LOCATION OF THE PROJECT

Details about the Project area are given in Table – 2.1. Key map

showing the location of various features around the Plant site is shown

in Fig – 2.1.



Final EIA

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SCALE

2km10

PROJECT :

TITLE :

KEY MAP

CLIENT :M/s. SARDA METALS & ALLOYS LTD.

SECUNDERABAD

Prepared by

N

FIG - 2.1

LEGEND

PROJECT SITE

ROADS

STREAMS / TANKS

SETTLEMENTS

FOREST

RAILWAY LINE

RIVER

MAIN POWER LINE

0.46

0.44

1.21

1.05

PROJECT SITE

SER

ADVANAPALEM

RESERVED FOREST

S E

R

MAIN

POW

ER L

INE

APIIC Industrial Park, Kantakapalli Village,Vizianagaram District, Andhra Pradesh.

AppannadorapalemKottavalasa

Ardhannapalem

Baligattam

Nimmalapalem

DattiKotta Sunkarapalem

Danninapeta

Nimmalapalem

Gollapeta

Chinnaraopalli

Ganivada

Chinnipalem

Jogayyapalem

Uttarapalli

Kotta Gangubudi

Mallividu

Erravanipalem

Chintaladimme

Sitampeta

Tummikapalli

SambayyapalemKantakapalli RS

Gandhinagaram

Appannapalem

Kotturu

Kantakapalli

Kantakapalli

Bhimali

Nidighattu

Kotta Kovvada

Rayipalli

Pata Sunkarapalem

Mulagapakavanipalem

Addupalem

Appannadorapalem

Appannadorapalem

Tummikapalli

Karrichennayyapalem

EXPANSION OF FERRO ALLOY PLANT, CAPTIVE POWER PLANT

AND INSTALLATION OF STEEL MELTING SHOP, MINERAL FIBRE PLANT



Final EIA

Report


TABLE - 2.1: DETAILS ABOUT THE PROJECT

State Andhra Pradesh

District/ Tehsil Vizianagaram

Village Kantakapalli

Survey No.

APIIC Industrial Park, 179/4,181,182,183/1 to 20, 185,

186,187,188/1&2, 189/1&2, 190,191,192/1 to 3, 193,

194,195,196,197,198,199,200,201,202 & 203

Area 280.96 Acres

Toposheet No. 65/O/1

Geo-

coordinates

S. No Latitude Longitude Direction

A 17°56'47.70"N 83°13'4.60"E NORTH

B 17°56'12.89"N 83°13'31.44"E SOUTH

C 17°56'39.92"N 83°12'46.32"E WEST

D 17°56'31.16"N 83°13'47.88"E EAST

Fig – 2.2 shows the Corner coordinates of the plant site superimposed

on toposheet. Toposheet showing 10 km radius of study area is

presented in Fig – 2.3.

Photographs of the project site are shown in Fig -2.4. Google Earth

Imagery of the project site is shown in Fig – 2.5.

The project site does not fall near the polluted stretch of river identified

by the CPCB/MoEF&CC.

2.5 SIZE AND MAGNITUDE OF OPERATIONS

TABLE - 2.2: PROPOSED EXPANSION OF FERRO ALLOYS, STEEL MELTING

AND CAPTIVE POWER PLANT

Unit Existing Proposed Total capacity after

expansion

(TPA)

Ferro Alloys 1,00,000 1,50,000 2,50,000

Captive Power Plant base on

PF boiler technology (MW) 1 x 80 1 x 80 2 x 80

Briquetting Plant 1,05,000 - 1,05,000

Steel Melting Shop (SMS)

(IF, TMT & WRM) - 3,00,000 3,00,000

Mineral Fiber Plant - 1,50,000 150,000



Final EIA

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Final EIA

Report


83° 1

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Final EIA

Report


FIG - 2.4 PHOTOGRPAHS OF THE PLANT SITE



Final EIA

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FIG - 2.5 GOOGLE EARTH IMAGERY OF THE PROJECT SITE



Final EIA

Report



2.6.1 RAW MATERIAL

The raw material requirement is given in Table- 2.3.

FINISHED PRODUCT/CAPACITIES

PRODUCT NAME QUANTITY, TPA

Ferro Alloys 2,50,000

Captive Power Plant (MW) 2 x 80

Briquetting Plant 1,05,000

SMS (TMT bars & Wire Rod Mill) 3,00,000

Mineral Fiber Plant 1,50,000

TABLE - 2.3: ANNUAL RAW MATERIAL QUANTITY EXISTING AND PROPOSED

S No Unit Raw

Material

Existing Additional Total

(TPA)

Source/

Distance

Mode of

Transportat

ion

1 Ferro

Alloys

Manganese

Ore 200000 300000 500000

South Africa,

Australia,

Brazil, Gabon,

India

Ship/Road

/ Rail

Coal 69000 103500 172500 South Africa Ship/Road

/Rail

Coke 12000 18000 30000 India / China Ship/Road

/Rail

FeMn Slag 100000 150000 250000 Japan/ India Ship/Road

Quartz 10000 15000 25000 India Road

Dolomite 20000 30000 50000 India Road

2

Captive

Power

Plant

Coal 505476 505476 1010952 Indonesia

Ship/Road

3

SMS &

Rolling

Mill

Scrap - 274305 274305 India / Import Ship/Road

DRI - 68575 68575 India Road

Ferro Alloys - 3349 3349 In house -

Aluminum - 80 80 India Road

Fluxes - 3508 3508 India Road

4 Briquettin

g Plant

GCP Dust 3000 4500 7500 In-house -

Mn Ore Dust 28672 43008 71,680 In-house -

Binder 700 1400 2100 India Road

Additive 350 700 1050 India Road

Coke Fines 2450 4900 7350 In house -

5

Mineral

Fibre

Plant

SiMn Slag - 1,50,000 1,50,000 In house /

India

Road



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2.6.1.2 MODE OF TRANSPORT OF RAW MATERIAL

Raw Material will be transported through Rail/road. Presently raw

material is being transported by road/rail from Visakhapatnam Port and

Gangavaram Port. Nearest railway siding is Kantakapalli at 1.5 km from

the site and nearest port (Visakhapatnam Port) is 28 km.

2.6.2 LAND

The proposed activities will be within the existing Industrial Area of

Andhra Pradesh Industrial Infrastructure Corporation (APIIC). The total


No.179/4,181,182,183/1to20,185,186,187,188/1&2,190,191,192/1to3,193,1

94,195,196, 197,198,199,200,201,202 & 203 in village Kantakapalli.



additional land is required for the expansion project. No forest land is

involved. The breakup of the land for the various activities for the

proposed project will be as follows:

TABLE - 2.4: LAND BREAKUP (Acres)

S.

No DETAILS Existing Proposed

Total (After

Expansion)

01 Process Area 32.69 85.22 117.91

02 Common utility area 21.43 - 21.43

03

Green Belt

a. Developed Greenbelt 93.23 - 93.23

b. Proposed Miyawaki

Plantation - 1.12 1.12

04 Vacant Land 133.61 - 47.27

Total Area 280.96 86.34 280.96

2.6.3 WATER





Lr.No.53/2012-13/E. II(WS-M) dated 16.01.2013 (Annexure – 2A).



Final EIA

Report


TABLE – 2.5: WATER REQUIREMENT FOR THE PROJECT (m3/day)

S.No Unit Purpose Existing Proposed Total

1 Ferro Alloys Cooling water makeup 470 683 1153

2 Captive Power Boiler Feed 110 110 220

Plant Cooling water makeup 60 60 120

3 DM Plant Softener regeneration 34 34 68

4 Briquette Plant Process 28 28 56

5 Steel Melting Shop Cooling 0 500 500

6 Common Service water 225 230 455

7 Staff Requirement Domestic 53 75 128

Total 980 1720 2700

2.6.4 POWER

The electric power requirement for the project will be fulfilled from

existing & proposed Captive Power plant.

TABLE – 2.6: PRESENT POWER REQUIREMENT

S. No UNITS Requirement (MW)

1 Ferro Alloy Division (2 Furnaces) 48.60

2 Auxiliary Power consumption in 1 x 80 MW CPP 5.60

3 Briquetting Plant 0.10

Total 54.30

TABLE – 2.7: PROPOSED POWER REQUIREMENT

S.No Schedule Units Requirement (MW)

1 2021 - 2023 FAD Furnace – 3 24.30

Mineral Fiber Plants (1 & 2) 2.40

Sub Total 26.70

2 2023 - 2025 FAD Furnaces – 4 & 5 48.60

Mineral Fiber Plants (3, 4 & 5) 3.60

Sub Total 52.20

3 2025 - 2027 Steel Melting Shop 33.0

Auxiliary Power consumption in 1 x 80 MW CPP 5.60

Sub Total 38.60

Grand Total 117.50




1 X 600 kVA diesel fired DG sets will be installed as standby power

supply units. These DG sets will be operated only when there is a normal

power supply failure. HSD will be used for power generation in DG Sets.



Final EIA

Report


2.6.5 MANPOWER

The employment potential of the Project (both existing and proposed is

given below: PARTICULARS DIRECT INDIRECT TOTAL EMPLOYMENT

Existing Project 215 650 865

Proposed Expansion 408 1250 1658

Total (After Expansion) 623 1900 2523

Apart from the above, the company engages various contractors for

transportation, repair, maintenance of equipment and services which

generates secondary employment.

2.6.6 SCHEDULE OF IMPLEMENTATION

Expansion activities at the site will be carried out after grant of

Environmental clearance from Ministry of Environment & Forests and

Consent to Establish from Andhra Pradesh Pollution Control Board. The

schedule for implementing the proposed project is given in below

table.

PROJECT IMPLEMENTATION SCHEDULE & PROJECT COST

The proposed expansion project will be implemented after receipt of

all statutory clearances as per the schedule. The total estimated cost of

the expansion is Rs 1242 crores. The details are given below:

TABLE - 2.8: PROJECT IMPLEMENTATION SCHEDULE & PROJECT COST

PROPOSED UNITS NO OF

UNIITS

Project Cost

(in Crores)

Implementation

Schedule

Furnace 3 of Ferro Alloy Plant 01 211 2021-2023

Mineral Fiber Plants (2nos) 02

Furnace 4 & 5 Of Ferro Alloy Plant 02 321 2023-2025

Mineral Fiber Plants 03

Steel Melting Shop 01 710

2025-2027 1x80 Mw Coal Based Captive Power

Plant Based on PF Boiler Technology

01

TOTAL PROJECT COST FOR EXPANSION 1242

2.6.7 PLANT LAYOUT

Total Are is 280.96 Acres. Present activities are covered under 54.12

Acres, Green Belt in 93.23 acres and area available for future

expansion is 133.61 Acres. The layout showing the existing and

proposed expansion facilities is given in Fig – 2.6.



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2.6.8 COLONY






workers.

2.7 GREEN BELT

The total plot area is 280.96 acres, out of which the company has

developed greenbelt as given below:

S.No. Description Area (Acres)

1 Developed Green Belt 93.23

2 Proposed Miyawaki

Plantation

1.12

Sub Total 94.35

As per CPCB guideline, every industry should develop minimum 33% of

total plot area as greenbelt area. SMAL has already developed

greenbelt on 93.23 Acres or 3,77,288 Sq.m i.e., 33.18 %. Green belt shall

be enhanced further on continuous basis by planting additional trees

to existing green belt.








The Company implemented the Miyawaki Plantation scheme on trial

basis developed by the Japanese Botanist Mr. Akira Miyawaki in an

area of 0.51 acres in which close to 6000 trees have been planted in

very close proximity in order to create a high dense green barrier.

Additionally, 1.12 acres will be developed in the proposed expansion.



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The ‘Miyawaki Method’ is a unique technique to grow forests. Under

the approach, dozens of native species are planted in the same area,

close to each other, which ensures that the plants receive sunlight only

from the top and grow upwards than sideways.

It requires very little space (a minimum of 20 square feet), plants grow

ten times faster, and the forest becomes maintenance-free in three

years.

The greenbelt in the post expansion phase will be 94.35 acres which is

33.58% of the total plot area of 280.96 acres.

2.8 SOCIAL INFRASTRUCTURE

The project area lies within the 280.96 acres. No colony is proposed

within the plant. The company has provided transport for bringing the

staff from Visakhapatnam. All facilities, such as canteen, toilets, rest

rooms, etc. will be provided for truck drivers labours and casual

workers. Separate office building equipped with all communication

and other infrastructure will be provided to the transporters.

2.9 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD, RAIL/ METRO/

WATERWAYS ETC.)

The proposed project is situated at Kantakapalli village, Kothavalsa

Mandal, Vizianagaram (District). The project is located within the APIIC

Industrial Park. The site is well connected with Road/Rail. The details are

as follows:

✓ Nearest Road: Road Connecting Kothavalasa to Vizianagaram –

Adjacent to site.

✓ State Highway (SH-39) – Araku – Visakhapatnam – 6 km

✓ Nearest railway station- Kantakapalli – 1.5 km

✓ Nearest Airport- Visakhapatnam – 25 Km

✓ Nearest Sea Port – Visakhapatnam Port – 28 Km


2.10.1 EXISTING PLANT FACILITIES

The following are the existing facilities in operation:



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a) Ferro Alloys Plant (Ferro Manganese and Silico Manganese) using

Submerged Arc Furnace

b) Captive Power Plant based on Pulverized Fuel Combustion Boiler

Technology

c) Briquetting Plant to recycle fines / bag house dust into the

furnaces

DESCRIPTION ABOUT PROCESS/SUB-PROCESS

M/s Sarda Metals & Alloys Limited is having various sections for

manufacturing the following products:

2.10.2 FERRO ALLOYS PLANT





composition of alloy. To produce FeMn/SiMn Manganese ore, reductants

like Coke & Coal and fluxes like Dolomite & Quartz are blended in

suitable proportion and fed into submerged arc furnace. The energy

required for smelting is provided from electricity passing through three

Soderberg electrodes that are submerged in the raw material charge.

The Electrical energy is converted into heat energy and smelting will take

place in the furnace with a bath at the temperature of 1600°C-1700°C.

During the chemical reaction gases evolved in the furnace bath come

up to furnace top through porous charge. These gases are collected

through a duct and then it passes through a forced draft cooler and then

into the Gas Cleaning Plant. The gases and fine dust particles are

separated in the Gas Cleaning Plant through high quality PTFE coated

glass fibre filter bags. The fine dust is collected in hoppers and recycled

back into the furnace in the form of briquettes. The clean gases/air is vent

out through chimney via ID fan.

The metal and slag is formed in the furnace bath after complete smelting

operation and are tapped out from the furnace bath at an interval of 2 –

2 1/2 hrs. The liquid melt is collected into ladle and slag pots. The metal is



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casted in casting beds /Pig Casting Machine (PCM) and slag poured into

beds/slag granulation pit. The metal is removed from casting beds/PCM

after sufficient cooling. The metal is sized in the finished product handling

section with different sizes as per customer requirement. The sized metal is

analyzed and dispatched to the parties as per their chemical

composition.

In case of Ferro Manganese, the slag generated is used in the silico

manganese process as a raw material. Silico Manganese slag is

granulated and then supplied to numerous brick manufacturing units in

the vicinity.

The Ferro Alloys plant will consist of the following major equipment

o Raw Material Handling System

o Submerged Arc Furnace

o Furnace Shell

o Electrode column

o Furnace Transformer

o Furnace Roof

o Smoke Hood

o Connecting Duct & Emergency Stack

o Switch Yard & HT Switch board

o Copper Bus Bar, Tubers, Flexibles etc.

o Finished Goods handling system

o Gas cleaning plant & Chimney

o Cooling towers

o Pig casting machine

o Slag granulation

o EOT crane

RAW MATERIAL HANDLING SYSTEM

The various Raw Materials viz. Ores, Quartz, Coke etc. will be received

through Road Transport/Rail. These will be unloaded in Raw Material

Storage area at the respective storage locations. An elaborate Raw

Material Handling System is provided to feed the correct and pre-

weighted mixture of Raw Material to the Furnace. The system will consist

of the followings major equipments:



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a. Feed Hopper of adequate capacity

b. Belt Conveyor

c. Screens

d. Day bunkers for Mn. Ore, Quartz, Coke and other fluxes.

e. Vibratory feeders

f. Weigh Hopper with load cell arrangement and digital panel

g. Belt conveyor

h. Receiving hopper

i. Charging bins with chutes

SUBMERGED ARC FURNACE

There are 2 x 33 MVA Sub-Merged Arc Furnaces equipped with 6 No’s,

12 MVA Furnace Transformers (3 for each furnace). The detailed

technical specification of the Furnace is as under:

MECHANICAL

Shell Diameter: 10550 mm

Electrode Diameter: 1400 mm

Type of Furnace: Semi closed

ELECTRICAL

Furnace Transformer 12 MVA - 6 Nos. (3 for each furnace).

Method of Tap Changing OLTC

Primary Voltage 33 KV

Secondary Voltage 142 to 275 in 33 taps

FURNACE SHELL

The Furnace Shell is of cylindrical casing of 25 mm thick MS Plate and

bottom constructed from thick plates of 25 mm MS section.

The Heavy stiffener rings and flats are provided all around shell to avoid

deformation of shell during operation of furnace due to high thermal

and mechanical stresses.

Two Spouts at the hearth level at 46° apart are attached to the

furnace for tapping purpose. The furnace bottom is supported by

providing rails.



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ELECTRODE COLUMN

Electrode column is cylindrical in shape and includes lower mantle,

upper mantle, slipping mechanism and electrode.

Lower mantle is the column portion inside the furnace and carries

contact clamps to pass electricity to electrodes, pressure bellows and

pressure rings. This portion of electrode column is protected by water

cooled heat shields.

Carbon electrode is consumed in the process of Ferro production is

kept in position and regulated by regulating cylinders and slipping

devices. These devices are operated through hydraulic system

supplied by Yuken India.

Furnace Transformer Detailed Technical Specifications are given

below:

Rated Capacity : 12000 KVA

Type of Cooling : OFWF

Rated Voltage : (Primary) 33000 Volts

(Secondary) 275 Volts

Rated Current : (Primary 630 Amps.

(Secondary) 92000 amp

Rated Frequency : 50 Hz

Connection : Delta / Open Delta

Type of Tap Changer: OLTC

FURNACE ROOF

The furnace is covered by Water Cooled Roof. The roof is fabricated with

thick MS Plate. The centre delta portion of roof is Water Cooled and

made out of SS 304 material with double wall construction. The roof is

having 3 openings for Electrodes and Charging Chute and two nos. for

exhaust gases.

SMOKE HOOD

The Smoke Hood is fabricated with thick MS plate and provided water

cooling system. The stiffener rings & flats are provided all around the hood

to avoid deformation.



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CONNECTING DUCT & EMERGENCY STACK

The water-cooled duct along with emergency stack is connected to top

of roof for emission of exhaust gases. These gases will be sucked by ID Fan

through Bag Filter to reduce the dust concentration present in the gases

to a permissible level and finally clean gases will be exhausted to

atmosphere.

220 KV GAS INSULATED SWITCH YARD

220 KV/33KV receiving electrical substation with all related facilities and

equipment like distribution transformer, SF6 Breakers, Lightning Arrestors,

Power Transformers, Current Transformers, Protection Relay, Capacitor

Bank and Substation control room with associated panels, cabling, and

controls.

SF6 BREAKER

For switching ON & OFF of the furnace the SF6 Breaker of 33 KV, 1250

Amps rating is provided, on primary side of the furnace transformer.

COPPER BUS BAR, TUBES, FLEXIBLES ETC.

Sub-Merged Arc Furnace works on the principal of submerged arcing

where the high current is supplied through electrodes and short circuit

inside the Furnace is done with the help of metallic charge. The

Electrodes can carry current upto 98 K Amps each. The current from the

secondary of transformer to the electrodes is supplied through the set of

Copper Bus Bar, Copper Bus Tubes, and Copper Flexible and through

Contact pads.

FINISHED PRODUCT HANDLING SYSTEM

The Ferro Alloys after tapping, metal will be casted in CI pan/PCM. The

metal cakes will be transported to finished product shed for breaking of

required size and will be packed for dispatching. Silico Manganese slag is

granulated in granulation pit and FeMn slag casted in sand bed. The slag

cakes shifted to finished yard for breaking required size and re used as

raw material to SiMn production.



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GAS CLEANING PLANT & CHIMNEY

Hot gases from furnace is cooled in Forced draft cooler to 260°C and dust

in gases is separated by passing it through Reverse Air Bag House and

finally filtered gas is vented into the atmosphere through concrete

chimney at 65m height. Entire dust is collected and recycled in furnaces

in the form briquettes produced by the briquetting plant.

TABLE - 2.9: REVERSE AIR BAG HOUSE TECHNICAL DATA

S. No Parameters Units Operating Data

1 Bag Filter Type/Model HE-2x4-(3W6W3)15-34

2 Gas Volume m3 /hr 500000 (Design)

3 Inlet Gas Temperature oC 225 Min

4 Inlet Dust Load gm/Nm3 4.4

5

Static Pressure across Filter After

Cleaning Under Normal

Operating Conditions

mmWC 150 to 175

6 Air to Cloth Ratio m3 /min/m2 Gross:0.63 & Net:0.69

7 Design Suction Pressure of

Housing mmWC +/- 400

8 Max Gas Temperature Allowed oC 280 for 5minutes in 1

week

9 Max Outlet Dust Load mg/Nm3 dry < 25

10 Hopper Volume m3 52 Approx Each

COOLING TOWER

4x400 m3/hr cooling tower cells are installed, 2 no’s for each furnace. Hot

water from Ferro alloys furnaces circuit is cooled in these towers to make

it a closed loop system and cooled water circulated back to furnaces to

absorb heat.

PIG CASTING MACHINE

Pig casting machine is used to cast liquid metal tapped from furnaces.

The casted material is weighed, broken to the desired size specifications

and finally packed for dispatch.

SLAG GRANULATION

Liquid slag from furnaces is generated by high pressure water jet. This

system handles 250TPD of liquid slag and granulated slag here is used in

brick manufacturing industries.



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EOT CRANE

2 no’s of 50/20 T capacity EOT cranes are used to handle metal & slag in

casting bay.

It is proposed to increase the Rating of Furnaces to 36 MVA. However,

there is no change in the capacity.

MATERIAL BALANCE FOR FERRO ALLOYS (2 X33 MVA FERRO ALLOYS –

1,00,000 TPA) OF EXISTING PROJECT

Input Output

Item Quantity (TPA) Item Quantity (TPA)

Mn Ore 200000 Ferro Alloys 100000

FeMn Slag 100000 SiMn slag 120000

Coal 69000 Gas Cleaning Plant

dust 4000

Coke 12000 LOI 187000

Quartz 10000 - -

Dolomite 20000 - -

Total 411000 Total 411000

MATERIAL BALANCE FOR PROPOSED PLANT (3X36 MVA FERRO ALLOYS – 1,50,000 TPA)

Input Output

Item Quantity (TPA) Item Quantity (TPA)

Mn Ore 300000 Ferro Alloys 150000

FeMn Slag 150000 SiMn slag 180000

Coal 103500 GCP dust 6000

Coke 18000 LOI 280500

Quartz 15000 - -

Dolomite 30000 - -

Total 616500 Total 616500

The process flow diagram of Ferro Alloys is shown in Fig – 2.7.

2.10.3 STEEL MELTING SHOP WITH CCM AND HOT CHARGING ROLLING MILL:



300000 TPA.







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Raw Material

DM Water Sump

FinesBriquette Plant

Ground Hopper

Screen House

Batching System

Feed BinsDM Plant Water

Cooling Tower Water

Metal

Hot Water

Cold Water

Dispatch

FG Yard

Casting Machine

StackFurnace

GCP Dust

Off GasGas Cleaning PlantFD Cooler

TappingTapping Fumes

Stock

Slag

Mineral Fiber Plant Slag Granulation

YardSlag Pit

Dispatch Disposal

Skull

Crusher

RecoveryPlant

Slag

Disposal

SlagSlag

MetalMetal

Metal

Metal

PROCESS FLOW DIAGRAM OF FERRO ALLOYS

FIG - 2.7


o Induction Furnace

o Continuous Casting

o Direct rolling

INDUCTION FURNACE

The greatest advantage of the induction furnace is its low capital cost

compared to other types of Melting units. Some advantages over

electric furnace are high power efficiency with little radiation losses as



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they are water cooled, it has no electrodes and electric arcs and thus

allows production of steel low in carbon and dissolved gases, low

operating cost of refractories due to no electrode consumption & 15-

20% lower consumption of costly ferro alloys due to lower oxygen level

of liquid steel.

The main charge material for induction Furnaces shall be DRI / Sponge

Iron / Steel Scrap. However, some quantity of Pig Iron may be used for

composition correction or depending on cost advantage. IFs can use

Iron fines much more effectively than EAFs.

Induction furnace works on the principle of Induction melting of

scrap/sponge iron with the help of electric power. An alternating

electromagnetic field induces eddy current in the metal so that the

electrical energy converts into heat whose quantity depends on the

resistively of the charge. If the charge consists of metal scrap, chips

and other metal rejections then the eddy currents arise between

separate pieces of charge because of high contact resistance. So

small charge pieces required increase frequency of current that feeds

the induction heater in order to speed up melting of the charge.

Induction furnaces operate on current of commercial frequencies

(50Hz) or on current of higher frequencies from 500 to 2000 Hz.

Induction furnaces are beneficial in steel making for low melting loss.

An induction furnace constitutes a single larger primary coil made of

water-cooled copper tube. The working voltage is impressed across

the terminals of the coil. These furnaces have a great much

application for melting of Iron, Steel and Nonferrous.

CHARGING

The pieces of scrap should be kept on the bottom gently to avoiding

impacts into a compact heap. The scrap pieces/ sponge iron should

be in small size that provides good compaction of the batch without

leaving spacing between the charge and crucible wall. This offers an

advantage of quick melting of the charge with a minimum power

spent in the stage for the heat. The zone of a highest temperature

during the melting lies in the power part of the crucible therefore it is

practical to place first high melting scrap on the crucible bottom.



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Large and high melting pieces should stand parallel and close to the

crucible while low melting components should be in the middle of the

crucible. Small capacity furnaces are loaded manually and the large

capacity furnaces with the aid of buckets.

MELTING

At the beginning of melting the furnace works for 5 to 10 minutes on

low power until the surge of current fed from the generator disappear.

The furnace power is then brought up to a maximum. The charge melts

with the crucible held closed. When the charge approaches the fluid

stages then the solid pieces are pressed back with a crowbar. The

furnace is then loaded to its capacity by adding small size of scrap as

soon as the charge melted, the slag is formed to protect the metal

from oxidation and to avoid / reduce the melting loss. If the slag

generated is in excess, it should be skimmed off periodically, and lastly

the metal is deoxidized with Ferro manganese, Silico manganese and

Ferro silicon. Now the metal is ready to tap for either in ingot or billet

casting.

CONTINUOUS CASTING OF BILLETS

In the proposed project the molten steel from the 4x22T IFs will be

casted in continuous casting machine to produce 3, 12,500 TPA billets.

The cast shape will be torch cut to length and the hot metal will be

transported to the rolling mill for further processing.

ROLLING MILL

The company proposed to set up a 3,00,000 TPA capacity rolling mill to

produce TMT bars & wire rod coils. The raw material i.e., Billet coming

from CCM in red hot condition is cut either by Gas Cutting or

automatic hot billet Shearing Machine. In the proposed plant

automatic hot billet shear machines are going to be installed with

each strand. The gas cutting facility will be maintained as a backup to

the hot billet shearing machine. After the Billet is cut into required

length and then pushed out to rolling stands for re-rolling. Steel Pieces

are rolled through all stands in order to get required shape of finished



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goods i.e., TMT bars/Wire rod. In case of production of TMT the rolled

bars are passed through the TMT quenching machine and then after

quenching of TMT are transferred to Cooling Bed for Cooling. After

Cooling, Wire rod Coils/TMT Bars are shifted to decoiling machine and

after inspection, bundled and are ready for dispatch.

Gaseous pollutants from induction furnaces are collected, Cooled and

cleaned through a bag filter by installing primary and secondary fume

extraction and dedusting systems.

MATERIAL BALANCE FOR STEEL MELTING SHOP

Raw Material Input (TPA) Product Out Put (TPA)

Scrap 2,74,305 Product 3,00,000

DRI 68,575 Slag 31,880

Ferro Alloys 3,349 Dust 5,320

Aluminium 80 Mill Scale 3,000

Fluxes 3,508 LoI 9,617

Total 3,49,817 Total 3,49,817

The Process Flow Diagram of Steel Melting shop (SMS) is shown in Fig –

2.8.

2.10.4 BRIQUETTING PLANT

A Briquetting Plant was implemented to recycle baghouse dust from

Ferro alloys plant and Steel Melting shop. The dust along with Manganese

ore fines & Coke fines to form hard briquettes with some use of binders

like cement, bentonite by the process of extrusion. In this process first fine

material is mixed manually on ground and fed by payloader onto the

hopper. From hopper material is conveyed through belt conveyors to Pug

mill. Binders are added before raw material is taken into pug sealer to

increase the strength and plasticity of the extruded product.


and binders such as cement bentonite 20mm diameter solid briquette is

extruded. It is cured for 3-4 days in an open area after which it becomes

strong, gaining enough mechanical strength to withstand the impact

during transferring through belt conveyors to furnace.



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Storage Yard

TMT+Wire Rod Mill

Rolling Mill

Cold Billets via cooling bed

Ferro Alloys PlantHot Billets

Re-Heating Furnace

Dispatch

Mill Scale

Bag House Filter Stack

Bag House Dust

Briquette Plant

Fumes

Raw Material

4x22T

Induction Furnace 1

Induction Heater

In- Line Billet

Machine

3 Strand 6/11 M

Radius

Liquid Steel

PROCESS FLOW DIAGRAM OF STEEL MELTING SHOP (SMS)

Continuous Casting

FIG - 2.8

MATERIAL BALANCE FOR PROPOSED BRIQUETTING PLANT


GCP Dust 12,820 Briquette 1,05,000

Mn Ore

Fines 71,680

(Water 10.5%)

Binder 2,100

Additive 1,050

Coke Fines 7,350

Total 95,000 Total 1,05,000

The Process Flow Diagram of Briquetting Plant is shown in Fig – 2.9.



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Fines

Additive

Water

Pug Mill

Binder

Extruder/Pug Seal Vaccum System

Green Briquette

Storage Yard

Ferro Alloy Furnaces

Feed Hoppers

GCP Dust &

Mn Ore Fines

PROCESS FLOW DIAGRAM OF BRIQUETTING PLANT

FIG - 2.9

2.10.5 MINERAL FIBRE PLANT






Mineral fibre wool is a name for fiber materials that are formed by

spinning or drawing molten minerals such as SiMn slag. Mineral Wool

manufacturing process consists of following steps:



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Raw material charging

Melting

Fiberisation of the melt

Product mat formation

Curing

Cooling

Product Finishing

The Process Flow Diagram of Mineral Fibre Plant is shown in Fig - 2.10.

Water

Processing

Edge Cutting

Heating in Oven

Cooling & Cutting

Packing & Storing

Specialized Furnace

Raw Material

(Si Mn Slag Waste

PROCESS FLOW DIAGRAM OF MINERAL FIBRE PLANT

Mineral Wool

Dispatch

StackBag

Filter

FIG - 2.10

MATERIAL BALANCE FOR MINERAL FIBRE PLANT


Si Mn Slag 1,50,000 Mineral Fiber 1,50,000

Total 1,50,000 Total 1,50,000



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Manufacturing process involves following steps:

❖ Hot SiMn slag will be charged in to Special furnace.

❖ The molten material is drawn from tap hole which is located at

the bottom of the furnace through a short trough, which is

positioned exactly above the spinning machine.

❖ The melt falls onto the rapidly rotating wheels of the spinning

machine and then it is thrown off in a fine spray producing fibers.

❖ Air is introduced at the back of the rotating wheels to attenuate

the fibers and direct them onto the collection wheel to form a

mattress.

❖ Binding material is then applied to the fibers by a series of spray

nozzles on the spinning machine.

❖ Water is also sprayed which cleans the collection wheel and

other parts of the plant.

❖ The secondary mat obtained after this process is then layered to

give the required product weight per unit area.

❖ Thereafter, the mat passes through hot oil chamber and is

heated at a temperature of about 400 0C.

❖ This additional heating sets the product thickness, dries the

product The Product is then air cooled & cut to the required size.

❖ These mats are then packaged as slabs or wire mat.

❖ Pipe section is a product manufactured by diverting the uncured

wool from the main process for reprocess for moulding & curing.

2.10.6 CAPTIVE POWER PLANT















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The captive thermal power plant will have the following major

equipments:

o Steam Turbine

o Steam Generator

o Electrostatic Precipitator

o Coal handling system

o Ash handling system

o Water treatment plant

STEAM TURBINE & GENERATOR

Make M/s Siemens

Steam Pressure 105 kg/cm2

Temperature 540

Exhaust Pressure 0.18 kg/cm2 abs

RPM 3000

Capacity 80 MW

Voltage 15.75 KV

Rating 95 MVA

STEAM GENERATOR

Make M/s Enmas

Type Pulverized coal fired Boiler

Capacity 309 TPH

Type Single drum water tube

Heat Source Coal

ELECTROSTATIC PRECIPITATOR

Make M/s Enmas

Gas Temperature (Opt/max.) 160°c

Gas Pressure -300 mm WC

ESP Inlet Dust conc. 89.04 g/Nm3

ESP Outlet Dust emission 50 mg/Nm3

A similar power plant based on Pulverized Fuel will be adopted during

the Expansion phase.

COAL HANDLING SYSTEM

The raw coal maximum size of 150 mm received by roadways,

unloaded to ground hopper and after preparation of max size 20 mm is



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stacked in covered coal yard. Then the coal is being fed to coal mill

through coal feeder and the final output from mill of size 75 microns is

fed to boiler for combustion.

FLY ASH HANDLING SYSTEM

For handling of fly ash from the steam generator, dense phase,


hoppers located in economizer, air preheated sections of SG and ESP


where the ash will be disposed off by road through trucks for

brick/cement manufacturers.

DRY-BOTTOM ASH HANDLING SYSTEM

In the dry bottom ash handling system, ash cooling is carried out by

ambient air, naturally drawn into the system by the negative pressure

of the furnace. That air recovers a significant amount of energy in the

form of ash sensible heat, ash chemical energy from unburnt particles

and boiler radiation flux through the throat to silo from where the ash

will be disposed off by road through trucks for brick/cement

manufacturers.

WATER TREATMENT PLANT

The source of raw water is from GVMC (Greater Visakhapatnam

Municipal Corporation). The water is the main raw material for

generation of captive power. Part of the water will be used to produce

DM water, necessary for boiler feed requirement. Part of raw water will

be treated in softening plant and distributed to closed circuit of the

plant as cooling tower make-up. The power plant is equipped with Air

Cooled Condenser as a part of water conservation. The proposed

power plant also will be designed with Air Cooled Condenser system to

save on Water.

Typical Process Flow Diagram of Captive Power Plant is shown in Fig –

2.11.



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CO

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DC

RU

SH

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PA

Fan

FD

Fan

ID

Fan

CHIMNEY

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LV

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LP

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VO

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BO

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M A

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FIG- 2.11TY

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MATERIAL BALANCE FOR CAPTIVE POWER PLANT


Coal 5,05,476 Electric Power 80 MW Fly &Bottom Ash 90000



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2.11 MITIGATION MEASURES INCORPORATED IN THE PROJECT TO COMPLY WITH

ENVIRONMENTAL STANDARDS

The plant complies with guidelines of MoEF & CC stipulated under

Corporate Responsibility for Environmental Protection (CREP) and the

Government Gazette Norms, dated 31st March 2012, stipulated under

GSR 277 (E) with the following measures.

1. Suitable capacity Air and water pollution Control Equipments/

arrangements like ESP, Dedusting System, Bag filters, Mist water

spraying system, fix and movable water sprinklers, settling tank,

soak pits, septic tanks installed at different location of plants as

per requirement.

2. Solid waste Management-

a) Generated Ash is being supplied to fly ash Brick

manufacturing plants in the vicinity.

b) Generated Slag from Steel Melting Shop after crushing,

screening and after recovery of metal will be supplied to Fly

Ash Bricks Manufacturing unit in the vicinity or cement plants.

c) Granulated slag from Ferro alloys unit is being supplied to fly

ash brick manufacturing units located near our plant.

3. Cooling tower Blow down is being collected in settling tank and

being used for plantation and dust suppression purpose.

Domestic discharge water is treated in STPs of 10 kld each.

4. Green belt has been developed all along plant premises in an

area of 93.23 acres.

5. Internal roads have been made of RCC / Bitumen and same are

being maintained in good condition by proper cleaning.

With advanced technology in emission reduction and energy

conservation will be taken in to consideration, while selecting the

suitable design. Some of the important design considerations at the

design & implementation stage are as follows:

➢ A proper layout plan is being chosen for the optimum

utilization of the available land and resources.

➢ The design should aim at minimum use of water.



Final EIA

Report


➢ Conservation of water through waste water treatment, recycling

& reuse.

➢ Zero discharge norms can be achieved with proper planning

and its implementation.

➢ Efficient dust extraction, dust suppression and dust collection

measures are incorporated in the design of plant equipment to

reduce the dust emission considerably.

➢ For reduction of SO2, low sulphur content, coal & fuel will be

used.

➢ Combustion control devices with the use of low temperature

burners, considerable NOx, emission will be controlled.

➢ Noise control measures adopted.

➢ The noise producing equipment will be designed with dynamic

balancing and vibration dampening by proper grouting so as to

produce minimum noise.

➢ The operation control rooms and pulpits would be provided with

noise shield walls.

2.12 ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR THE RISK OF

TECHNOLOGICAL FAILURE

TECHNOLOGY FOR MINERAL FIBRE PLANT

The slag will be used to create fibres used as an insultation material

called Slag wool. SMAL has collaborated with the Environment Studies


convert the Silico manganese slag into mineral fibre. The hot silico

manganese slag is fed into specialized furnace to maintain the

property of the slag at 14000C. The molten material falls into the

fiberization device which are in form of rotors and distributed into a

thin film on the surfaces by centrifugal force and form into Fibre. This

will help in making a value-added product from the waste slag

material.

CHAPTER - 3

DESCRIPTION OF ENVIRONMENT

Expansion of Ferro Alloy Plant, CPP & Installation of SMS, MFP – M/s. Sarda Metals & Alloys Ltd.

APIIC Industrial Park, Kantakapalli (V), Kothavalasa (M), Vizianagaram (Dist.), A.P. Final EIA

Report


CHAPTER – 3: DESCRIPTION OF ENVIRONMENT

3.1 STUDY AREA





3.1.1 ACTIVITIES IN STUDY AREA



below:







Pedda Gedda is a nalla located at a distance of 8.7 k min SE. This is





3.2 STUDY PERIOD



3.3 SCOPING OF BASELINE STUDY WITH PROJECT ACTIVITIES

SMAL is operating the Ferro Alloy Plant and Captive Power Plant in

Kantakapalli Village, Kothavalsa Mandal, Vizianagaram district, Andhra

Pradesh.

The water requirement is met from GVMC. Considering the expansion

activities and activities in the study area, the baseline parameters



Report


which can have influence have been identified for baseline data

collection as given in Table-3.1.

TABLE – 3.1: SCOPING OF BASELINE ENVIRONMENTAL PARAMETERS Env.

Component

Aspect

(Expansion Activities)

Impact Zone Impact

Parameters to

Monitor Project

area

Buffer zone

(10 km)

Air Raw material handling

Coal burning in Power Plant

Fugitive Dust emissions

Process related emissions

Transportation

Yes Upto 3.0 km PM10, PM2.5,

SO2, NOx and

CO.

Noise Coal Mill Operations

Power generation - Turbines of

Power plants CPP, Boiler Feed

Pumps, Air Compressors

Conveyor operations

Yes Upto 5.0 km

Day Equivalent

and Noise

equivalent

Water

Environment

Cooling water for power plant,

Furnace cooling, Process

Requirement

Wastewater generation from

power plant, Process and

canteen

Yes Upto 0.5 km Ground water as

per IS 10500

Surface water to

establish

baseline quality

as per CPCB

Land

Environment

Usage of Land for industrial

activity, reuse of surplus

excavated earth.

Development of greenbelt,

rain water harvesting systems

Yes Upto 3.0 km LULC pattern

using Remote

sensing

Crops and

Pattern details

Soil quality for

Fertility

Hydro

Geology

Rainwater harvesting and

storm water measures

Yes Upto 1.0 km Ground water

status – Stage of

development

Ground water

Quality

Ecology Impact on ecology due to

proposed expansion

Yes Upto 3.0 km Flora and Fauna

in the area

Schedule – I

species

identification (if

any)



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Env.

Component

Aspect

(Expansion Activities)

Impact Zone Impact

Parameters to

Monitor Project

area

Buffer zone

(10 km)

Socio

Economy

No R & R is involved. Existing

project is in operation

Employment potential due to

expansion

Development of CSR activities

in surrounding villages to

improve the infrastructure,

education and health

- Study area Development of

suitable action

plan with

necessary

budget to

implement the

issues raised

during the public

hearing process.

3.4 BASELINE ENVIRONMENT

Baseline data was collected on various environmental components for

studying the existing baseline quality of the study area during Winter

Season 2020-21. The data collected has been interpreted based on the

information collected from the sampling sites and activities around. The

description of the study area activities is provided in above paragraph

at para no 3.1.1. In addition to primary data, secondary data also was

used with respect to ground water status, geology and socio economy.

The detailed description of various environmental components is

detailed in subsequent paragraphs.

3.5 MICRO METEOROLOGY

Site specific micro meteorological data was procured from M/s.

Envitrans for the parameters like Wind speed, Wind direction,

temperature, and relative humidity on hourly basis continuously for the

Winter Season, 2020-21.

The meteorological data thus collected has been used for

interpretation of the existing Ambient Air Quality status, and the same

data has been used for prediction of impacts of future scenario due to

the project.

Secondary data was collected from IMD and District profile to study the

climatology of the area.

3.5.1 REGIONAL METEOROLOGY - VISAKHAPATNAM

The India Meteorological Department (IMD) data of Visakhapatnam



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has been considered. Visakhapatnam is at an aerial distance of 21.37

km in Southern direction from the project site. The Regional Climate of

Visakhapatnam is tropical. Winter rainfall is much less than in summer.

The average temperature in Visakhapatnam is 26.9 °C. The annual

rainfall is around 1071 mm. The average wind speed in Visakhapatnam

is 4m/s with the maximum wind speed of 11 m/s with predominant wind

direction from SSW-SW-WSW sector.

TABLE – 3.2: REGIONAL METEROLOGY – VISAKHAPATNAM DISTRICT Avg.

Temperature °C

Min.

Temperature °C

Max.

Temperature °C

Rainfall

mm

Humidity

(%)

Rainy

days

(d)

Avg. Sun

hours hours)

January 22.7 18.9 26.6 11 73 2 9

February 24.7 20.6 29 12 71 2 9.4

March 27.5 23.9 31.8 10 70 2 10.1

April 29.4 26.3 33.6 10 73 1 10.4

May 30.9 27.9 34.9 51 72 3 10.7

June 29.8 27.3 32.9 125 73 10 11.0

July 28.2 26.2 30.6 187 79 14 10.7

August 27.7 25.8 30 205 81 14 10.3

September 27.6 25.6 30 182 83 14 9.4

October 26.8 24.3 29.6 163 80 1 8.9

November 24.9 21.8 28.1 87 74 5 9.1

December 23.1 19.6 26.6 28 72 2 9.0

Data: 1998 – 2018

Source : https:// https://en.climate-data.org/asia/india/andhrapradesh/visakhapatnam-2804/

https://www.indianclimate.com

3.5.2 STUDY AREA – WINTER 2020-21


with minimum of 11.30C in the month of December.



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The predominant wind direction is from NE-ENE-E Sector accounting to

33.51 % with calm wind for 9.44 % and wind from other directions

accounting to 57.05%.

Wind roses of the site during Winter Season, 2020-21 is shown in Fig – 3.1

and 3.2. Summary of wind pattern is given in Table 3.3.

TABLE - 3.3: SUMMARY OF WIND PATTERN -WINTER SEASON, 2020-21

Duration

Hrs)

Predominant

Wind Direction Sector)

Predominant

Wind Percentage Sector)

Calm

Percentage

00:00 – 08:00 SSE-S-SSW 60.56 6.94

08:00 – 16:00 NE-ENE-E 62.78 13.61

16:00 – 23:00 S-SSW-SW 31.11 7.78

00:00 – 23:00 NE-ENE-E 33.51 9.44

3.6 AMBIENT AIR QUALITY (AAQ)

Ambient Air Quality (AAQ) of the study area has been assessed

through a network of eight ambient air quality stations located within

the study area.

AAQ status has been monitored for PM10, PM2.5, SO2, NO2 and CO.

PM10, PM2.5, at each location as per CPCB norms of 2 days/week for

four weeks/month for three months.

Pre-calibrated respirable dust & Fine dust samplers have been used for

monitoring of the AAQ status.

Methodologies adopted for sampling and analysis were, as per the

approved methods of Central Pollution Control Board (CPCB).

Maximum, minimum, average and percentile values have been

computed from the raw data collected at all individual sampling

stations to represent the ambient air quality status of the study area.

3.6.1 AAQ STATIONS SELECTION CRITERIA

Ambient Air Quality of the study area has been assessed through a

network of eight AAQ stations. The location of AAQ stations with

respect to the project site, representation of each station with respect

to wind pattern of the area and the justification for selection of

particular location for AAQ sampling are details below in Table – 3.4.



Report


DURATION : 16 - 23 HRS.

WINDROSE DIAGRAM

NOTE : All readings are in percentage occurrence of wind


LEGEND

C = Calm Conditions in Percentage

5.01-10

0-1

C

1.01-5

>15 KMPH

10.01-15

PROJECT : EXPANSION OF FERRO ALLOY PLANT, CAPTIVE POWER PLANT

LOCATION : APIIC Industrial Park, Kantakapalli (V), Kothavalasa (M), Vizianagaram (Dist), A.P


N

10 %5 %

SCALE

PERIOD : WINTER SEASON - 2020 - 21

FIG - 3.1

CLIENT : SARDA METALS & ALLOYS LTD.

NNE5.69

NE3.47

ENE5.28

E5.83

ESE4.44

SE2.92

SSE6.39

S21.53

SSW32.64

SW1.53

WSW1.11

W0.69

WNW0.14

NNW0.28

CALM6.94

N1.11

NNE1.25

N0.69

NE22.22

ENE29.17

E11.39

ESE6.67

SE3.19SSE

2.78

S1.25SSW

2.78

SW2.5

WSW2.08

W0.42

CALM13.61

NNE1.94

N2.36 NE

3.75

ENE3.47

E15.97

ESE7.5

SE4.72

SSE4.17

S7.78

SSW13.19

SW10.14

WSW5.56

W4.31

WNW2.92

NW2.78

NNW1.67

CALM7.78




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WINDROSE DIAGRAM

NOTE : All readings are in percentage occurrence of wind LEGEND

C = Calm Conditions in Percentage

0-1

C>15 KMPH

10 %5 %

SCALE

N

5.01-10

1.01-5 10.01-15


FIG - 3.2

PERIOD : WINTER SEASON - 2020 - 21

NNE2.96N

1.39

NE9.81

ENE12.64

E11.06

ESE6.2

SE3.61

SSE4.44

S10.19

SSW16.2

SW4.72

WSW2.92

W1.81

WNW1.02

NW0.93

NNW0.93

CALM9.44

PROJECT : EXPANSION OF FERRO ALLOY PLANT, CAPTIVE POWER PLANT

LOCATION : APIIC Industrial Park, Kantakapalli (V), Kothavalasa (M), Vizianagaram (Dist), A.P

CLIENT : SARDA METALS & ALLOYS LTD.




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TABLE – 3.4: AMBIENT AIR QUALITY MONITORING STATIONS

Station

Code

Locations Distance

[km]

Direction

w.r.t

Plant

Representation Selection

Criteria/

Justification

A1 Plant site ------ ------ 500 m downwind The area is devoid of

any other industrial

operations, the AAQ

stations identified are

mainly to study the

pre-expansion baseline

status which can have

impact from the

expansion activity of

SMAL

A2 Kantakapalli 1.2 N Crosswind

A3 Bhimali 3.4 N Crosswind

A4 Kovvada 3.9 ENE Upwind

A5 Gangubudi 4.4 WNW Downwind

A6 Ganivada 3.8 NW Downwind

A7 Erravanipalem 1.8 SW Downwind

A8 Relli 4.7 S Crosswind

Fig – 3.3 shows the location of ambient air quality monitoring stations in

the study area. Data on the activities surrounding the ambient air

quality monitoring stations were collected for interpretation of the

ambient air quality status.

3.6.2 AMBIENT AIR QUALITY STATUS OF THE STUDY AREA

The date wise data collected at each AAQ station is presented in

Annexure-3A along with statistical values. The Summary of the AAQ

data of the study area represented as 98th percentile value is given

below in Table – 3.5.

TABLE – 3.5: 98th PERCENTILE VALUES OF AAQ MONITORING (g/m3)

Station

Code Locations PM10 PM2.5 SO2 NO2

A-1 Plant site 65.6 32.3 16.2 17.4

A-2 Kantakapalli 54.9 27.9 14.5 15.7

A-3 Bhimali 46.2 27.5 14.6 15.9

A-4 Kovvada 54.3 28.5 15.1 16.4

A-5 Gangubudi 44.6 26.3 14.2 16.9

A-6 Ganivada 57.2 25.6 13.7 16.0

A-7 Erravanipalem 43.7 28.6 13.4 15.8

A-8 Relli 51.3 26.5 14.4 15.6

NAAQ Standards for Industrial,

Residential, Rural and Other Areas

(24 Hrly)

100 60 80 80

Note: CO values are observed less than 1 ppm during study period.



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M/s

. S

AR

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3.6.3 INTERPRETATION OF AMBIENT AIR QUALITY

A1- PLANT SITE

The minimum and maximum baseline values of PM10 and PM2.5

recorded at plant site are ranging from 56.7 to 67.2 g/m3 and 24.3 to

32.8 g/m3 respectively.

SO2 and NO2 values at this location are ranging from 10.6 to 16.4 g/m3

r 11.9 to 17.8 g/m3 respectively. The high values may be due to the

operation of the plant.

A2- KANTAKAPALLI VILLAGE

Kantakapalli Village is located on the crosswind direction from the

plant. The minimum and maximum baseline values of PM10 values are

ranging from 48.3 to 55.2 g/m3 and PM2.5 ranging from 23.2 to 28.6

g/m3 respectively.


and 10.8 to 15.9 g/m3 respectively.

A3- BHIMALI VILLAGE

Bhimali Village is located on the crosswind direction from the plant. The

minimum and maximum baseline values of PM10 values are ranging

from 30.6 to 36.6 g/m3 and PM2.5 ranging from 22.4 to 27.8 g/m3

respectively.



A4- KOVVADA VILLAGE

Kovvada Village is located on the upwind direction from the plant. The



respectively.

SO2 and NO2 values at this location are ranging from 10.2 to15.3 g/m3




Report


A5- GANGUBUDI VILLAGE

Gangubudi Village is located on the downwind direction from the



g/m3 respectively.



A6- GANIVADA VILLAGE

Ganivada Village is located on the downwind direction from the plant.

The minimum and maximum baseline values of PM10 values are ranging


respectively.



A7- ERRAVANIPALEM VILLAGE

Erravanipalem Village is located on the downwind direction from the



g/m3 respectively.



A8- RELLI VILLAGE

Relli Village is located on the crosswind direction from the plant. The



respectively.





Report


CARBON MONOXIDE – CO

CO concentration monitored on eight hourly basis at all the locations

found to be less than 1 ppm.

3.6.4 STACK EMISSION MONITORING

As part of EIA study, emissions from existing units have been monitored

in the month of February, 2021. The following table gives the stack

emission data.

STACK EMISSION MONITORING

Stack Particulars Particulate

Matter

(mg/Nm3)

Sulphur

dioxide

(mg/Nm3)

Oxides of

Nitrogen

(mg/Nm3)

Ferro Alloy Division (FAD) 40 NA NA

Captive Power Plant (1x80

MW) 40 440 175

Source: Third Party Monitoring Report provided by SMAL

3.7 NOISE ENVIRONMENT

Noise levels were collected from eight locations in the study area. Data

was collected using Lutron, Model: SL- 4033 SD. At each location Noise

levels were recorded during the day and night times to compute day

equivalent and night equivalent levels.

Noise levels were collected from eight different locations in study area

mainly to represent the rural activities of villages. Noise levels were also

recorded within the plant site. The noise levels recorded are computed

to obtain single value index of day-equivalent and night-equivalent.

Details of noise monitoring stations and the summary of the day & night

– equivalent values computed for eight locations in the study area are

given in Table – 3.6. The Noise recording stations are shown in Fig - 3.4.



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S L

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PRO

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SCALE

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Published u

nder

the d

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ION

the S

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Genera

l of In

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To

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km

17° 5

5'

18° 0

0'

To

Vis

hakhapatn

am

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Lin

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la

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abhadra

pura

m A

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m

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manda

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manda

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tala

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TABLE - 3.6: NOISE MONITORING STATIONS

Code Locations

w.r.t plant NOISE LEVEL, dB (A)

Distance

[km] Direction

Day

Equivalent

Night

Equivalent

N1 Plant site --- --- 71.8 67.4

National Ambient Air Quality Standards w.r.t

Noise for industrial area 75 70

N2 Kantakapalli 1.2 N 54.3 43.1

N3 Bhimali 3.4 N 51.9 42.9

N4 Kovvada 3.9 ENE 52.7 41.3

N5 Gangubudi 4.4 WNW 53.8 44.0

N6 Ganivada 3.8 NW 54.1 43.7

N7 Erravanipalem 1.8 SW 51.6 42.8

N8 Relli 4.7 S 52.4 43.9

National Ambient Air Quality Standards w.r.t

Noise for Residential area 55 45

3.7.1 NOISE LEVELS IN STUDY AREA & PLANT SITE


equivalent noise levels of 71.8 dB (A) and 67.4 dB (A) respectively which

are within the limits of National Ambient Air Quality Standards w.r.t Noise

for industrial area.






of vehicles.

3.7.2 SOURCE NOISE LEVELS – PLANT AREA

Noise levels in the plant have been measured at various places within

the site. The spot noise levels measured during the study period at 1m

from various noise generating sources are given in Table – 3.7.

The maximum level of noise in the plant complex was produced at

Power Plant Area.



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TABLE – 3.7: SPOT NOISE LEVELS AT VARIOUS SOURCES

S.No Location Noise Level in dB (A)

1 Steam turbine 96

2 Generator 83

3 Boiler Feed Pump 86

4 Air Compressor 83

5 Submerged Arc furnace 90

6 Coal Mill 84

3.8 WATER ENVIRONMENT

The ground water and surface water sources existing in the study area

were studied. Ground status of the area was assessed under

hydrogeological status. Water quality status of the ground water and

surface water are assessed.

3.8.1 DRAINAGE PATTERN

Drainage pattern of the project and 5 km radius of study area is shown

in Fig – 3.5

3.8.2 HYDRO GEOLOGY AND GROUND WATER POTENTIAL

Ground water potential of the study area was obtained based on

secondary information. The yield of aquifer zones in the study area are

found to be good to moderate as they occur under unconfined to

semi-confined conditions.

Ground water occurs in all most all geological formations of the

Vizianagaram district and its potential depends upon the nature of

geological formations, geographical setup, incidence of rainfall,

recharge and other hydrogeological characters of the aquifer.

The water levels in the study area near to project site showed the 3.0 –

4.0 m below ground level. Most of the domestic needs of the study

area depend on ground water. 80% of the agricultural and plantation

activities in the study area are rain fed. Streams originating in hilly areas

form ponds in catchment area down the hill and act as water source

for plantations. However, they are dry except in monsoon.

The total area irrigated by ground water is 300 ha. There are 93 ground

water abstraction structures in the study area.



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FIG – 3.5: 5 KM RADIUS SHOWING DRAINAGE PATTERN OF THE PROJECT



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The bore wells in the villages are 70 m to 100 m depth. The yields of the

bore wells in these formations range between 20 to 70m3/day. The

depth of filter points/tubewells varies from 30 to 40 m with discharges

ranging from 80 to 400 m3/ day. The average yield of the bore wells is

75,000 litres per hour.

The dug wells are having a range of depth from 2 m to 15m bgl. The

yields in the weathered zones of hard formations range from 30 to 45

m3/day. The average yield of the dug wells is 40,000 liters per hour.

Source: CGWB report of Visakhapatnam District – September – 2013.

GROUND WATER DRAFT OF THE STUDY AREA

The study area consists of 35 villages. Under the geohydrological

survey, the inventory of existing irrigation bore wells, drinking water bore

wells fitted with hand pumps and piped water supply villages and the

surface water structures like tanks, ponds etc., has been considered.

Few natural tanks formed in the catchment area of hills in the study

area. Small artificial ponds are also created to store rain water which is

utilized for development of plantations in the study area. All these tanks

together receive about 11.4 MCM of rainwater. Taking 10 % of Surface

water as return recharge, it is 1.14 MCM.

The total irrigation bore wells in the study area are 93 with 54bore wells

and 39 dug wells. Thus the ground water draft is worked out by taking 1

hrs of pumping with an average yield of 75,000 liters per hour for bore

well and 40,000 liters per hour for dug well. The total ground water draft

per annum works out to 2.04 MCM.

The human consumption also contributes for the Ground water draft

and it is worked out by taking the population as per the 2011 census in

the study area and the total population is 65,968. Thus the draft from

human consumption works out annually to 3.25 MCM.

GROUND WATER POTENTIAL OF THE STUDY AREA

The main source of ground water is rain water. To study the ground

water potential, the rainfall infiltration method is adopted. Since, this

area falls in the Hard rock area category the rainfall infiltration factor is



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taken as 10 % of average rainfall. The ground water potential works

out to 36.75 MCM.

The other sources of ground water recharges are the return irrigation

from the surface water and ground water. a) The return recharge from

ground water structures irrigation is 10 % of the draft. This works out to

0.204 MCM and b) from return irrigation from tanks, here also 10 % is

taken out of the water used for irrigation, this works out to 1.14 MCM.

The total recharge from all these sources works out to 36.954 MCM.

GROUND WATER BALANCE OF THE STUDY AREA

Ground Water Balance is worked out and given in Table - 3.8.

TABLE - 3.8: GROUND WATER BALANCE OF THE STUDY AREA

In MCM

a) Total water available from rainfall 367.5

b) Ground Water recharge from rain water 36.75

c) Return recharge from Tanks 1.140

d) Return irrigation recharge from Draft 0.204

e) Present annual draft

i) Domestic 3.25

ii) Bore wells 2.04

f) Total Ground Water Available (b+c+d) 36.954

g) Total Ground Water Draft e = (i+ii) 5.29

h) Net Ground Water available 31.664

i) Water drawl for Present proposal 0

j) Ground Water available for drawl 31.664


SMAL has obtained permission from GVMC to draw 2700 m3/day water

vide Lr.No. 53/2012-13/E. II(WS-M) dated 16.01.2013. At present SMAL

has reduced its water drawl to 1500 m3/day and as per the agreement

with GVMC, the same can be enhanced to 2700 m3/day as and when

required. Letter has been submitted to enhance water from 1500KLD to

2700KLD on 21.08.2021. No ground water is used in the existing project

or for the proposed expansion.

The stage of ground water extraction in the study area works out to

14.31% which is less than 70% and thus the study area is categorized as

“Safe” as per the Ground water Estimation Committee, 2015 norms.



Report


3.8.3 WATER QUALITY OF THE STUDY AREA

Ground water samples were collected to study the water quality of the

study area. Ground water samples collected were checked for

drinking water quality with respect to IS 10500:2012 standard.





Methodologies adopted for sampling and analysis were according to

the IS methods. The Water sampling locations are shown in Fig – 3.6.

Details of water sampling locations are given in Table-3.9.

TABLE-3.9: WATER SAMPLING LOCATIONS

CODE LOCATIONS DISTANCE

[KM]

DIRECTION w.r.t

PLANT

GROUND WATER

GW1 Plant Site --- ---

GW2 Chinnarapalli Village 2.0 NNE

GW3 Nidigattu Village 3.3 NNW

GW4 Bhimali Village 3.5 N

GW5 Kantarapalli Village 0.9 N

GW6 Kotturu Village 0.9 NNW

GW7 Alamanda Village 5.3 NNE

GW8 Kothavalasa Dabala Village 6.5 SSW

GW9 Sunkarapalem Village 1.0 SW

Annexure – 3B presents the water quality data at the above locations.

3.8.4 GROUND WATER QUALITY

The ground water samples were collected at Plant Site, Chinnarapalli,

Nidigattu, Bhimali, Kantarapalli, Kotturu, Alamanda, Kothavalasa

Dabala, Sunkarapalem villages are considered to establish baseline

status of 3 km radius of the project as these can have influence in the

post project scenario. Summary of water quality in the study area is

given in Table – 3.10.



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GROUND WATER QUALITY INTERPRETATION

The ground water samples collected from various locations are

predominantly used for Drinking and domestic purpose. All parameters

of ground water samples are well within the acceptable limits of IS

10500:2012 except for Total Dissolved Solids, but they are well within the

permissible limits of IS 10500:2012.

TABLE – 3.10: SUMMARY OF GROUND WATER QUALITY IN THE STUDY AREA

S.

No

Tests Results

IS 10500:2012

[Drinking Water Standard]

Acceptable

Limits

Permissible

Limits

1 Colour, Hazen <5 5 15

2 pH 6.72 - 7.48 6.5-8.5 No

Relaxation

3 Turbidity, NTU <1 1 5

4 Total Dissolved Solids @ 105⁰ C 282 - 1198 500 2000

5 Total Hardness as CaCO3, mg/l 195 - 575 200 600

6 Calcium as Ca, mg/l 40 - 132 75 200

7 Magnesium as Mg, mg/l 21 - 60 30 100

8 Chlorides as Cl, mg/l 40 - 198 250 1000

9 Iron as Fe, mg/l <0.06 - 1.8 1.0 No

Relaxation

10 Sulphate as SO4, mg/l 20 - 120 200 400

11 Fluoride as F-, mg/l 0.29 - 1.36 1 1.5

12 Nitrate as NO3, mg/l 3.1 - 44

45 No

Relaxation

13 Total Alkalinity as CaCO3, ,

mg/l 120 - 540 200 600

14 Boron as B, mg/l <0.1 - 0.18 0.5 2.4

15 Copper as Cu, mg/l <0.02 0.05 1.5

16 Manganese as Mn, mg/l <0.02 –

0.07 0.1 0.3

17 Zinc as Zn, mg/l 0.02 - 1.69 5 15

18 Lead as Pb, mg/l <0.01 0.01 No

relaxation

19 Mercury as Hg, mg/l <0.001 0.001 No

relaxation

20 Total Arsenic as As, mg/l <0.01 0.01 No

relaxation

21 Sodium as Na, mg/l 11 - 225 -- --

22 Potassium as K, mg/l 1.0 - 23 -- --

23 Total Chromium as Cr, mg/l <0.02 0.05 No

Relaxation



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3.9 LAND ENVIRONMENT

Soil samples were collected from various locations to establish the

baseline status of soil quality in the study area. Standard procedures

were followed for sampling and analysis.

Landuse, Land cover of the study area was assessed by using Remote

Sensing Satellite Data. Classification of landuse was done for

identification of different land use land cover features within the study

area and preparation of land use land cover map and drainage

pattern. Ground truthing has been done for interpretation of the

satellite data to establish the landuse land cover of the study area.

Primary survey has been done for establishing the ecological status of

the of study area on flora and fauna. Secondary data was collected

from Forest Department.

Baseline Geology and Hydro Geological status of the study area was

established through secondary data.

3.9.1 PHYSIOGRAPHY

The study area is undulating terrain with hillocks varying RL over 86 m to

162 m RL over a stretch of 10 km radius. Elevated and undulated

terrains are located beyond 10 km radius. Digital elevation model

(DEM) of 10 km radius of the plant site is shown in Fig – 3.7.

Project site is a plain area with altitude ranging from 87 to 162 m above

mean sea level. The project site also has a hillock in the northern

direction ranging from 102 to 162 m above mean sea level.

3.9.2 GEOLOGY

The study area geologically belongs to Archaean group. The Archaean

group of rocks includes Khondalites and Charnockites of Eastern Ghat

super group and Granitic gneisses of Migmatite group. The study area is

characterized by Eastern Ghat mobile belt. The Eastern Ghats Super

Group comprising Khondalite and Chamockite Groups is exposed in

the central part of the upland area where the Eastern Ghat Mobile Belt

trending in NNE-SSW in the area. The rock is medium to coarse grained

texture comprises Greasy quartz, hypersthenes, orthoclase and

plagioclase with or without Garnet.



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3.9.3 LANDUSE PATTERN OF STUDY AREA

Landuse pattern of the study area has been assessed through Remote

Sensing methodology using IRS-P6, LIS-IV geocoded images dated

21.06.2021. Fig – 3.8. shows Level – II land use / land cover categories

identified in the area are built-up, agricultural land, wasteland, water

bodies and others. Fig – 3.9 shows the satellite imagery of the study

area.

TABLE 3.11: LEVEL – II LAND USE / LAND COVER CATEGORIES WITH IN STUDY AREA

S.No LU\LC AREA

Sq km. Percentage

1 Barren Land Barren/ Waste Land 53.21 16.93

2 Built up

Land

Residential/ Commercial 14.14 4.50

Industry/ Mining 5.20 1.65

3 Dense Scrub

Land

Scrub Land 35.28 11.23

Reserved Forest 18.10 5.76

4 Mixed

Vegetation

Plantation/ Crop Land 55.43 17.64

Fallow Land 118.42 37.69

5 Water body Local Water Bodies/ Lakes/ Ponds 11.91 3.56

River Beds 3.18 1.01

TOTAL 314.87 100

3.9.4 SOILS OF STUDY AREA AND SOIL QUALITY

The study area is characterized by Red loamy Soils and sandy loams.

These soils are light textured and are easily drained and fertile.

The study area comprises mainly sandy loams. Soil samples collected

indicated predominantly sand and sandy loam texture. The pH of the

samples collected in the study area, were found in neutral range.

Based on the secondary information available Department of

Agriculture Govt. A.P (https://soilhealth7.gov.in/) the most of the soils of

the study area are Moderately alkaline in pH, medium range of

Nitrogen, organic carbon, Deficient of Boron, Manganese and Zinc,

Sufficient range of Sulphur, Iron and Copper, High in Phosphorus and

Very High range of Potassium.


area and analysed to study the fertility. Fig - 3.10 and Table - 3.12

shows the location of soil sampling stations.

https://soilhealth7.gov.in/



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Toposheets

Index t

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PREPARED

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km

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5'

18° 0

0'

To

Vis

hakhapatn

am

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km

17° 5

5'

18° 0

0'

83° 1

5'

83° 1

0'

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Lin

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Main Power Line

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arlapalli

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manda

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mM

am

idip

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gam

peta

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madevip

eta

Vechala

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m

Rangapura

m

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m

Sirik

ipale

m

Sin

gavara

n

Ala

manda R

S

Latlapalli

Ala

manda

Gandhavara

m

Palle

Ananta

vara

m

Gollala

pale

m

Pekeru

Penta

Kott

a K

ovvada

Rayip

alli

Muchcherla

Gid

ijala

Vem

akotipale

m

Err

avanip

ale

m

Kola

vanip

ale

m

Gorinta

Ram

avara

m

Bantu

mera

ka

Relli

Mum

manavanip

ale

m

Bhim

annadora

pale

m

Boddunayudupale

m

Mudapaka

KO

TTAVALASA

Kott

avala

sa

Mangala

pale

m Desapatr

unip

ale

m

Ram

achandra

pura

mM

indiv

ala

sa

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pale

mChip

uru

vala

sa

Raja

patr

unip

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m Sitam

peta

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pale

m

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avala

sa

Chid

ivala

sa

Sundara

yyapeta

Gollala

pale

m

Mula

gapakavanip

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mChin

tala

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me

Tum

mik

apalli

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avanip

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m

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alingapura

m

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alingapura

m

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yam

peta

Raja

niv

anip

ale

mArd

hannapale

m

Appannadora

pale

m

Devada

Nara

pam

Karr

ichennayyapale

m

Addupale

mVirabhadra

pura

m

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am

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ale

m

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mala

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mN

imm

ala

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m

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i

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ara

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ali

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nip

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m

Jogayyapale

m

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bayyapale

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kapalli RS

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ara

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a G

angubudi

Gangubudi

Gaja

patinagara

m

Srira

mapura

m

Kott

apale

m

Malliv

idu

Malliv

idu R

S

Rellig

aviram

mapeta

Pudiv

anip

ale

m

Gorlevanip

ale

m

Yeta

kanam

am

Gollala

Kanam

am

Gam

podupale

m

Baduru

pale

m

Mukundapura

m

Sirla

pale

m

Tunip

ale

m

Bandevupura

m

Rangara

yapura

m

Khasapeta

Venkannapale

m

Gullvin

dada

Ganis

ett

ipale

m

Chin

tala

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mSiram

sett

ipale

m

Rega

Pediredla

pale

m

Err

avanip

ale

m

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S5

S7

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Kovvada

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IL Q

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QU

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ITY

FIG

- 3

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ial Park

, Kanta

kapalli Villa

ge,V

izia

nagara

m D

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Andhra

Pra

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Organic carbon content along with other parameters. Summary of soil

quality is given below in Table – 3.13.

TABLE-3.12: SOIL SAMPLING STATIONS

TABLE – 3.13: SUMMARY OF SOIL QUALITY

S.

No Parameters

RANGE

1 pH 1:2 Soil water Extract 6.12 - 8.16

2 Electrical conductivity 1:2 Soil water

Extract(µS/cm) 97 - 215

3 Mineralized / Available Nitrogen as N,

kg/ha 151 - 461

4 Available Phosphorous as P2O5, kg/Ha 23 - 196

5 Available Potassium as K2O, kg/ha 105 - 610

6 Available Sodium as Na2o, mg/Kg 20 - 132

7 Organic Carbon % 0.27 - 1.04

8 Manganese as Mn, mg/kg 158 - 9168

9 Zinc as Zn, mg/kg 16.5 - 188.6

10 Copper as Cu, mg/kg 11 - 108.1

The summary of fertility status is given below:



❖ Soil of Sunkarapalem nad Relli, indicated medium fertility

Results of soil sampling analysis are given in Annexure – 3C.

Code LOCATION/

VILLAGE

W.R.T PLANT SITE

Distance (km) Direction

S1 Plant Site --- ---

S2 Sunkarapalem Village 1.0 SW

S3 Kovvada Village 3.9 ENE

S4 Bhimali Village 3.5 N

S5 Kantakapalli Village 0.9 N

S6 Kothavalasa Dabala

Village 6.5 SSW

S7 Alamanda Village 5.3 NNE

S8 Relli Village 4.7 S



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3.9.5 AGRICULTURE - CROPS

More than 70% of the rural population is dependent on agriculture. The

study area has fairly good rainfall good enough to support the crops

during the kharif season. The crops grown in the area are Rice,

sugarcane and millet crops like maize, ragi, jowar and bajra are all

grown in the study area both under irrigation as well as under rainfed

condition.

Agricultural area cultivated between June/July to September/ October

coinciding with SW monsoon season is considered Kharif crop. It is

associated with rain-fed crops under dryland farming with limited or no

irrigation and areas of rain-fed paddy and other dry crops.

Mango, Banana, Cashew nut and coconut under plantation crops are

thriving in the study area.

3.10 BIOLOGICAL ENVIRONMENT

Ecological studies were carried out in the study area during Winter

Season. The project development area of 280.96 acres was considered

as the “Core Zone Area” Area within 10 km of the project site

considered to be the “zone of influence” or the “Buffer Zone Area” of

the project. The objectives of the study are:

1) Habitat identification

2) Assessment of floral diversity

3) Assessment of nature and distribution of the vegetation

4) Categorization/Identification of endangered species if any) of flora

and fauna

5) Identification of threatened faunal species listed in Schedule-I if

any) of Wildlife Protection) Act 1972.

6) Preparation of Wildlife Conservation Plan for the Schedule-I fauna if

any)

7) Identification of presence of Protected areas as per Wildlife

Protection) Act, 1972

3.10.1METHODOLOGY OF FLORA-FAUNA STUDIES

Primary survey was conducted with established and accepted

ecological methods in different habitats of study area. The field data

collection mainly included biodiversity status assessment of different life



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forms) of floral elements such as Trees, Shrubs, Climbers, Herbs and

Grass. Faunal diversity was assessed by inventorying the major

taxonomical groups like mammals, Herpetofauna, birds both aquatic

and terrestrial.

During the study, to know more about the seasonal presence of floral

and faunal species, information was obtained from local people.

FLORA

Status of floral species was assessed by using quadrat method in the

representative habitat types at five sampling locations in study area

given in Table-3.14 and shown in Fig-3.11.

At each sampling location the protocol adopted to collect primary

data were trees-5 quadrates of 10 x 10 m, Shrubs-5 Quadrates 5 x 5 m

and herbs-5 quadrates of 1 x 1 m.

TABLE-3.14: SAMPLING LOCATIONS IN PROJECT AREA

S.

No

Location


Distance

from project

site in km)

Direction

from project

site

1 T-1 Plant Area ---- ----

2 T-2 Advanapalem Reserve

Forest 2.2 ESE

3 T-3 Muchcherla Reserve

Forest 7.5 ESE

4 T-4 Near Alamanda Village 5.3 NNE

5 T-5 Near Dabala Village 6.0 SW

FAUNA

Qualitative check list of fauna for their presence and absence was

done using indirect evidences and signs such as footprints, droppings,

diggings, scrap marks, etc. in the study area. Information from locals

was also collected. Secondary information was obtained from Forest

Department and elderly people in villages.

For Avi fauna, Area Search Method/Extensive search was adopted

near small ponds, open areas, scrubland, isolated trees, village

peripheries, agriculture areas etc.



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Surv

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Toposheets

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03

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m

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the S

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- 2

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65

J 16

65

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K 14

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O 2

65

O 5

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N 865

N 4

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O 6

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CAN

AL

MAIN

PO

WER L

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83° 1

5'

To

Viz

ianagara

m15.0

km

83° 1

0'

To

Sru

ngavara

pukota

10.0

km

17° 5

5'

18° 0

0'

To

Vis

hakhapatn

am

24.0

km

17° 5

5'

18° 0

0'

83° 1

5'

83° 1

0'

Main

Power

Line

Main Power Line

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VA

NA

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ER

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Main Power Line

Main Power Line

SOUTH E

ASTERN R

AIL

WAY

Pata

Marlapalli

Kott

a M

arlapalli

Kurm

avara

mu

Koty

ada

Tala

riKirla

Ram

abhadra

pura

m A

Kala

gada

Mett

uru

Sirik

ipale

m

Ala

manda

Ala

manda

Dasullapale

mM

am

idip

alli

Lin

gam

peta

Jam

madevip

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Vechala

puvanip

ale

m

Rangapura

m

Gedela

vanip

ale

m

Sirik

ipale

m

Sin

gavara

n

Ala

manda R

S

Latlapalli

Ala

manda

Gandhavara

m

Palle

Ananta

vara

m

Gollala

pale

m

Pekeru

Penta

Kott

a K

ovvada

Rayip

alli

Muchcherla

Gid

ijala

Vem

akotipale

m

Err

avanip

ale

m

Kola

vanip

ale

m

Gorinta

Ram

avara

m

Bantu

mera

ka

Relli

Mum

manavanip

ale

m

Bhim

annadora

pale

m

Boddunayudupale

m

Mudapaka

KO

TTAVALASA

Kott

avala

sa

Mangala

pale

m Desapatr

unip

ale

m

Ram

achandra

pura

mM

indiv

ala

sa

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pale

mChip

uru

vala

sa

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patr

unip

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mSitam

peta

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Appannadora

pale

m

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avala

sa

Chid

ivala

sa

Sundara

yyapeta

Gollala

pale

m

Mula

gapakavanip

ale

mChin

tala

dim

me

Tum

mik

apalli

Kott

avanip

ale

m

Ram

alingapura

m

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alingapura

m

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yam

peta

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niv

anip

ale

mArd

hannapale

m

Appannadora

pale

m

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Nara

pam

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ichennayyapale

m

Addupale

mVirabhadra

pura

m

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am

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anip

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m

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mala

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mN

imm

ala

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patinagara

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ram

apura

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apale

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idu

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idu R

S

Rellig

avir

am

mapeta

Pudiv

anip

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m

Gorl

evanip

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m

Yeta

kanam

am

Gollala

Kanam

am

Gam

podupale

m

Baduru

pale

m

Mukundapura

m

Sir

lapale

m

Tunip

ale

m

Bandevupura

m

Rangara

yapura

m

Khasapeta

Venkannapale

m

Gullvin

dada

Ganis

ett

ipale

m

Chin

tala

pale

mSiram

sett

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m

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edla

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m

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avanip

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m

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- 3

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, Kanta

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ge,V

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Visual Encounter Survey VES) method is followed for the survey of the

Butterflies in the study area. Butterflies spotted in the study area were

identified as per “The Butterflies of India” Author: Arun Pratap Singh).

3.10.2 HABITATS

The study area is categorized into four major habitat types for

ecological study

a. Forests

b. Open scrubs

c. Agricultural land

d. Water Bodies

FORESTS




with stunted growth

As per Champion's classification (1968), two type of forest were

observed in the study area

1. Southern Tropical Dry Deciduous Forest

2. Dry Deciduous Shrub Forest0020

The study area is part of Vizianagaram District in Andhra Pradesh.

Table-3.15 provides list of forest areas around the project within study

area.

TABLE-3.15: DETAILS OF FOREST AREAS IN STUDY AREA

S. No Locatio

n code Name of the location

Distance

from project

site (in km)

Direction

from

project

site

1 F1 Advanapalem Reserve

Forest 1.3 E

2 F2 Muchcherla Reserve Forest 6.9 ESE

OPEN SCRUBS

The open scrub which dominated the project area spread over the

buffer area was mostly very open with very sparse short trees, shrubs,



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grass and herbs in the blanks or open areas. This type was dominated

by floral species like Prosopis juliflora followed by Pongamia pinnata,

Azadiracta indica, Tectona grandis, Senna tora, Tamarindus indica,

Cassia fistula, Acacia nilotica and Ziziphus mauritiana.

AGRICULTURAL LAND

Agriculture crops of the buffer zone of the project areas consist of Rice

(Oryza sativa), Sugarcane (Saccharum officinarum) and Cotton

(Gossypium hirsutum). The vegetables such as Brinjal (Solanum

melongena), Bhendi (Abelmoschus esculentus) were cultivated in

farmlands of buffer zone.

HOMESTEAD PLANTATION

Homestead plantations near human habitations mostly comprise of

species of Syzygium cumini (Jamun), Tectona grandis (Teak),

Tamarindus indica (Tararind), Ficus religiosa (Sacred Fig), Azadiracta

indica (Neem) etc.

WATER BODIES

Pedda Gedda is present in buffer zone of the study area. There are few

small tanks (mostly dry) present with surrounding dominated by flora

like, Lantana camara, Phoenix sylvestris, Prosopis juliflora, Senna tora,

Jatropha gossypiifolia and Pongamia pinnata

3.10.3 PRESENCE OF SENSITIVE AREAS

As per Ministry of Environment Forests & Climate change, Forest

department of Government of Andhra Pradesh notifications reveal that

there are no National Park, Wildlife Sanctuary, Bio-sphere Reserve,

Notified Wildlife Corridor, etc. is located within 10 km from the project

site.

3.10.4 FLORA

A total of 229 plant species belonging to 68 families were

observed/reported in the study area. The family Fabaceae is the most

dominant family with (29) species followed by Poaceae (17). The major

and main natural tree species found within the study area is Prosopis



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juliflora Besides, there are also several other common natural tree

species found within the study area are Pongamia pinnata, Azadiracta

indica, Calotropis procera, Phoenix sylvestris, Senna tora, Lantana

camara, Sida acuta, Annona squamosa and Acacia nilotica which are

predominant. The list of floral species documented in the study area is

enlisted in Annexure-3D.

HABIT WISE ANALYSIS OF FLORAL SPECIES IN STUDY AREA

3.10.5 PHYTO-SOCIOLOGICAL STUDIES

DIVERSITY

The Shannon species diversity varies between 1.68 and 3.25 in studied

population and highest was recorded in T-2 (Advanapalem Reserve

Forest) and lowest in T-1 (Near Rayapurajupeta Village). The species

diversity indices for five sampling locations are presented in below

table.

SPECIES DIVERSITY INDICES IN STUDY AREA

Code Location Diversity

Index

T-1 Plant Area 2.56

T-2 Advanapalem Reserve Forest 3.25

T-3 Muchcherla Reserve Forest 2.96

T-4 Near Alamanda Village 1.81

T-5 Near Rayapurajupeta Village 1.68



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3.10.6 ENDANGERED FLORA




species observed or reported in the study area

3.10.7 FAUNA

Total of 116 faunal species were recorded in which 7 species of

Mammals, 10 Reptiles, 3 Amphibians, 80 Birds and 16 Butterflies were

observed/reported.

MAMMALS

There are several minor carnivorous and herbivorous wild animals in the

study area. Totally 7 species were observed/reported in the study area.

Most frequently observed species are Black-naped Hare and Wild Boar.

None of the mammal species are listed under Schedule I category

species as per Indian Wildlife Protection Act, 1972 and no endangered

species listed under IUCN Red List. The details of mammals during study

period are presented below in Table – 3.16

TABLE – 3.16: LIST OF MAMMALS OBSERVED/REPORTED IN STUDY AREA

S.

No Scientific Name Common Name

IWPA

(1972)

Schedule

IUCN Status

1 Anathana ellioti Madras

Treeshrew II Least Concern

2 Canis aureus

indicus Jackal II Least Concern

3 Felis chaus Jungle Cat II Least Concern

4 Herpestes smithii Ruddy

Mongoose II Least Concern

5 Hystrix indica Indian Porcupine IV Least Concern

6 Lepus nigricollis Black-naped

Hare IV Least Concern

7 Sus scrofa Wild Boar III Least Concern

REPTILES AND AMPHIBIANS

The species like Oriental Garden Lizard (Calotes versicolor), Indian



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Chameleon (Chamaeleo zeylanicus) Common Viper (Viper ruselli),

Common Indian Toad (Duttaphrynus melanostictus) and Indian Bull

Frog (Hoplobatrachus tigerinus) were sighted during the primary survey.

No endangered species observed from the core and buffer area of the

project site. The details of reptiles and amphibians observed/reported

in study area are given below in Table – 3.17.

TABLE – 3.17: LIST OF REPTILES AND AMPHIBIANS IN STUDY AREA

S.

No Scientific Name Common Name

IWPA (1972)

Schedule IUCN Status

Reptiles

1 Ahaetulla nasuta Green Vine Snake IV Least Concern

2 Bungarus caeruleus Common Krait IV Least Concern

3 Calotes versicolor Oriental Garden

Lizard IV Least Concern

4 Chamaeleo

zeylanicus Indian Chameleon IV Least Concern

5 Daboia russelli Russell’s Viper II Least Concern

6 Dendrelaphis tristis

Common

Bronzeback Tree

Snake

IV Least Concern

7 Viper ruselli Common Viper II Least Concern

8 Ptyas mucosus Common Rat

Snake II Least Concern

10 Varanus bengalensis Monitor Lizard II Least Concern

Amphibians

11 Duttaphrynus

melanostictus

Common Indian

Toad IV Least Concern

12 Fejervarya

limnocharis Indian Cricket Frog IV Least Concern

13 Hoplobatrachus

tigerinus Indian Bull Frog IV Least Concern

AVIFAUNA/BIRDS

A total of 80 species were observed/reported from study area. Among

the 80 bird species 52 species were directly sighted during the primary

survey. According to the IUCN red list 76 species were listed as least

concern and 4 Near Threatened. None of the bird species listed under

Schedule I category species as per Indian Wildlife Protection Act, 1972.



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Among the total species observed and reported, 45 (56%) species are

Terrestrial, 35 (44 %) Aquatic Habitat are recorded during the survey. Six

major foraging categories of birds were recorded. These were

Insectivorous (19), Omnivorous (23), Granivorous (6), Carnivorous (28)

Frugivorous (2), and Nectarivorous (2). Insectivorous and Carnivorous

birds were recorded maximum foraging categories in study area.

The lists of avifauna observed or reported in study area are presented

in below Annexure-3D.

BUTTERFLIES

The list of butterflies in the study area presented in Annexure-3D

3.10.8 ENDANGERED FAUNA

There are no endangered species in study area as per IUCN Red Listed

Categories. IUCN Status of species in study area is shown in below

graph:

IUCN STATUS OF FAUNAL SPECIES IN STUDY AREA

3.10.9 SCHEDULE-I SPECIES

SMAL has approached the DFO, Visakhapatnam to provide the

information on presence of any schedule-I species in the reserve forest

of the study area. The DFO vide letter dated 13.08.2021 has provided

the list of fauna. There is no Schedule-I species in the study area as

authenticated by DFO, Visakhapatnam (Annexure – 3E)



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3.11 SOCIO ECONOMIC ENVIRONMENT

Secondary data of Census of India, 2011 has been used for establishing

the demographic profile of the study area.

Primary data was collected through discussion at selected villages for

identifying the needs of the village which form the basis for CSR by

Project Proponent.

3.11.1 PROJECT SITE

The proposed activities will be within the existing area of SMAL. The

total land area for the project is 280.96 acres. It is Andhra Pradesh

Industrial Infrastructure Corporation Ltd (APIIC) Industrial Park. Khasra

No. 179/4,181,182,183/1 to 20, 185,186,187,188/1&2, 189/ 1&2, 190,191,

192/1 to 3, 193,194,195,196,197,198,199,200,201,202 & 203 in village-

Kantakapalli. Present activities are covered under 195.74 acres and for

expansion additional area of 85.22 acres available within the project

site will be used.

3.11.2 SOCIO ECONOMIC PROFILE-NEAREST VILLAGE/JURISDICTION

VILLAGE

The project site falls under the jurisdiction of Kantakapalli Village (427

hectares) which is located 0.6 km. The demographic profile of the

village is given below:

▪ Total population - 2773 people

▪ Number of Houses - 714 houses

▪ Literacy rate – 64.24 %

▪ Schedule Caste (SC) – 9.8 %

▪ Schedule Tribe (ST) – 0.3 %

The occupational status of the village showed 1350 were engaged in

work activities. Of which 85.6 % of workers are Main Workers

(Employment or earning more than 6 Months) with 14.4 % -Marginal

Workers (Livelihood for less than 6 months).

Working population under “Other category” are mainly work forces of

Industries in 50 km radius of the study area.



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OCCUPATIONAL PATTERN OF MAIN WORKERS

The village has the following amenities:

• Education: Private Pre-Primary, Government Primary,

Government Middle and Government Secondary Schools are

available in this village.

• Health: 1 Primary Health Sub-Centre, 2 MBBS Doctor Practices, 1

RMP doctor, 4 Medical Shops are available in this village.

• Drinking Water: Untreated Tap Water Supply all-round the year

and in summer available. Hand Pump is other Drinking Water

sources.

Open Drainage System Available in this Village. This Village

Covered Under Total Sanitation.

• Communication facilities are available in the form of telephones,

public call office and mobiles.

• Post office facility is available

• Transport: Public and private bus facility is available in the village.

• Roads: Paved Road are available

• Power Supply: This Village has a Power supply with 15-hour power

supply in summer and 18-hour power supply in winter.

• Welfare schemes: Agriculture credit services, self-help groups

and public distribution system are available. Integrated Child

development scheme, Anganwadi centers and ASHA workers

are helping the area.

3.11.3 VIZIANAGARAM

Vizianagaram is the nearest town located at 25 km and has population

of 2,28,025, of which male and female are 1,11,950 and 1,16,075

respectively. Total literacy rate is 81.4 %.



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The area has number of educational facilities which include Convent

Schools, Govt. and Municipal Primary schools Junior, Degree and PG

colleges.

Vizianagaram has all facilities which cover health center, hospital,

education, health and market.

The literacy rate of Vizianagaram district is 52.82% out of which 60.91%

males are literate and 44.88% females are literate. The total area of

Vizianagaram is 6539 sq.km with population density of 359 per sq.km.

3.11.4 SOCIO ECONOMIC PROFILE OF THE STUDY AREA

The study area is part of Kothvalsa Mandal in Vizianagaram District of

Andhra Pradesh state. Mandal Head Quarters is at Kothavalsa which is

6.3 km in SW direction from the project site.

Kantakapalle Village is located at 0.6 km. Cities like Visakhapatnam,

Bheemunipatnam, Anakapalle and Vizianagaram are close to

Kothavalsa.

Kothavalsa consists of 73 villages and 25 panchayats. Pedaraopalle is

the smallest village and Veerabhadrapuram is the biggest vllage. It is at

an elevation of 58m.

The project is situated in Kantakapalli Village, Kothavalsa mandal,

Vizianagaram district. The nearest railway station is located at 1.2 km

from the project site.

The area depends on rainfall for the agricultural activities.

The study area comprises of 35 villages falling in Kothavalsa Mandal.

Most of the villages are connected by roads with Kothavalsa town

which has all facilities which cover health center, hospital, education,

health, market and Railway station.

The habitations of area are well-connected with roads and

government transport, especially those located on the roadside; but

the approach roads leading to a couple of villages are unpaved

(kutcha).

The area has Scheduled Tribes and Schedule Castes.



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Major crops in the area are Paddy, Maize, Ragi, Jowar, Bajra and

Chillies. The main source of water for this activity is rainfall.

Infrastructural facilities such as internal roads, Drinking Water,

education, sanitation, and health facilities though existing needs

development.

3.11.5 POPULATION

Total population of the study area villages is 65,968. The villages falling

in this Study area are given in Table - 3.18.

TABLE – 3.18: VILLAGES IN THE STUDY AREA

Village Name House

Holds Population Village Name

House

Holds Population

0.5-3.0km 3.0-5.0km

Chinaraopalle 202 835 Nidigattu 269 1050

Katakapalle 471 1837 Relli 635 2418

Gollapeta 141 588 Gollalapalem 208 1013

Balighattam 493 2054 Venkannapalem 3 10

Chinnipalem 151 799 Malliveedu 803 3128

5.0-7.0km 7.0-10.0km

Kalagada 365 1465 Kirla 69 252

Mamidipalle 106 418 Godikommu 178 715

Alamanda 1503 5948 Singavaram 466 1810

Kottavalasa 280 1163 Kurmavaram 92 307

Narapam 68 257 Khasapeta 591 2211

Veerabhadrapuram 1457 6310 Kotyada 637 2551

Source: - Census: 2011

In village category, Veerabhadrapuram has the highest population of

6310 and Venkannapalem has the lowest population (10).

The total population density of the study area is about 185 persons/sq.

km. The population profile of the study area is given in Annexure- 3F.

TABLE – 3.19: POPULATION, HOUSEHOLD SIZE & SEX RATIO

Total (0 - 10 km)

Household 16517

Population 65968

Male Population 32658

Female Population 33310

Household Size 3-4

Sex Ratio 1020




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3.11.6 SEX RATIO

The sex ratio No. of females per thousand males for the state Andhra

Pradesh and district Vizianagaram is 996 and 1014. The sex ratio in the

study area is 1020 as per census 2011. The details are given in Annexure

– 3F. Comparative Sex Ratio is given in below Figure.

SEX RATIO IN THE STUDY AREA


3.11.7 SCHEDULED CASTE (SC) & SCHEDULED TRIBE (ST) POPULATION

The Percentage of SC population for state Andhra Pradesh and district

Vizianagaram is 19.2% and 10.3% respectively. The percentage of SC

population for the study area is 10.2%, which is lower than state and

higher than the district SC population percentage.

The Percentage of ST population for state Andhra Pradesh and district

Vizianagaram is 9.3% and 12.2% respectively. The percentage of ST

population for the study area is 2.6 %, which is lower than the state and

district ST population percentage. Comparative analysis of SC & ST

population is given below. The details of SC & ST population are given

in Annexure – 3F.

COMPARATIVE ANALYSIS OF SC & ST PERCENTAGE IN THE STUDY AREA



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3.11.8 LITERACY

The literacy level for the state Andhra Pradesh and district

Vizianagaram is 53.9 % and 48.1% respectively. The literacy percentage

of the study area is 53.0%, which is lower than state and higher than

district level.

The literacy level of the male population for the state Andhra Pradesh

and district Vizianagaram is 57.3% and 58.7% respectively. The literacy

level of male population for the study area is 57.9% which is higher than

state and lower than the district level.

The literacy level of the female for the state Andhra Pradesh and

district Vizianagaram is 42.7% and 41.3% respectively. The literacy level

of female population for the study area is 42.1% which is lower than

state and higher than district level.

The Literacy status of the study area is given in Annexure – 3F.

Comparative analysis of literacy level is given in below Figure

COMPARATIVE ANALYSIS OF LITERACY LEVEL IN THE STUDY AREA

3.11.9 ECONOMIC PATTERN AND LIVELIHOOD

Total work participation rate for the state Andhra Pradesh and district

Vizianagaram is 51.5% and 52.9% respectively. The work participation

rate of the study area is 48.4%, which is lower than state and district.

The main workers in the study area are 83.0 % and marginal workers are



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17.0 % of the total labor force.

Comparative Analysis of the workforce in the Study Area

The employment pattern in the villages indicate that only 24.1 % work

as cultivators, 52.9 % as agricultural labourers, 21.5% as other workers

and 2.5 % as household industry workers. Most of the villagers are

agriculturists. The occupation status in the study area is given in

Annexure – 3F.

COMPARATIVE ANALYSIS OF ECONOMIC ACTIVITY IN THE STUDY AREA

The male workers in the study area account to 58.8 % of the total

working population. The female workers in the study area account to



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41.2 % of the total working population.

TABLE - 3.20: WORK PARTICIPATION: MALE & FEMALE

Category

Study Area

Male Female

No. % No. %

Total Workers 18958 58.8 13273 41.2

Main Workers 16703 62.4 10053 37.6

Marginal Workers 2255 41.2 3220 58.8

Cultivators 5135 60.6 3345 39.4

Agricultural Laborers 7208 47.1 8084 52.9

Household Workers 505 57.3 376 42.7

Other Workers 6110 80.6 1468 19.4 Source: - Census: 2011

3.11.10 LANGUAGES AND RELIGION

Telugu is the prominent language spoken in this district. Hinduism is the

predominant religion in the area.

3.11.11 PRIMARY SURVEY

The primary survey was done in the nearby villages (3 km radius) to

understand their socio-economic conditions and needs in those

villages. The villages covered are listed below:

Village Name No of House Holds Population

Chinaraopalle 202 835

Katakapalle 471 1837

Gollapeta 141 588

Balighattam 493 2054

Chinnipalem 151 799

3.11.11.1 SAMPLE SIZE

The study covered 150 Households for quantitative structured Interviews

considering the Covid-19 Pandemic conditions.

As part of the qualitative component, ten In-depth interviews were

carried out with community Leader / Sarpanch / Village Head.

3.11.11.2 FIELD WORK

The field work was carried out by a team coordinated by FAE following

Covid – 19 protocols.



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3.11.11.3 SOCIAL PROFILE OF RESPONDENTS

GENDER

About two third of the respondents are males across the villages

covered.

GENDER OF RESPONDENTS (%)

AGE OF RESPONDENT (IN YEARS)

The respondents are of all ages but majority are of 55 + years.

AGE DISTRIBUTION OF RESPONDENTS Age

years

Chinaraopalle Katakapalle Gollapeta Balighattam Chinnipalem Over All

N % N % N % N % N % N %

<= 25 3 10.0 0 0.0 2 6.7 2 6.7 0 0.0 7 4.7

26-35 7 23.3 5 16.7 11 36.7 6 20.0 6 20.0 35 23.3

36-45 12 40.0 9 30.0 8 26.7 9 30.0 8 26.7 46 30.7

More

than 55 8 26.6 13 53.4 9 30.0 13 43.4 16 53.3 62 41.3

Mean 41.1 46.9 40.6 45.2 48.1 44.4

SD 12.1 11.5 12.1 12.9 13.2 12.6

Total 30 100.0 30 100.0 30 100.0 30 100.0 30 100.0 150 100.0

EDUCATION

Across the villages, many of the respondents are illiterates. Only 20% of

the respondents completed SSC and above indicates low levels of

literacy and education in the study villages.



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EDUCATIONAL QUALIFICATION OF HEAD OF HOUSEHOLDS (HH)

Education Chinaraopalle Katakapalle Gollapeta Balighattam Chinnipalem Over All

N % N % N % N % N % N %

Illiterate 16 53.3 14 46.7 17 56.7 17 56.7 15 50.0 79 52.7

Literate, But No

Formal

Schooling

2 6.7 1 3.3 0 0.0 3 10.0 4 13.3 10 6.7

School - Upto

4th Standard 2 6.7 1 3.3 1 3.3 1 3.3 2 6.7 7 4.7

School - 5th -

9th Standard 8 26.7 4 13.3 5 16.7 1 3.3 4 13.3 22 14.7

SSC/HSC (10th-

12th) 2 6.7 4 13.3 3 10.0 4 13.3 4 13.3 17 11.3

Some College

(Incl. Diploma)

But Not

Graduate

0 0.0 2 6.7 0 0.0 3 10.0 1 3.3 6 4.0

Graduate 0 0.0 2 6.7 4 13.3 1 3.3 0 0.0 7 4.7

Post-Graduate 0 0.0 2 6.7 0 0.0 0 0.0 0 0.0 2 1.3

Total 30 100.0 30 100.0 30 100.0 30 100.0 30 100.0 150 100.0

3.11.11.4 ECONOMIC PROFILE

PRINCIPAL SOURCE OF INCOME OF THE HH

The principal sources of HH income include nonagricultural labour, own

cultivation, and agricultural labour.

PRINCIPAL SOURCE OF INCOME FOR HOUSEHOLD

Source of

Income

Chinaraopall

e

Katakapall

e

Gollapet

a

Balighatta

m

Chinnipale

m Over All

N % N % N % N % N % N %

Owner-

cultivator 4 13.3 9 30.0 6 20.0 11 36.7 10 33.3 40 26.7

Agricultura

l labour 9 30.0 7 23.3 7 23.3 7 23.3 8 26.7 38 25.3

Non-

agricultura

l labour

13 43.3 8 26.7 9 30.0 8 26.7 7 23.3 45 30.0

Other non-

farm

occupatio

n

2 6.7 6 20.0 8 26.7 4 13.3 5 16.7 25 16.7

Others 2 6.7 0 0.0 0 0.0 0 0.0 0 0.0 2 1.3

Total 30 100.0 30 100.0

3

0

100.

0 30 100.0 30 100.0

15

0

100.

0

HH MONTHLY INCOME

Two fifth of the HHs have monthly HH income of Rs. 5000 to Rs. 7500,

while one fifth each reported an income of upto Rs 5000 and Rs 7500-



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10000. Overall average monthly HH income is Rs 7604.

MONTHLY HH INCOME

Income

Chinaraopall

e

Katakapall

e

Gollapet

a

Balighatta

m

Chinnipale

m

Over all

N % N % N % N % N % N %

Upto Rs

5000 9 30.0 10 33.3 8 26.7 5 16.7 2 6.7 34 22.7

Rs 5000 -

Rs 7500 8 26.7 12 40.0

1

1 36.7 16 53.3 21 70.0 68 45.3

Rs 7500 -

Rs 10000 8 26.7 5 16.7 7 23.3 8 26.7 6 20.0 34 22.7

More

than Rs

10000

5 16.7 3 10.0 4 13.3 1 3.3 1 3.3 14 9.3

Averag

e 2899 2775 2153 1995 1839 2332

Total 30 100.0 30 100.0

3

0

100.

0 30 100.0 30 100.0

15

0

100.

0

WHETHER HOUSEHOLDS OWN LAND

Ownership of land is high as almost three fourth of the respondents

reported so.

PERCENTAGE OF HHS WHO OWN LAND

AMOUNT OF LAND OWNED (IN ACRES)

The average land holding size is less than 1 acre (0.71 acres).

80

70 7073

7073

0

20

40

60

80

100

Chinaraopalle Katakapalle Gollapeta Balighattam Chinnipalem Overall



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LAND HOLDING SIZE

LH size Chinaraopalle Katakapalle Gollapeta Balighattam Chinnipalem Over All

N % N % N % N % N % N %

0 6 20.0 9 30.0 9 30.0 8 26.7 9 30.0 41 27.3

< 1

acre 9 30.0 7 23.3 9 30.0 9 30.0 7 23.3 41 27.3

1 Acre 6 20.0 6 20.0 8 26.7 12 40.0 13 43.3 45 30.0

> 1

acre 9 30.0 8 26.7 4 13.3 1 3.3 1 3.3 23 15.3

Mean 0.96 0.78 0.68 0.57 0.57 0.71

SD 0.9 0.8 0.8 0.5 0.5 0.7

Total 30 100.0 30 100.0 30 100.0 30 100.0 30 100.0 150 100.0

MAIN SOURCE OF IRRIGATION IN VILLAGE

Rain water emerges as the major irrigation source for the villages

followed by tank/pond. Thus, irrigation is another area of concern.

SOURCE OF IRRIGATION

Source Chinaraopalle Katakapalle Gollapeta Balighattam Chinnipalem Over All

N % N % N % N % N % N %

Rain water 18 75.0 14 66.7 13 61.9 13 59.1 14 66.7 72 66.1

Tank/pond 4 16.7 5 23.8 8 38.1 9 40.9 7 33.3 33 30.3

Tube well 1 4.2 1 4.8 0 0.0 0 0.0 0 0.0 2 1.8

Other 1 4.2 1 4.8 0 0.0 0 0.0 0 0.0 2 1.8

Total 24 100.0 21 100.0 21 100.0 22 100.0 21 100.0 109 100.0

OWNERSHIP OF LIVESTOCK

Ownership of hen is very high while that of cow and buffalo is low.

Sizeable proportion of the HHs doesn’t own any live stock.

LIVESTOCK OWNED

Livestoc

k

Chinaraopall

e

Katakapall

e

Gollapet

a

Balighatta

m

Chinnipale

m Over All

N % N % N % N % N % N %

Cow 7 23.3 11 36.7 3 10.0 4 13.3 3 10.0 28 18.7

Buffalo 4 13.3 6 20.0 0 0.0 5 16.7 11 36.7 26 17.3

Goat 1 3.3 0 0.0 3 10.0 2 6.7 0 0.0 6 4.0

Pigs 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0

Hen 20 66.7 16 53.3

2

0 66.7 19 63.3 19 63.3 94 62.7

None 6 20.0 9 30.0

1

0 33.3 11 36.7 9 30.0 45 30.0

Total 30 100.0 30 100.0

3

0

100.

0 30 100.0 30 100.0

15

0

100.

0

Note : Total exceeds N/100 due to multiple response

AVAILABILITY OF CATTLE SHED

Many of the HHs reported to be not having cattle shed.



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CATTLE SHED AVAILABILITY

Cattle

shed


N % N % N % N % N % N %

Available 6 25.0 12 57.1 4 20.0 9 47.4 10 47.6 41 39.0

Not

available 18 75.0 9 42.9 16 80.0 10 52.6 11 52.4 64 61.0

Total 24 100.0 21 100.0 20 100.0 19 100.0 21 100.0 105 100.0

TYPE OF RATION CARD

Most of the respondents or families have BPL card indicating low levels

of economic status of the families.

TYPE OF RATION CARD (%)

33 3327

0 0

19

5763

73100 100

79

103 0 0 0 3

0

20

40

60

80

100

Chinaraopalle Katakapalle Gollapeta Balighattam Chinnipalem Over all

APL BPL No Ration Card

3.11.11.5 BENEFITS AND AMENITIES

BENEFITS RECEIVED BY FAMILY

The benefits received by most of the families include cooking gas

subsidy, and NREGS followed by social pension. Thus, the families seem

to be getting the benefits from the Government.

BENEFITS RECEIVED BY FAMILY

Benefit Chinaraopalle Katakapalle Gollapeta Balighattam Chinnipalem Over All

N % N % N % N % N % N %

Social

Pension

(old age,

Widow,

disability

etc)

16 53.3 24 80.0 15 50.0 19 63.3 15 50.0 89 59.3

NREGS 17 56.7 14 46.7 21 70.0 30 100.0 24 80.0 106 70.7

Cooking

gas

subsidy

26 86.7 21 70.0 24 80.0 23 76.7 23 76.7 117 78.0

Scholarship 3 10.0 1 3.3 2 6.7 0 0.0 0 0.0 6 4.0

Total 30 100.0 30 100.0 30 100.0 30 100.0 30 100.0 150 100.0

Note : Total exceeds 100 due to multiple response



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MAIN SOURCE OF DRINKING WATER

Piped water merges as the major source of drinking water followed by

ground water. That means sizeable proportion of the HHs depend on

ground water and we need to look into quality of the water.

MAIN DRINKING WATER SOURCE (%)

7057

80 90 80 75

3043

20 10 20 25

0

20

40

60

80

100


Ground water Piped water

TYPE OF TOILET USED

More than half of the HHs go for open defecation and only two fifth

have own individual HH toilet. This needs attention as the goal is to

reach open defecation free villages. This problem seems to be in all the

villages.

TYPE OF TOILET USED BY HHS (%)

TYPE OF DRAINAGE FACILITY AVAILABLE

Underground drainage facility is not available in most of the villages as

only open drainage is available. This is another action area.

47 43 47 47 43 45

55 57 53 53 57 55

0

20

40

60

80

100


Open defecation Individual HH Toilet (owned)



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TYPE OF VILLAGE DRAINAGE FACILITY

Drainage

facility


N % N % N % N % N % N %

Underground

drainage 1 3.3 2 6.7 0 0.0 0 0.0 0 0.0 3 2.0

Open with

outlet 29 96.7 16 53.3 26 86.7 26 86.7 25 83.3 122 81.3

Open

without

outlet

0 0.0 12 40.0 4 13.3 4 13.3 5 16.7 25 16.7

Total 30 100.0 30 100.0 30 100.0 30 100.0 30 100.0 150 100.0

DURATION OF ELECTRICITY SUPPLY

Availability of electricity 24X7 is an issue in all the villages as four fifth of

the respondents mentioned about availability of electricity only for 6-18

hours in a day. Only 15 % of the respondents mentioned about

availability of electricity for 18-24 hrs in a day.

DURATION OF ELECTRICITY SUPPLY TO YOUR HOUSE IN A DAY

Duration

Chinaraopall

e Katakapalle Gollapeta Balighattam Chinnipalem Over All

N % N % N % N % N % N %

Less than 6

hours 4 13.3 0 0 0 0 0 0 0 0 4 2.7

6 - 12 hours 8 26.7 14 46.7 13 43.3 7 23.3 10 33.3 52 34.7

12 -18 hours 18 60 10 33.3 12 40 17 56.7 14 46.7 71 47.3

18 - 24 hours 0 0 6 20 5 16.7 6 20 6 20 23 15.3

Mean 11.8 13.4 13.4 14.8 14.2 13.5

Total 30 100 30 100 30 100 30 100 30 100 150 100

PLACE OF TREATMENT FOR CATTLE, INCASE FALL SICK

The respondents mostly mentioned about the treatment facility for the

cattle near the village but a few mentioned about such facility in the

village.

TREATMENT PLACE FOR CATTLE Place of

treatment


N % N % N % N % N % N %

In the

village 2 8.3 4 19.0 3 15.0 2 10.5 5 23.8 16 15.2

Nearby

village 15 62.5 14 66.7 16 80.0 17 89.5 15 71.4 77 73.3

Our side

block/

mandal

6 25.0 6 28.6 8 40.0 9 47.4 7 33.3 36 34.3

Don’t

know any

facility for

treatment

1 4.2 0 0.0 0 0.0 1 5.3 0 0.0 2 1.9

Others 1 4.2 0 0.0 1 5.0 0 0.0 2 9.5 4 3.8

Total 24 100.0 21 100.0 20 100.0 19 100.0 21 100.0 105 100.0



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AVAILABILITY OF EDUCATIONAL FACILITIES IN VILLAGE

All the villages have primary school in the village, while Gollapeta has

secondary school in the village.

AVAILABILITY OF HEALTH FACILITIES IN VILLAGE

Availability of RMP /local healer was reported by three fifth of the

respondents across the villages. Availability of private clinic and visits

by the ANM were reported by not more than one tenth of the

respondents across the villages with village wise variations.

Non-availability of any health facility was reported by about one third

of the respondents. Thus, availability of health facilities is an issue.

HEALTH FACILITIES AVAILABLE IN VILLAGE

Health

facility


N % N % N % N % N % N %

Private

clinic 0 0.0 14 46.7 0 0.0 0 0.0 0 0.0 14 9.3

RMP /

Local

healers

16 53.3 14 46.7 19 63.3 19 63.3 21 70.0 89 59.3

ANM Visits

to village 2 6.7 1 3.3 0 0.0 6 20.0 1 3.3 10 6.7

No health

facility in

village

12 40.0 9 30.0 11 36.7 7 23.3 9 30.0 48 32.0

Total 30 100.0 30 100.0 30 100.0 30 100.0 30 100.0 150 100.0

From the qualitative day analysis, ANM and ASHA visit the village, but

there is no proper health facility in the villages. For any kind of health

issues, people will got to the hospitals at Kothavalasa.

ANGANWADI CENTERS (AWC)

All the 5 villages have Anganwadi centre in the village

Most of the respondents mentioned about membership of HH members

in mahila mandal or SHG.

SKILL DEVELOPMENT PROGRAMME

Three fifth of the respondents reported about need of skill development

programme for the family members. The skill development

programmes in which the family mentioned participated include



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tailoring, knitting, computer training, making handloom items, and

financial literacy.

SKILL DEVELOPMENT PROGRAMME Need of skill

development


N % N % N % N % N % N %

Yes 12 40.0 16 53.3 17 56.7 27 90.0 25 83.3 97 64.7

No 18 60.0 14 46.7 13 43.3 3 10.0 5 16.7 53 35.3

Total 30 100.0 30 100.0 30 100.0 30 100.0 30 100.0 150 100.0

Kind of skill development programme needed*

Tailoring/stitching 12 40.0 15 50.0 24 80.0 25 83.3 24 80.0 100 66.7

Weaving

/knitting 10 33.3 12 40.0 17 56.7 20 66.7 20 66.7 79 52.7

Making

Handloom items 10 33.3 8 26.7 14 46.7 14 46.7 11 36.7 57 38.0

Computer

training 9 30.0 9 30.0 12 40.0 17 56.7 13 43.3 60 40.0

Financial literacy 6 20.0 7 23.3 12 40.0 15 50.0 12 40.0 52 34.7

Spoken English 3 10.0 4 13.3 7 23.3 9 30.0 10 33.3 33 22.0

No skill

development

training required

18 60.0 13 43.3 6 20.0 4 13.3 4 13.3 45 30.0

Total 30 100.0 30 100.0 30 100.0 30 100.0 30 100.0 150 100.0

*Note: Total exceeds 100 due to multiple response

The Qualitative study respondents reported that very few women

attended skill development training for Tailoring and Knitting

conducted by the Anganwadi Centre.

3.11.11.6 CONCLUSION AND RECOMMENDATIONS

The primary survey has brought out the following issues which helps in









• Drainage system






Report


PHOTOGRAPHS SHOWING THE SURVEY

Interview with Local Leader in Chinna Rao

Palli Household Interview in Chinna Rao Palli

Household Interview in Gollapeta Household Interview in Gollapeta



Report


Household Interview in Chinnapalem Houshold Interview in Chinnapalem

Household Interview in Chinnapalem

Household Interview in Chinnapalem



Report


Household Interview in Chinnapalem Household Interview in Chinnapalem

Household Interview in Ballighatam

with Anganwadi Teacher in Ballighatam



Report


DI with AWW , ANM in Gollapeta DI with ANM in Gollapeta

DI with AWW in Ballighatam

DI with Secretary in Katakapalli



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Household Interview in Katakapalli Household Interview in Katakapalli

Household Interview in Katakapalli

Household Iinterview in Katakapalli



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Houshold Interview in

Katakapalli

Household Interview in

Katakapalli

Household Interview in

Ballighatam

Household Interview in Ballighatam DI with Local Leader Ballighatam

CHAPTER - 4

ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION

MEASURES



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CHAPTER – 4 : ANTICIPATED ENVIRONMENTAL IMPACTS AND

MITIGATION MEASURES

4.0 INTRODUCTION

Sarda Metals & Alloys Ltd (SMAL) is operating a Ferro Alloys

manufacturing unit and a Captive Power Plant. The company is

certified for the following:

❖ Environment Management Certification: ISO 14001:2015

❖ Occupational Health and Safety Management Systems: ISO

45001: 2018

❖ Quality Management Systems: ISO 9001:2015

The company also received the following awards:

❖ CII Excellence EHS awards – 4 Star

❖ Greenbelt Development – Haritha Mithra

❖ Total Productive Maintenance – Jury Award in Waste

Management

❖ Grow Care India CSR Award 2020

SMAL proposes to expand the capacities by adding the following units:

a) Ferro Alloys plant (3x36 MVA capacity Submerged Arc

Furnaces) - 1,50,000 TPA

b) Steel Melting Shop (SMS) ((Induction Furnace (IF), Continuous

Casting Machine (CCM), Re-Heating Furnace, TMT & Wire Rod

Mill (WRM)): - 3,00,000 TPA

c) Mineral Fiber Plant – 150,000 TPA

d) Captive Power Plant with PF fired boiler - 1x 80MW

Operation of the existing Ferro Alloy Plant, Captive Power Plant,

Briquetting Plant and the proposed expansion units will result in air

emissions, water consumption and there by wastewater generation,

noise levels and solid waste generation.

Environmental Impacts are quantified to predict the impacts due to

proposed expansion on physical, ecological, and socio-economic

environments. The prediction of impacts helps in minimizing the

adverse impacts on environmental quality during pre and post

expansion.



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An attempt has been made to predict the ground level concentration

of Ferro Alloy plant considering total capacity of the plant after

expansion. The mathematical models used for predictions in the

present study is an EPA approved AERMOD model which is based on

steady state Gaussian plume dispersion model designed for point

sources and area sources for air quality. The predicted ground level

concentrations were computed using EPA approved AERMOD model

and plotted as isopleths.

In case of water, land, biological and socio-economic environments,

the predictions have been made based on scientific methodology.

Based on the quantified environmental impacts, an Environmental

Management Plan for implementation in the post expansion phase has

been formulated to comply with stipulated standard limits specified by

State Pollution Control Board and CPCB.

The proposed Environmental Management Plan comprises a set of

mitigation, monitoring and institutional measures which will be

implemented during operation of the plant at expanded capacity to

minimize adverse environmental impacts.

CORPORATE RESPONSIBILITY FOR ENVIRONMENT PROTECTION (CREP) -

COMPLIANCE

Compliance to CREP- action points as part of implementation EMP

measures are given in Table - 4.1.

TABLE – 4.1: CREP COMPLIANCE

S.NO ACTION POINTS COMPLIANCE

1. COKE OVEN PLANTS

To meet the parameters PLD (% leaking

colors), PLL (% leaking lids), PLO (% leaking

off take), of the notified standards under

EPA within three years by December

2005). Industry will submit time bound

action plan and PER Chart along with the

Bank Guarantee for the implementation

or the time.

To rebuild at least 40% of the coke oven

batteries in next 10 years (by December

2012).

Not applicable since there is no coke

oven plant



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2. STEEL MELTING SHOP

Fugitive emissions - To reduce

30% by March 2004 and 100% by March

2008 (including installation of secondary

dedusting facilities).

SMS is part of the expansion plan. The

design will comply with the current

fugitive emission standard.

3. BLAST FURNACE

Direct inject of reducing agents by June

2013.

Not applicable since there is no blast

furnace

4. SOLID WASTE /HAZARDOUS WASTE

MANAGEMENT

Utilization of Steel/ Melting shop (SMS)/

Blast Furnace (BF) Slag as per the

following schedule:

By 2004 – 70%

By 2006 – 80% and

By 2007 – 100 %.

SMS slag will be used as road ballast/

road fill material/Mineral Fiber plant.

HAZARDOUS WASTES

Charge of tar sludge/ ETP sludge to Coke

Oven by June 2003.

Inventorization of the Hazardous waste

as per Hazardous Waste (M& H), Rules,

1989 as amended in 2000 and

implementation of the Rules by Dec. 2003.

(tar sludge, acid sludge, waste

Lubricating oil and type fuel falls in the

category of Hazardous waste).

There is no Coke Oven plant.

Used oil/grease is the only hazardous

waste which will be disposed to APPCB

approved vendors.

5. WATER CONSERVATION/ WATER

POLLUTION

To reduce specific water consumption to

5 m3/t for long products and 8 m3/t for flat

products by December 2005.

To operate the Co-BP effluent treatment

plant efficiently to achieve the notified

effluent discharge standards by June

2003.

Not applicable since it is not an

integrated steel plant. However, water

conservation measures are being

implemented as part of Expansion

phase. The existing CPP is based on air

cooled condenser and dry bottom ash

handling system. Similar system will be

provided for the CPP in the expansion

phase.

6 Installation of Continuous stacks

monitoring system & its calibration in

major stacks and setting up of the online

ambient air quality monitoring stations by

June 2005.

Continuous online stack monitoring

system for PM/SOX/NOX installed for all

the major stacks. Similar systems will be

provided in the expansion units.

7 To operate the existing pollution control

equipment efficiently and to keep proper

record of run hours, failure time and

efficiency with immediate effect.

Compliance report in this regard is

submitted to CPCB/SPCB every three

months.

Compliance report is submitted to

SPCB every month and to MoEFCC

Regional Office, every six months

8 To implement the recommendations of SMAL will undertake a LCA study in



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Life Cycle Assessment (LCA) study

sponsored by MoEF&CC by December

2003.

consultation with CII after

implementation of the Expansion Plan

and based on availability of data with

respect to Indian Steel sector.

9 The industry will initiate the steps to adopt

the following clean technologies

measures to improve the performance of

industry towards production, energy and

land environment.

• Energy recovery of top Blast

Furnace (BF) gas.

Not Applicable since there is no Blast

Furnace

• Use of Tar- free runner linings. Not applicable

• De- dusting of Cast house at tap

holes, runners, skimmers ladle and

charging points.

Not applicable

• Suppression of fugitive emissions

using nitrogen gas or other inert gas

Not Applicable

• To study the possibility of slag and

fly ash transportation back to the

abandoned mines, to the abandoned

mines, to fill up the cavities through

empty railway wagons while they return

back to the mines and its

implementation.

Fe Mn Slag will be used as raw material

for Si Mn production

Si Mn Slag will be provided to brick

manufacturer/as raw material to the

proposed Mineral Fiber Plant

Fly ash from the captive power plant

will be disposed to local brick

manufacturing / Cement units.

• Processing of the waste

containing flux & ferrous wastes

through waste recycling plant.

Not Applicable

• To implement rainwater harvesting Rainwater harvesting Pond in 5.71 acres

is proposed to harvest the rainwater

and reuse in the plant.

• Reduction Green House Gases

by:

➢ Reduction in power consumption

➢ Use of by –products gases for

power generation

➢ Promotion of Energy Optimization

technology including energy/ audit

The development of greenbelt in 93.23

acres will have positive impact on the

reduction of GHG gases.

The company has implemented a

biogas plant for processing the food

waste from canteen.

The company proposes to evaluate

Waste Heat Recovery Boiler (WHRB)

potential for the Ferro Alloy Division

after complete installation of 5 furnaces

as part of energy conservation.

• Up- gradation in the monitoring

and analysis facilities for air and water

pollution. Also, to impart elaborate

training to the manpower so that

realistic data is obtained in the

environmental monitoring laboratories.

NABL and MOEF recognized

Laboratories are engaged to monitor

air and water pollution. In house

training to staff will be done for

obtaining realistic data.



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• To improve overall housekeeping

and Greenbelt.

Greenbelt is developed to control

fugitive dust and Noise. Housekeeping

will be improved.

10 SPONGE IRON PLANTS

Inventorisation of sponge iron plants to be

completed by SPCBs/CPCE by June 2003

and units will be asked to install proper air

pollution control equipment by

December 2003 to control primary and

secondary emissions. As per rebuilding

schedule submitted to CPCB/MoEFCC.

Not applicable since no Sponge Iron

Plant is proposed

This chapter details the environmental impacts and environmental

Management Plan of the plant for construction phase and operational

phase.

4.1 QUANTIFICATION OF ENVIRONMENTAL IMPACTS AND MITIGATION

MEASURES

Environmental impacts are quantified using two quantifiable

environmental criteria i.e., Duration and Severity. Duration is based on

the activity rate and severity is based on the impact of activity on

specific environmental components.

The aspects leading to impact are listed and qualitative assessment is

carried out with respect to aspect impact analysis. The quantitative

assessment is carried out adopting matrix method.

The major activities are listed as environmental aspects. The duration

value is assigned based on the scale of 1 to 5 with criteria of duration

of activity as given below:

Criteria for Duration of Activity Scale

Nil 1

Occasional 2

Daily, intermittently 3

Daily, continuously 4

Continuous for 365 days 5

The impact value is assigned for various significant environmental

components on the scale of 1-5 based on severity of the impact as

given below:



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Criteria for Severity on Env.

Component

Scale

Not severe 1

somewhat severe 2

severe 3

very severe 4

extremely severe 5

The various significant aspects and significant environmental

components considered for quantification of impact are given below

Table – 4.2.

TABLE – 4.2: MATRIX OF IMPACTS (NUMBER INDICATED IS SCALE OF IMPACT) S.

No

Aspects Dura

tion

Air

Pollutio

n

Water

Pollutio

n

Noise/

Vibratio

n

Soi

l

Lan

d

Use

Ecolo

gy

SE

(Socio-

Economy

)

Hydro

Geolo

gy

Risk &

Hazar

d

Solid and

Hazardou

s Waste

Intensity

1 Raw Material

Handling &

Storage

3 4 2 3 2 2 1 1 1 3 2

2 Manufacturing

Process 4 5 2 4 1 2 2 1 1 3 3

3 Finished

Product

Handling

3 3 1 3 2 2 1 1 1 2 2

4 Transportation 3 4 1 2 2 2 2 2 1 2 2

5 Water

Consumption 4 1 3 1 2 1 2 1 1 1 1

6 Solid waste

handling 4 2 2 2 2 4 2 1 1 3 3

7 Rainwater

Harvesting 5 1 2 1 2 2 2 1 3 1 1

8 Employment 5 1 1 1 1 1 1 3 1 1 1

9 Social Welfare

Measures 4 1 1 1 1 1 1 2 1 1 1

10 Use of Natural

Resources 4 2 3 2 2 3 3 3 3 2 2

4.1.1 QUANTIFICATION OF IMPACTS

Environmental impacts are quantified by multiplying Matrix – A with

Matrix B to obtain the score of each environmental component under

Matrix – C for the values assigned.

Matrix – A (Duration of activity on 1-5 scale for the listed Aspects) X

Matrix – B (Severity of activity on Environmental component on 1-5

scale) = Matrix –C (Impact Score)



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TABLE – 4.3: MATRICES OF QUANTIFICATION Matrix “A” represents the duration Matrix “B” represents the severity

Activity Duration of S.No.1 to Severity on 10 Env components

4 2 3 2 2 2 2 2 3 2

5 3 4 2 2 2 2 2 3 3

3 2 3 2 2 2 2 2 2 2

3 4 3 3 4 4 5 5 4 5 2 2 2 1 2 3 2 1 1 1

1 4 1 2 1 2 1 2 1 1

2 3 2 3 4 2 2 2 3 4

1 3 1 2 2 3 1 3 1 1

1 1 1 1 1 1 3 1 1 1

1 1 1 1 1 1 4 1 1 1

2 3 2 2 3 3 3 3 2 2

TABLE – 4.3: Matrix “C” SCORE OF VARIOUS ENVIRONMENTAL COMPONENTS

Air

Pollution

Water

Pollution

Noise/

Vibration Soil

Land

Use Ecology

SE (Socio-

Economy)

Hydro

Geology

Risk &

Hazard

Solid and

Hazardous

Waste

87 71 74 65 77 67 64 57 71 68

The maximum environmental impact is on Air Pollution (87 points)

followed by Water pollution (71 points). Also, high scores are on Socio

Economy (64 points), Ecology (67 points) and Land use (77 points)

followed by Soil (65 points), Solid Waste (68 points), Risk (71 points) and

Noise (74).

AIR POLLUTION

The score of various environmental components considering all major

activities of Ferro Alloy Plant and Captive Power Plant and the

proposed expansion showed that the maximum impact is on Air

Pollution. Considering these aspects, focus is made on Air pollution to

identify various areas of process leading to air pollution sources i.e.,

Raw Material Handling & Storage, Manufacturing Process, Finished

Product Handling and Transportation for providing various pollution

control measures

The Expansion is designed to comply with the new emission norms

specified in MoEFCC notification GSR 277 (E) for Particulate Matter,

Sulphur Dioxide and Oxides of Nitrogen.

Further details of Air pollution impact quantified, and proposed control

measures proposed along with equipment details are provided in Para

4.3.1 to 4.3.1.6.12.



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WATER POLLUTION

The water will be required in the existing and proposed Ferro Alloy Plant

and Captive power plant for Cooling of the furnaces, electrode

cooling system requirement and cast mould cooling. DM water is

required for makeup water of power plant.

Treated wastewater of the existing plant is recycled to minimize

consumption of fresh water. SMAL has implemented zero l iquid

discharge system.

Further details of water pollution along with mitigation measures for

proposed expansion are detailed under Para 4.3.3.

NOISE/ VIBRATION

Noise / Vibration from the plant is mainly from Rotating equipment like

Fans, Blowers, Feed Water Pumps, TG Boiler & Set, Compressors, Mill

motors, etc.,

The rotating equipment is provided with necessary acoustic control

arrangements to keep the sound level between 85 to 90 dB(A). This

includes selection of packaged equipment with acoustic enclosures,

intake, and outlet silencers, etc. The start-up vent, safety valve outlets

are provided with silencers to reduce the noise level to acceptable

limits. The Hogging Ejector is provided with silencer. The turbine will be

covered with acoustic enclosure. The buildings where turbines, blowers

and air compressors are installed is provided with soundproof walls

separating the control rooms.

The SMS and Rolling Mill generally produce noise level of up to about

85 dB(A). Moreover, when the plant is in operation, most of the

operating people normally will be working with PPE and use the cabins

to sit and observe the operation of equipment. Personnel protection

measures like use of ear plugs/earmuffs are provided for people who

work near the equipment for checking / inspection during operation.

Further details of Noise pollution control measures are provided in Para

4.3.2.1.



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ECOLOGY

The Ecology will not have significant impacts due to operations like

Raw Material Handling & Storage, Manufacturing Process, Finished

Product Handling, since these activities are within the project site.

However, there will be impact on the existing flora and fauna due to

movement of trucks in the in 10 km radius. The DFO Visakhapatnam

vide letter No 728/2021-S5 dated 13.08.2021 has provided the list of

fauna. There is no Schedule-I species in the study area as

authenticated by DFO, Visakhapatnam.

SOCIO ECONOMY

The impact on Socio economic is positive mainly due to employment

provided to locals and social welfare measures taken up since

inception of the plant and additional measures proposed under

expansion.

The existing industry is providing employment to about 865 people

(direct and indirect) and the proposed expansion will provide

employment about 1658 people (direct and indirect). Thus, the total

direct employment will be 2523 (direct and indirect) post expansion

and priority to local people will be given.

LANDUSE

The plant will not use any additional land. The score points on land use

stands at 77 with most of the greenbelt already developed.

As per CPCB guideline, every industry should develop minimum 33% of

total plot area as greenbelt area. SMAL has already developed

greenbelt on 93.23 Acres or 3,77,288 Sq. m i.e., 33.18 %. Green belt shall

be enhanced further on continuous basis by planting additional trees

to existing green belt.

SOLID WASTE GENERATION

The solid waste generation from various processes is given below:



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FERRO ALLOY PLANT

The following are the major solid wastes from the Ferro Alloy Plant

• Slag from production of Silico Manganese

• GCP Dust

STEEL MELTING SHOP

• Dust laden fumes from Induction Furnace Primary Fume

Extraction System

• Dust laden fumes from Induction Furnace Secondary Fume

Extraction System

• Mill scales from CCM and Rolling Mill

• Slag from Induction Furnace

The existing Briquetting plant and the proposed Mineral Fiber Plant to

recycle the wastes into the process.

BRIQUETTING PLANT – Existing

The dust from Ferro alloy plant and Steel melting shop along with

Manganese Ore fines, coke fines, binders, and additives are used to

make hard briquettes at the briquetting plant. The briquettes are

recycled to the process.

MINERAL FIBER PLANT - Proposed

The proposed Mineral Fiber Plant will convert the Silico Manganese Slag

to Slag wool.

POWER PLANT

The flyash and bottom ash generated to disposed to vendor for brick

manufacturers or use as road ballast.

RISK AND HAZARD

Impact on risk and hazard is less, as no storage leading to any impact is

involved in the plant which has high intensity of hazard.



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SMAL has developed a detailed onsite and offsite Emergency

Response Plan and the same will be updated post expansion. The

details regarding emergencies and preventive measures are provided

in Chapter – 7.

SOIL

Construction Period: The proposed expansion is coming up within the

plant premises which are already under possession of SMAL. For the

foundations to be laid during construction it would alter the prevailing

soil cover and topsoil generation is anticipated.

The soil would lose its nutrient values, if stacked for long time. Hence this

removed topsoil is to be judiciously managed, and spread out in such

a fashion that gainful use of the unused land is made for greenbelt and

horticulture development.

No negative impact on the soil quality in the study area during

construction is anticipated, as the disturbance will be within the project

area and limited to the excavated areas only.

Operation Period: The dust and gaseous emissions from the proposed

activity may lead to deposition of dust or gases on the soil in the study

area once the expansion is completed and the plant starts operations.

However, it is very minimal. Soil testing is carried out periodically to

check for the same.

The greenbelt and increase of density of greenbelt will provide good

binding of the soil.

The treated wastewater and dry sludge from proposed STP as manure

will be used for greenbelt development which will provide adequate

nutrients to the plants.

4.2 IMPACTS AND MITIGATION MEASURES DURING CONSTRUCTION PHASE

SMAL through its Lead Project Contractor will provide the necessary

infrastructural facilities to the labor. The proposed expansion will be

carried out in the existing premises of the plant. The site is already



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developed and Ferro Alloy Plant and Captive Power Plant are in

operation. There will be no significant impact due to site development.

Frequent water sprinkling in the vicinity of the construction sites would

be undertaken. All the internal roads are made of Concrete/Bitumen

to minimise fugitive dust emissions. It will be ensured that both gasoline

and diesel-powered vehicles are properly maintained to comply with

exhaust emission requirements.

The water requirement during construction is estimated will be 20 – 40

Kl.

There will be marginal increase in noise levels during construction

phase, which is temporary. An increase in noise level during night-time

is mainly from welding/ construction activity during the construction

phase and is limited to construction period only. Management of SMAL

will give preference to local people for employment.

OCCUPATIONAL SAFETY & HEALTH MANAGEMENT

Senior Environment and Safety Officer will be made in-charge of the

Environment and Safety aspects during construction.

The EHS department will supervise the safe working of the contractor

and their employees. Work spots will be maintained clean, provided

with optimum lighting and enough ventilation to eliminate dust/fumes.

24 hr. Medical Aid Room with qualified para-medical staff and fully

equipped Ambulance will be made available at site.

The Company will provide regular training to its staff on Occupational

Safety and Health both during construction and operation.

4.3 IMPACTS AND MITIGATION MEASURES DURING OPERATION

PHASE

Each of the Environmental aspects of the plant considering expansion

are discussed under the following heads for the impacts and proposed

pollution control measures

Air Environment



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Noise Environment

Water Environment

Land Environment

Socio Economic aspects

Occupational Health and Safety


4.3.1.1 EMISSION SOURCES



emission.

Air pollution emissions from all the units of proposed expansion are

quantified to estimate the impact in the study area.

Details of the emission from various units of the proposed expansion are

given in Table – 4.4.

TABLE 4.4: EMISSION DETAILS

A. FERRO ALLOY DIVISION AND STEEL MELTING SHOP (EXPANSION)

S.

No.

Stack Details Height

(m)

Dia

(m)

Exit

Temp

(°C)

Exit

Velocity

(m/s)

PM SO2 NOx

Emission

(g/sec)

PROPOSED

1. Ferro Alloy Plant

(FAC3,4,5) 65 4.0 148 6.89 1.84 - -

2. SMS (2 x 22T

induction furnaces)

(SMS1)

30 1.25 91 24.2 0.73 - -

3 SMS (2 x 22T

induction furnaces)

(SMS2)

30 1.25 91 24.2 0.73 - -

B. CAPTIVE POWER PLANT – Existing (1x80 MW)

S.

No.


(m)

Dia

(m)

Exit

Temp

(°C)

Exit

Velocity

(m/s)

PM SO2 NOx

Emission (g/sec)

4

Captive Power

Plant (CPP1)

(Without FGD)

120 6.7 132 6.58 8.43 101.1 50.6



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C. CAPTIVE POWER PLANT – EXPANSION WITH FGD FOR TWO CPPs (2x80 MW)

S.

No.


(m)

Dia

(m)

Exit

Temp

(°C)

Exit

Velocity

(m/s)

PM SO2 NOx

Emission (g/sec)

5

Captive Power

Plant (CPP1)

(With FGD)

120 6.7 132 6.58 5.06 16.85 16.85

Captive Power

Plant (CPP2)

(With FGD)

120 6.7 132 6.58 5.06 16.85 16.85

4.3.1.1.1 FERRO ALLOY PLANT

SMAL is producing 1.0 Lakh TPA of Ferro alloys with 2 no’s of Submerged

Arc Furnaces each of 33 MVA capacity. These Furnaces will be

upgraded to 36 MVA rating, but there will be no change in production

capacity. In order to increase the ferro alloy production capacity,

three new furnaces each of 36 MVA capacities will be implemented.

The total production capacity after expansion will be 2,50,000 TPA. The

exhaust emissions are mainly PM.

4.3.1.1.2 STEEL MELTING SHOP

The air emissions from the plant are mainly metal dust which is emitted

due to material transfer into the furnaces. No fuel burning is envisaged

as furnaces are electrically operated.

SMAL has provided 4 no’s x 22 T capacity Induction Furnaces under

expansion plan. A continuous casting machine and a Rolling mill are

planned.

4.3.1.1.3 ROLLING MILL

No generation of pollutants due to rolling of hot billets direct from the

CCM is envisaged. However, Fume Extraction systems (FES) are

proposed to be implemented

4.3.1.1.4 MINERAL FIBER PLANT

The dust emission from Mineral Fiber Plant is not significant as per the

estimation based on AP-42 Emission data of Mineral Wool



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Manufacturing. However, SMAL will provide adequately sized bag filers

to trap the dust.

Particulate

Matter Unit

USEPA EMISSION FACTOR =

0.1 lb/ton of

feed

= 0.0453

kg/ton of

feed

Total Raw Material Feed

to Mineral Fiber plant = 150000 TPA

Mineral Feed/ Furnace = 30000

TPA /

furnace

91 TPD

Emissions = 4.12 kg/day

0.0000000477 g/sec

4.3.1.1.5 CAPTIVE POWER PLANT

The fly ash generated from the power plant is disposed to brick

manufacturing units. The bottom ash is disposed for road construction.

The following graphs give the month wise coal consumption, fly ash

generation/disposal and bottom ash generation/disposal (tons per

month) for the period April 2019 – March 2021. It may be observed that

the fly ash and bottom ash has been completely disposed.



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4.3.1.2 SIMULATION MODEL FOR ESTIMATION OF GROUND LEVEL

CONCENTRATIONS – AERMOD

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 ground level concentrations mainly depend up on 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 plant, an EPA approved AERMOD model has been

employed. AERMOD provides option to model emissions from a wide

range of sources that are present at a typical industrial source

complex. The model considered the sources and receptors in

undulated terrain as well as plain terrain and combination of both. The

basis of the model is the straight-line steady state Gaussian Plume

equation, with modifications to model simple point source emissions

from stacks, emission from stack that experience the effects of

aerodynamics down wash due to nearby buildings, isolated vents,

multiple vents, storage piles, conveyor belts etc.

AERMOD Model with the following options has been employed to

predict the ground level concentrations due to the proposed

expansion.

1. Areas being rural, rural dispersion parameters are considered.

2. Predictions have been carried out to estimate concentration

values over radial distance of 10 km around the sources.



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3. A combination of Cartesian and polar receptor network has been

considered.

4. Emission rates from the sources were considered as constant

during the entire period.

5. The ground level concentrations computed were as is basis

without any consideration of decay coefficient.

6. Calm winds recorded during the study period were also taken into

consideration.

7. Meteorological data of the site has been obtained from

ENVITRANS for the study period and has been employed to

compute the mean ground level concentrations.

4.3.1.3 METEOROLOGICAL DATA

The meteorological data for the study period was procured from

ENVITRANS with respect to wind speed, wind direction & temperature

has been processed to extract the data required for simulation.

Stability classes computed for each hour is based on wind speed &

solar radiation. Mixing heights representative of the region have been

taken from the available published literature.

The guidelines of Central Pollution Control Board and IMD have been

followed for the purpose of modelling. Annexure – 4A gives the hourly

meteorological data of the 24 hours of study period used for estimation

of ground level concentrations.

4.3.1.4 ESTIMATION OF GROUND LEVEL CONCENTRATIONS

Ground level concentrations are computed taking into consideration

emissions from all units of Ferro Alloy Plant and Captive power plant at

its existing and expanded capacity.

4.3.1.5 POST PROJECT SCENARIO

Predicted maximum ground level concentrations considering

meteorological data of winter season 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. The overall scenario with predicted concentrations over the

maximum baseline concentrations is shown below in Table - 4.5.



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TABLE – 4.5: OVERALL SCENARIO WITHIN STUDY AREA (g/m3)

CUMULATIVE GROUND LEVEL CONCENTRATIONS OF FERRO ALLOY PLANT

AND CAPTIVE POWER PLANT WITH FGD

24-Hourly

Concentrations

Particulate

Matter

(PM10)

Sulphur

dioxide

(SO2)

Oxides of

Nitrogen

(NOx)




Overall Scenario 73.16{100} 20.69{80} 21.89{80} NOTE: 1. Values in parenthesis are National Ambient Air Quality (NAAQ) standard limits

specified for Industrial, Residential, Rural and other areas.

2. The above Overall Scenario is based on post implementation of expansion without

FGD

Annexure – 4B shows the predicted 25 high 24-hourly average

cumulative ground level concentrations of PM10, SO2 and NOX.

Fig – 4.1 to Fig - 4.3 shows the distribution of ground level

concentrations in the study area as result of the meteorological

conditions of the study area during study period.

4.3.1.6 AIR POLLUTION CONTROL MEASURES


phase are described below:



conveying, transporting, stacking etc., vehicular movement,










water sprinkling.



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Fig - 4.1 SHOWS THE DISTRIBUTION OF GROUND LEVEL CONCENTRATIONS OF

PARTICULATE MATTER



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SULPHUR DIOXIDE



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OXIDES OF NITROGEN



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5. The reductants coal storage is stored in the Coal storage shed. The

other fugitive dust emission sources such as material transfer points

etc., will be equipped with dust extraction systems of adequate

capacity.


system only.

DUST EXTRACTION SYSTEM S.No Location / Shop Facilities

1

Raw material handling

area, Material Transfer

points

Dust suppression system comprising of spray nozzles,

piping network, valves pumps, instrumentation and

controls, electrics, water tank etc.


Gas Cleaning Plant

Dust extraction system comprising of Reverse Air Bag

House type bag filter, Centrifugal fan and motor, duct

work including suction hoods, duct supports, stack, duct

hopper, rotary air lock valves, etc

3 Ladle Furnace Gas

Cleaning Plant

Dust extraction system comprising of Reverse Air Bag

House type bag filter, Centrifugal fan and motor, duct

work including suction hoods, duct supports, stack, duct

hopper, rotary air lock valves, etc


Fugitive emissions-

Installation of

secondary dedusting

facilities.

One bag filter proposed to install to reduce fugitive

emissions at steel melting area. Water sprinkling will be

done to suppress the fugitive dust at raw material

handling area, pulverizing area, raw material feed area,

cooler discharge area and the product processing area.

5 Captive Power Plant Dust extraction system comprising of pulse jet type bag

filter, Fly Ash Silo, Bottom Ash handling system, Electro

Static Precipitator, centrifugal fan and motor, duct work

including suction hoods, duct supports, stack, dust

hopper, rotary air lock valves, etc.

ASH HANDLING SYSTEM





where the ash will be disposed of by road trucks for brick


Interlocking system is provided for raw material feed and air pollution

control equipment. In case of any excess raw material flow, the

interlocking system is activated automatically and the plant as well as

air pollution control equipment will trip simultaneously.



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through MAC belt conveyor. The same will be crushed in the clinker

crusher to reduce the size high dense ash in to small particles. These

small particles transferred to Dry bottom ash silo through post cooler

chain belt conveyor.

4.3.1.6.1 FUGITIVE EMISSION CONTROL

















transportation in order to arrest dust.



planted in close vicinity. Further 1.12 acres will be developed.

WATER SPRINKLING





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4.3.1.6.2 POWER PLANT



be implemented as part of the expansion plan. MOEFCC stipulated has

revised standards for Thermal Power Plants as per the Gazette





SOx : 100 mg/Nm3

NOx : 100 mg/Nm3









Dampers.



option.

4.3.1.6.3 FUGITIVE DUST PROTECTION FOR WORKERS





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dust generation

area

Dust protection

technology proposed

for workers



Raw material

unloading area,

handling area

Nose mask, face


ear plugs


handling of fines, and dropping

of raw materials, wind break,

sheet cover

Stock house, day

bins

Nose mask, face


ear plugs



Work shop and

other confined work

area inside plant

Nose mask, face


ear plugs


exhaust fans, proper illumination

Internal roads -- Concrete roads, daily sweeping












noise

4.3.2.1 NOISE POLLUTION CONTROL MEASURES



barricades to keep the sound level of 85 to 90 dB (A). This

includes selection of packaged equipment with acoustic

enclosures, intake and outlet silencers, etc.







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during operation.




generating sources.



In addition to the above, the following general measures are

implemented to reduce noise pollution

The use of concrete and masonry walls and barriers - keeping in

view the benefits of stiffness weight and cavity construction and the

need to provide well sealed sound attenuating doors and windows.

The use of complete or partial enclosures.

Attenuation by use of sound absorbents on walls and fixed or

suspended ceilings

Introduction of control and monitoring rooms having good sound

insulation properties.

The use of vibration isolation techniques

The use of ducts and plenum chambers

The use of mufflers, sound attenuation and acoustic louvers in air

flow paths.

Development of greenbelt along the periphery of the plant and

also inside the plant.



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MEASURES TO PROTECT WORKERS FROM HIGH NOISE LEVELS:

The following measures will be undertaken to protect the workers from






4.3.3.1 WATER CONSUMPTION



The total water requirement post expansion will be 2700 m3/day. The

details of unit wise water requirement and wastewater generation is

presented in Table – 4.6.

TABLE - 4.6: WATER BALANCE (EXISTING + PROPOSED), (m3/day)

S.No Unit Purpose Existing Proposed Total

1 Ferro Alloys Cooling water makeup 470 683 1153


Plant Cooling water makeup 60 60 120

3 DM Plant Softener regeneration 34 34 68


5 Steel Melting Shop Cooling 0 500 500

6 Common Service water 225 230 455


Total 980 1720 2700

The water consumption of less than 3.5 m3/MWhr in the existing power

plant is not applicable since the power plant is based on Air Cooled

Condensor system. Similar such system will be incorporated in the

proposed expansion of Captive Power Plant which achieves

substantial conservation of fresh water.

4.3.3.2 WASTEWATER GENERATION TREATMENT AND DISPOSAL

4.3.3.2.1 WASTE WATER GENERATION





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The wastewater generation from the different units is given in the

Table – 4.7 and water balance diagram is shown in and Fig – 4.4.

TABLE – 4.7: WATER BALANCE (POST EXPANSION) (In m3/day)

S.No Unit Purpose Water

Requirement

Evaporation/

Loss

Waste

Water

Generation

1 Ferro Alloys Cooling

water

makeup

1153 922 231


Plant Cooling

water

makeup

120 96 24

3 DM Plant Softener

regeneration 68 14 54


5 Steel Melting

Shop

Cooling 500 450 50

6 Common Service

water 455 419 36


Total 2700 2202 498





generation is minimal from the process.

The waste water from the Ferro Alloy Division and captive power plant

will be sent to an ETP.



CPCB/APPCB standards. ETP flow diagram for Captive Power Plant is

shown in below figure.



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28

8D

M P

lan

t2

20

Bo

iler F

eed

22

0

Ferro

Allo

y

54

92

21

15

3

12

0

Briq

uett

e P

lan

t

56

56

Co

olin

g T

ow

er (

CP

P)

Servic

e W

ate

r

41

9

45

5

Do

mesti

c

26

12

8

10

2

Oil

ST

PG

ard

en

ing

87

15

96

WA

TER

BA

LA

NC

E D

IA

GR

AM

27

00

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day

3

GV

MC

RE

SE

RV

IO

R

23

1

24

36

LE

GE

ND

RA

W W

AT

ER

WA

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ER

RE

CIR

CU

LA

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N

LO

SS

NO

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:-

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ntitie

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/day

3

39

6

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el M

elt

ing

Sh

op45

0

50

0

50

39

6&

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rap

ET

P

59

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2R

ecycle

13

5D

ust

Su

pp

ressio

n

14

33

7

FIG

- 4

.4



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4.3.3.2.2 WASTE WATER TREATMENT PLANT

The wastewater is collected in equalization tank. These will be

operated on batch wise basis and will have approximately 8 hours

retention period.

The equalization tanks will be provided so that self-neutralization &

dilution will take place due to discharge of regeneration cycles. The

wastewater will be pumped to neutralization tanks. Depending upon

the pH, addition of acid (H2SO4) or alkali (lime solution) will be done.

The contents of neutralization tank will be stirred for at least one hour.

The reclaimed water will be used for slag cooling / gardening.

4.3.3.3 TREATMENT AND UTILISATION OF WASTEWATER

SMAL will implement an effluent management plan with collection,

treatment, recirculation and disposal of effluents. The various plans

proposed are given below:

• ETP for the Captive Power Plant

• Domestic wastewater will be treated in Modular STPs. The treated

water from the STP is reused for greenbelt development.

4.3.3.4 RAIN WATER HARVESTING

The quantities of rain water which can be harvested at the project site

are given below:



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Total plot area : 1137004.78 sq.m

Paved area : 454801.91 sq.m

Unpaved area : 682202.87 sq.m

Annual rainfall of the area : 1071 mm (1.071 m)

Runoff coefficient for paved area : 0.70

Runoff coefficient for unpaved area : 0.15

Runoff from paved area : 3,40,964.99 m3

Runoff from Unpaved area : 1,09,595.90 m3

Total runoff : 4,50,560.89 m3 per year

Total runoff after accounting for slippage : 3,37,920.67 m3 per year

& Evaporation Losses







Rain water Storage


RWH POND 185 125 15 5.71 3,46,875

SMAL will ensure containment of 100% rainwater to reuse in the plant

wherever applicable.


Details of solid waste management are given below:

➢ 100% Mill scale is used for captive consumption in Ferro Alloys

Plant as raw material.

➢ Dust from Steel melting shop, Bag Filter of Submerged arc

furnace and tapping process will be collected, stored in the

covered storage sheds. This dust will be reused to manufacture

briquettes and these briquettes will be used as raw material in

the Furnace.

➢ Miss-Roll and End Cuts (100%) will be used in captive

consumption in Steel Melting Shop as raw materials.



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➢ The additional fly ash generated by the second 80 MW captive

power plant will also be supplied to fly ash brick manufacturing

units as is the current practice.



Type of Waste Quantity,TPA Mode of Disposal

Slag from


Manganese


manufacturers / Raw material for Mineral

Fiber Plant.

GCP Dust 3,000 As a raw material for Briquetting Plant in

making Briquettes.




of Silico Manganese

3,00,000 SiMn Slag will be provided to brick



GCP Dust 4,500 Recycled and used as feed material

for Briquetting Plant.


Slag from Induction

Furnace

Quantity

(TPA) Mode of Disposal


Primary FES

3,640 Reused as feed material for Briquetting

Plant.


Secondary FES

1,680 Reused as feed material for Briquetting

Plant.


rolling Mill


Alloys plant

Slag from Induction

Furnace


material.

CAPTIVE POWER PLANT




Manufacturers.




Manufacturers.



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MINERAL FIBER PLANT

The SiMn slag will be used to create Fibers which is used as an insulation

material called Slag wool. SMAL had collaborated with Environment

Studies Department of Peking University, China and developed a

process to convert the Silico Manganese Slag into mineral fiber.


maintain the properties of the slag at 1400oC through which a stream

of air is blown in to specialized furnaces. The molten material falls into

the fiberization devices which are in form of rotors and distributed in a

thin film on the surfaces by centrifugal force and form into Fiber.

BRIQUETTING PLANT

Dust from Ferro Alloy Plant & Steel Melting Shop along with Mn Ore fines





CHEMICAL COMPOSITION OF WASTES

The details about typical chemical composition of various wastes

generated during the process are given in Table - 4.8.

TABLE 4.8: CHEMICAL COMPOSITION OF WASTES

S.No DESCRIPTION CHEMICAL COMPOSITION

1. Fly Ash of 80 MW

Coal based Thermal

Power plant

Parameter Composition %

Fe2O3 3.76

SiO2 51.82

CaO 6.5

MgO 1.17

Al2O3 31.41

MnO 0.54

P2O5 1.34

K2O 0.54

LOI 2.46

Misc. 0.46



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S.No DESCRIPTION CHEMICAL COMPOSITION

2 Ferro Alloy Slag Parameters Composition %

Fe2O3 1.5

SiO2 40.0

CaO 21.8

MgO 7.0

Al2O3 18.2

MnO 11.5

3. SMS slag Parameters Composition %

Fe2O3 22.5

SiO2 16.8

Cao 42.6

MgO 5.15

Al2O3 2.5

MnO2 10.3

P 0.15

The analysis of the trace metals for Fly ash, Granulated Silico Manganese

Sample and GCP Dust done by Chennai Test Laboratory Pvt. Ltd. is enclosed

as Annexure – 4C.




balance, is being sold to authorized agency as per APPCB. The

following is the hazardous waste generation & disposal in the plant

(Table 4.9).

TABLE 4.9: HAZARDOUS WASTE GENERATION

S.

No.

Type of

Hazardous Waste

Hazardous

Waste

Category

Quantity Disposal

1. Waste Oil/Spent

Oil

5.1 224

ltrs/Month

Stored in covered HDPE

Drums, used for

lubrication purpose & will

be given to APPCB

approved vendors.

4.3.5 GREENBELT DEVELOPMENT PLAN








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The layout of the Plant post expansion along with the greenbelt is given

in Fig – 4.5.

4.3.5.1MIYAWAKI PLANTATION

Invented by and named after Japanese botanist Akira Miyawaki, the

‘Miyawaki Method’ is a unique technique to grow forests.

Under the approach, dozens of native species are planted in the same

area, close to each other, which ensures that the plants receive sunlight

only from the top and grow upwards than sideways. It requires very little

space (a minimum of 20 square feet), plants grow ten times faster, and

the forest becomes maintenance-free in three years.

The typical schematic of Miyawaki Plantation and the actual plantation

is given below:



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Photograph showing Mumbai’s first Miyawaki forest (Colaba Woods Park,

Cuffe Parade) developed by environment conscious citizens. About 5,000

saplings comprising 33 species of native plants, including neem, baheda,

karanj, banyan, kadam, and sapindus, and fruit trees such as mango,

jackfruit, tamarind, custard apple, and cherry, were planted at this soon-to-

be dense urban forest patch.

MIYAWAKI PLANTATION AT SMAL

The Company implemented the Miyawaki Plantation scheme on trial

basis developed by the Japanese Botanist Mr. Akira Miyawaki in an

area of 0.51 acres in which close to 6000 trees have been planted in

very close proximity in order to create a high dense green barrier.

Additionally, 1.12 acres will be developed in the proposed expansion.



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4.3.6 SOCIO ECONOMIC IMPACT AND MEASURES

REHABILITATION & RESETTLEMENT ACTION PLAN

SMAL Has procured the land to the extent of 280.96 acres from APIIC.

The proposed expansion project will be located within the existing

project site. No additional land is required for the proposed expansion.

Hence no R & R is involved.

EMPLOYMENT AND WELFARE ACTIVITIES






The project proponent is already implementing various CSR activities.

An amount of Rs.87.6 lakhs was spent on various CSR activities for the

period 2016-17 to 2020-21.



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4.3.7 OCCUPATIONAL SAFETY & HEALTH MANAGEMENT

SMAL is certified for ISO 9001:2015, IS14001:2015 and ISO 45001:2018 i.e.,

Occupational Health and Safety Management Systems. The company

has provided Personal Protection Equipment to ensure safety of

personnel working in the plant.

A detailed onsite and offsite emergency response plan has been

prepared listing the various types of hazards which can happen at the

work place and the mitigation measures, PPE required to ensure safety

of personnel and zero accidents. Provision of proper ventilation

systems, fume extraction systems and other pollution control equipment

ensures good work place conditions.

Regular training and mock drills are also conducted to ensure

employee awareness about safety and safe operational practices.

SMAL ensures that all the employs undergo the following medical tests

PERIODIC MEDICAL EXAMINATION – YEARLY

➢ Pulmonary Function Test (PFT) – Yearly

➢ Audiometry Tests – Yearly

➢ Chest X-ray - Yearly

➢ Eye tests - Yearly

First aid training is imparted to the selected employees regularly. The list

of first aid members will be displayed at strategic places.

A budget of Rs. 10 Lakhs towards Occupational Health and Safety is

provided in the EMP budget. The typical health record of the workers

evaluated is enclosed as Annexure– 4D.

4.3.7.1 OCCUPATIONAL HEALTH CENTER

SMAL has established Occupation Health Center (OHC) at the plant

site. SMAL has access to Sri Venkateshwara Hospital in Kothavalsa

located at distance of 5.5 km from the site to administer the treatment

in case of medical emergencies and the patient can be shifted to

Visakhapatnam for further specialized treatment.



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4.4 ENERGY CONSERVATION

EXISITING PLANT

A biogas plant has been installed to treat food waste from the

canteen. The biogas is used for cooking.

PROPOSED EXPANSION

SMAL is evaluating potential to install WHRB for Ferro Alloy Division after

commissioning of at least four furnaces for generating power

economically.

NATURAL RESOURCE CONSERVATION

The implementation of Air-Cooled Condenser system has significantly

reduced the consumption of fresh water by 85%. Similarly, Air-Cooled

Condenser system is planned for the expansion Power Plant.

SMAL has also installed a dry bottom ash handling system significantly

reducing water consumption in the existing 1x 80 MW CPP. Thus,

significant water conservation has been achieved.

The development of Greenbelt with 17000 no of trees has resulted in

Sequestering Potential of 425 tonnes of CO2 per year. Apart from this

the greenbelt has prevented soil erosion, act as noise and dust barriers.

SMAL is going to implement the MIYAWAKI PLANTATION Scheme which

can generate an urban forest in very small footprint. This will further

increase the density of tree plantation.

CHAPTER - 5

ANALYSIS OF ALTERNATIVES

(TECHNOLOGY & SITE)



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CHAPTER – 5: ANALYSIS OF ALTERNATIVE (TECHNOLOGY & SITE)

5.1 SELECTION OF ALTERNATIVE TECHNOLOGY

The present EIA report is prepared for the proposed expansion of Ferro

Alloy Plant and Captive Power Plant. The following technology is

implemented in the existing plant:

❖ Ferro alloy production

❖ Power generation based on Rankine cycle using PF boiler

technology

The technology for the Ferro Alloy production, Captive Power Plant,

Steel Melting Shop etc., is based on proven technology with

improvements in energy conservation measures.

5.1.1 SELECTION OF TECHNOLOGY FOR MINERAL FIBRE PLANT

The Silico Manganese Slag is reused to manufacture insulation

material called Slag wool. SMAL has collaborated with Environment

Studies Department of Peking University- China and developed a

process to convert the Silico Manganese Slag into mineral fibres.

The major advantage of this new technology is utilizing the heat of

the molten slag to produce mineral fiber. This process has extremely

small carbon footprint as compared to the traditional method of

making mineral fiber as there is no use of coke as fuel.

The hot Silico manganese slag is fed into specialized Electric furnace

to maintain the properties of the slag such as temperature of 14000C

and viscosity.

The molten material falls into the fiberization devices which are in

form of rotors and distributed in a thin film on the surfaces by

centrifugal force and form into Fibers.

The mineral fiber produced has applications for insulation in factories

and buildings and other value-added building materials.



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5.1.2 SELECTION OF TECHNOLOGY FOR FLUE GAS DESULPHURIZATION (FGD) FOR

CAPTIVE POWER PLANT



be implemented as part of the expansion plan.

MOEF & CC stipulated has revised standards for Thermal Power Plants

as per the Gazette Notification S.O. 3305 (E) dated 07.12.2015.

However, for power plant which is being commissioned after 2017 have

to comply with the following emission standards.


SOx : 100 mg/Nm3

NOx : 100 mg/Nm3


SMAL has evaluated the following technologies:

S.

No

Technology provider Pollutant

control

Description of technology

1 Fortum Next, Finland NOx Low NOx burners and Over

fire air

2 Marsulex Environmental

Technologies, India, USA

based company

SOx FGD comprising reactor, bag

filter and other associate

equipment’s.

3 GE Power India Limited,

India

NOx Low NOx burners and Over

fire air

4 Berdichev Machine-Building

Plant "Progress", Ukraine

SOx,

NOx

and PM

Adsorber reactor, Bag filter

and other associate

equipment’s

5 Ion Exchange, Amtek and

Abhitech energycon, India

SOx Sox reduction catalyst

chemical injection in

combustion zone

SMAL has prepared techno-economic evaluation of FGD systems by





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Typical schematic of Dry/ semi dry scrubber flue gas desulfurization



For NOx control, SMAL will implement Low NOx Burners and Over fire Air

Dampers.

OVERFIRE AIR FUEL REBURNING


layout.



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5.2 SELECTION OF SITE

SMAL has implemented the Ferro Alloy Plant and Captive Power Plant

which are in operation since 2013 after obtaining all statuary

clearances. The total Plot area is 280.96 acres. Present activities are

covered under 54.12 Acres, Green Belt in 93.23 acres and area

available for future expansion is 133.61 Acres. Hence no additional

land is required for implementation of proposed expansion.

CHAPTER - 6

ENVIRONMENTAL MONITORING PROGRAM



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CHAPTER – 6 ENVIRONMENTAL MONITORING PROGRAMS

6.1 ENVIRONMENTAL MONITORING PROGRAM

SMAL is regularly monitoring the operational performance of installed

pollution control facilities to check the adequacy of mitigation

measures implemented. The monitoring plan also ensures compliance

with the environmental legislation and consent.

A full-fledged Environment Management Department with qualified

and experienced staff is functioning in the plant. Following are the

environmental aspects strictly considered in conducting regular

Environmental Monitoring within and outside the plant premises:

o Two Online Stack Monitoring System are installed at Ferro Alloys &

Captive Power Plant to measure PM and PM, SO2 and NOx

respectively.

o Three Continuous Ambient Air Quality Monitoring Systems

(CAAQMS) are currently installed at three different locations at 120o

angle to each other at the edge of the plant boundary to monitor

fugitive emissions for PM2.5, PM10, SO2, NO2.

o Work Zone Air Quality Monitoring near Furnace, coal yard, loading

and unloading points, and stacking areas, etc.

o Monitoring of ground water quality at plant site, dump yard,

surrounding area of dump yard for pH, conductivity, total solids,

suspended solids, oil and grease, metals.

o Wastewater quality and quantity from various units for pH,

Temperature and TSS, with evaluation of treatment system with

respect to above parameters.

o Ambient Noise Level Monitoring near the plant units, D.G sets,

Plant boundary, Main gate, Loading and Unloading points, etc.

o Monitoring of solid wastes, quantity and quality

o Greenbelt plantation, maintenance, development of other forms of

greenery like Avenue plantation, Miyawaki plantation.

o An automatic weather monitoring station is already installed within

the plant premises for measurement of meteorological parameters.

The monitoring is carried out as per Environment Clearance (EC) &

Consent for Operation (CFO) conditions.



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Continuous online stack monitoring equipments will be installed for

stacks viz., Particulate emissions from the stacks will be maintained well

within the prescribed limits and it will be connected to APPCB server &

CPCB server. One no. Continuous Ambient Air Quality Monitoring

Systems (CAAQMS) will be installed and connected to APPCB and

CPCB server.

A screenshot of the online display is given below:

The details of Environmental monitoring program of various

environmental parameters along with parameters and frequency of

monitoring are given in Table – 6.1.

6.2 ENVIRONMENTAL LABORATORY

SMAL is hiring the services of reputed third party NABL Accredited

environmental laboratory to carry out the monitoring of Environmental

parameters.

6.3 BUDGET FOR ENVIRONMENTAL MONITORING PROGRAM

SMAL has budgeted an amount of Rs. 20.0 lakhs per annum (Table –

6.2) for carrying out regularly the monitoring of environmental

parameters by a reputed third party NABL Accredited Laboratory.



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TABLE – 6.1: PLAN FOR MONITORING OF ENVIRONMENTAL PARAMETERS

S.

No

Particulars Monitoring

Frequency

Method of

Sampling

Parameter

I Air Pollution & Meteorology

A Meteorology Continuous

with

frequency of

15 minutes

Continuous

using auto

weather

station

Temperature (Dry Bulb,

Wet Bulb), Relative

Humidity, Rainfall, Wind

speed & Wind

Direction

B Stack Emission Monitoring

1 Main Stacks Continuous Online PM, SO2, NOX.

2 Ambient Air Quality (3

Locations)

Continuous Online PM10, PM2.5, SO2, NO2

C Ambient Air Quality Monitoring

1

Four locations in and

around the plant.

(Third Party Monitoring)

Once in

month

24 hr

continuously-

HVS

PM10, PM 2.5, SO2, NO2.

2 Fugitive Emissions Monitoring

Raw material handling,

feed area, and other

areas specified by SPCB.


(Once in 3

Months)

8-hour basis

with High

Volume

Sampler

SPM, RPM, TPM.

II Noise Levels Monitoring

1

On the Plant Boundary at

three locations

Once in a

month for the

various plants

24 hr

continuous

with one hr

interval

Noise levels in dB(A)

2 Work zone Noise

Monitoring

Twice in a

month

One hr

interval

Noise levels in dB(A)

III Water and Wastewater Quality Monitoring

A Water Quality

1

Ground Water


Once in a

season

Grab Parameters specified

under IS:2296

(Class C) and IS:10500,

1986

B Industrial Effluents

1 Zero Waste & Effluents Continuous Online

Monitoring

pH, Temperature, TSS

2 Zero Waste & Effluents

Manual Monitoring


Once in 3

Months)

pH, Temperature, TSS,

Oil & Grease

3 Domestic Effluents

(STP Waste Water)


Once in 3

Months

24 hr

composite

IV Soil Quality Monitoring

1 In and around the plant


Once in Pre-

Monsoon and

Post Monsoon

season

Grab Physio-chemical

parameters and

metals

V Occupational Health and Safety 1 All Plant personnel Yearly - Blood Test, Pulmonary

Function Test (PFT),

Audiometry test, Chest

X- rays and eye test.



Final EIA

Report


TABLE 6.2: PROPOSED BUDGET FOR IMPLEMENTATION OF

ENVIRONMENTAL MONITORING PROGRAM (COST IN Rs. LAKHS)




Water quality 2.0


Soil Quality 0.5

Noise Levels 0.5




10

TOTAL 20.0

CHAPTER - 7

ADDITIONAL STUDIES


APIIC Industrial Park, Kantakapalli (V), Kothavalsa (M), Vizianagaram (Dist.), A.P. Final EIA

Report


CHAPTER – 7: ADDITIONAL STUDIES

7.1 PUBLIC CONSULTATION




– 7A.





Pollution Control Board. Photographs of Public Hearing are shown

below:

FIG – 7.1

PHOTOGRAPHS OF PUBLIC HEARING

Summary of public hearing issues and response of SMAL along with

budget is given in Table – 7.1.



Report


TABLE – 7.1

SUMMARY OF PUBLIC HEARING ISSUES AND RESPONSE OF SMAL ALONGWITH BUDGET

(Note: S1, S2……… Represents the speakers & W1, W2……… Represents the Written

Representations Received)

S.

No.

Issues raised Management

response

Action Plan/

Activities proposed

Budget

allocation

Timeline

1. Land Related Issues

Speaker No. S2, S7, S11, W7, W8

a) Compensation to the

land losers

SMAL has paid the

cost of land to APIIC.

APIIC has to make

necessary payments

to the land losers.

To follow up with

APIIC for payments

to sellers. - -

b) Compensation to the

farmers whose

mango garden was

disturbed during

laying the power line

through

Kothasunkarapalem

village

SMAL has given

compensation of Rs.

2,15,15032/- to all the

people on whose land

towers/conductors

are going through

during laying power

transmission line from

Pendurthi to

Company (18 Kms) as

stipulated by

APTRANSCO. Those,

who have not

received payment

may please approach

the personnel

department.

We request the

villagers to submit

their claims request

in writing which will

be looked into case-

by-case basis by

SMAL.

- -

2. Air Pollution Related issues

Speaker No. S7, W5, W8, W11, W16, W17

a) Impact on black dust

pollution on mango

and cashew

plantation from the

industry

SMAL has installed

pollution control

systems in process and

ambient air quality

continuous monitoring

systems is connected

to APPCB website

directly. These stations

located at 120

degrees direction

which covers 360

degrees of dust

evolution from the

plant and ensuring the

emissions are under

control. However,

suggestions are noted,

and we will try to

control the emissions

to maximum extent

possible by adopting

latest technologies.

SMAL will Install latest

pollution control

systems for

expansion projects

also.

SMAL has

earmarked

an amount

of Rs. 16877

lakhs towards

air pollution

control

system and

online

monitoring

systems

Within 3

years



Report


S.

No.


response

Action Plan/

Activities proposed

Budget

allocation

Timeline

b) Option to reduce

coal consumption to

meet COPS guideline

for reducing CO2

emissions

SMAL is highly power

intensive industry and

approximately 45% of

input cost is power. As

high quality

continuous 24X7

power is very critical

for production

reliance on

renewable energy for

only a very small

portion can be

explored. At this

juncture power

through renewable

energy may not be

possible for the

quantum needed for

our production

process.

SMAL has plan to

install WHRB to

reduce coal

consumption.

SMAL is exploring the

roof top solar panels

wherever possible.

Rs. 7500

Lakhs

Rs. 10 Lakhs

Within 3

years

3. Water Pollution Related issues

Speaker Nos. S1, S2, S6, S9, W7, W8

a) Water pollution to

Marrigedda

SMAL adopted zero

liquid discharge

facility. At monsoon

run-off water only,

which will be flowing

during heavy rains.

SMAL will ensure the

quality of the runoff

water before leaving

company premises

during monsoon.

SMAL is continuously

monitoring ground

water quality is being

tested through NABL

accredited

environmental

agency and is

ensuring all the

parameters are well

within the limit.

SMAL will construct a

sedimentation pit

before monsoon to

collect the runoff

water. Analysis of the

water will be carried

out periodically.

However,

suggestions are

noted and will work

out accordingly.

Rs. 20.0 Lakhs Three Years

b) Impact of rainwater

being discharged

from the plant site

and joining the

narasapalli Tank.

4. Greenbelt Development Related Issues

Speaker No. W1, W2, W3, W4, W6, W12, W13, W14, W16, W17

a) Avenue plantation

on internal roads

SMAL has already

planted trees on both

sides of the roads

internally.

SMAL in association

with forest dept. and

SMAL will take the

support of local

Sarpanches to

execute plantation

in nearby areas in

association with

Rs. 6 Lakhs for

Avenue

Plantation

SMAL has

earmarked a

3 Years

3 years b) Plantation of Fruit

bearing and

medicinal Plants



Report


S.

No.


response

Action Plan/

Activities proposed

Budget

allocation

Timeline

R&B department has

planted trees on both

sides of the

Kothavalasa-

Vizianagaram state

highway for 2kms.

SMAL developed a

greenbelt in an area

of 93.23 acres and

1.12 acres under

Miyawaki method of

plantation.

forest department. capital

amount of

Rs. 20 lakhs

for greenbelt

development

which

includes Fruit

bearing and

medicinal

Plants

5. Employment related issues

Speaker No. S3, S4, S5, S7, S8, S9, W4, W7, W8, W10, W13

a) Jobs to local and

surrounding villages

753 people out of 865

are from A.P. and 392

persons belong to

various villages of

Kothavalasa Mandal,

Vizianagaram District

have benefited by

employment in SMAL.

Further, in the

expansion phase

company will give

similar preference to

local people based

on their

qualifications and

vacancies.

- -

b) 75 to 80 %

employment should

be given for locals

c) Provide the

employment to the

people who lost the

land

d) Priority to local and

unemployed youth

e) Preference to local

people for petty

contracts like earth

works, civil works etc.,

Preference will be

given to petty


works, civil works etc.,

-

6. Occupational safety related Issues

Speaker No. W2, W3, W4, W15, W16, W17

a) Monitoring the heat

near furnace

SMAL has semi-closed

furnace and mostly

keep the shutters in

closed condition to

avoid any heat

radiation around

furnace area. SMAL is

also using mudgun

and drilling machine

at tapping area which

is state of art

technology where the

human intervention is

avoided.

To save the tapping

crew from heat

exposure SMAL

provide them

appropriate full body

SMAL has planned to

conduct Industrial

Hygiene tests as part

of further

improvements at

workplace.

PPEs will be provided

Rs. 15.0 Lakhs

Rs. 10.5 Lakhs

3 Years

Three Years



Report


S.

No.


response

Action Plan/

Activities proposed

Budget

allocation

Timeline

heat retardant suits

boots, gloves made of

Aluminium and face

shields etc., which

costs around

Rs.50000/per person.

b) PPE to all the workers SMAL is an ISO 45001

certified company

and provides its

workers all required

PPEs to ensures safe

working environment.

SMAL has bagged

several awards for

best safety practices.

SMAL is providing

helmets, Shoes and

goggles to all the

persons working inside

the premises.

Apart from regular

PPE’s SMAL also

providing special

PPE’s like Aluminium

suits at high heat

areas, Aluminium

aprons, Shoes at

casting areas.

Specialised Face

shields are provided

at high heat areas.

High visible jackets

being provided at

confined areas.

Gloves like cotton,

leather, knitted palm

grip are being

provided based on

the activity.

Safety harness at work

at height areas.

SMAL will continue

the same and

always tries to adopt

new practices.


7. Rain water Harvesting Related Issues

Speaker No. W1

a) Rainwater Harvesting SMAL has built a

rainwater harvesting

pond of 371 million

Litres capacity in the

At present as part of

project expansion

the existing pond has

to be relocated to

Rs. 60 Lakhs

towards

Capital cost

In one year



Report


S.

No.


response

Action Plan/

Activities proposed

Budget

allocation

Timeline

year 2013-14.

Rainwater collected in

this pond has lead to

increase in the ground

water level in


which led to multiples

crops in the villages

which was not there

earlier. Rainwater

collected in the pond

was being used for

gardening and dust

suppression within the

plant premises.

utilise that area to

build new plant.

SMAL will built a new

rainwater harvesting

pond of 346.9 million

Litres capacity.

8. Compliance to Pollution Control Rules and Regulations Issues

Speaker No. W7, W10, W11, W16, W17

a) Comply with emission

standards and follow

the rules and

regulation of

MoEFCC / APPCB

SMAL is complying

with standards

prescribed by

MoEFCC / APPCB.

Will implement

continuous

monitoring emission

system and

monitoring of

environmental

parameters by NABL

accredited third

party laboratory

SMAL has

earmarked

an amount

of Rs. 16877

lakhs towards

air pollution

control

system and

online

monitoring

systems

Within 3

years

9 CSR Related Issues

Speaker No. S8, S9, S11, W1, W2, W3, W4, W5, W6, W7, W8, W10, W12, W13, W14

a) Charging for RO

water

R.O plant was

established and

handed over to

villagers. They

themselves are

charging for

maintenance and to

avoid misuse.

- - -

b) Medical camps, Issue

of Health Cards and

supply of medicines

SMAL has been

conducting mega

medical camps on

half-yearly basis out of

which 5000 villagers

got benefitted from

the same in the past 5

years. SMAL is also

issuing free medicines

to the people during

camps.

SMAL has started a

polyclinic in which

registered MBBS

Existing practices will

be continued




Report


S.

No.


response

Action Plan/

Activities proposed

Budget

allocation

Timeline

Doctor sits for

alternate days to give

free health check-ups

and consultancy.

company also

provides free

medicines to all the

villages as prescribed

by the doctor. So far

>20000 villagers have

got benefitted from

this.

Further SMAL also has

assisted for free eye

cataract operations

and provided free

goggles 30 villagers.

c) CSR amount is not

spent in the nearby

villages

As per Company Act,

industry has to spend

2% of the average

profit of previous three

financial years.

SMAL has been

spending more than

2% of the profits on

CSR activities. Even

though company

incurred losses during

few years and was not

required legally to

invest in CSR,

Company carried out

CSR activities to a

good extent during

those years also.

During last five years

SMAL was required to

invest Rs.45.50 lakhs

(as per act) whereas

SMAL invested

Rs.83.16 Lakhs during

this period.

Further, in the

expansion phase

company will give

similar preference to

local people based

on their

qualifications and

vacancies.

SMAL will continue

spending on CSR as

per the act in-vogue

and will address

needs in the

surrounding areas

under its CSR

policies.

SMAL will allocate

the budget as per

the CSR act and will

take the necessary

activities of the

committee to be

constituted by

District Collector,

Vizianagaram.

Rs. 200 Lakhs

Budgeted

2 years

(2022-24)

d) CSR amount should

be 5% of the net

profit

e) Formation of

Coordination

committee with

Govt. officials, PCB

Officials and Local

Villagers

Collector,

Vizianagaram will form

committee comprising

of all the relevant

Govt. Officials and

local sarpanches and

SMAL representatives

for the same purpose

As per the outcome

of meeting action

will be taken.

Rs. 1.0 Lakhs Every Year



Report


S.

No.


response

Action Plan/

Activities proposed

Budget

allocation

Timeline

f) Construction of

Hospital

SMAL is regularly

undertaking the

health camps for the

benefit of the local

villagers. SMAL has

started a polyclinic in

which registered MBBS

Doctor sits for

alternate days to give

free health check-up

and consultancy.

company also

provides free

medicines to all the

villages as prescribed

by the doctor.

SMAL is providing the

ambulance service to

transport in case of

emergency to local

Government hospital

which located at

Kothavalasa within

6kms.

SMAL will try to

contribute more to

local health centers

Rs. 30.0 Lakhs 3 Years

g) Construction of

burning shed in grave

yard of Kantakapalli

Noted and will take

up this activity with

the help of local

leaders

Construction of

burning shed in the

graveyard will be

done.

Rs. 10 Lakhs One year

h) Construction of

Community Hall

SMAL will discuss the

same in the

committee formed by

collector and will

explore the possibilities

of the same.

SMAL will discuss the

same in the

committee formed

by collector and will

explore the

possibilities of the

same.

SMAL will take up

such village

development

activities based on

the

recommendation of

the committee to be

constituted by

District Collector,

Vizianagaram.

Subject to

provide site

by villagers

and decide

by

committee

to be formed

for CSR

activities.

Budget will

be estimated

based on site

and required

size.

By

December

2023

i) Construction of

additional overhead

tank in kantakapalli,

Sunkurapalem

SMAL had received

this requirement 4-5

years back as theses

villages were not able

to get 24X7 water

supply due to small

SMAL has upgraded

the transformer

capacity to ensure

that 24X7 water

supply in the villages.

However, this issue

SMAL

already

spent Rs. 5.0

Lakhs

-



Report


S.

No.


response

Action Plan/

Activities proposed

Budget

allocation

Timeline

size of tank.

To address this issue,

SMAL had provided 3

phase transformer

and since then all

nearby villages are

getting 24X7 water

supply.

will be taken up by

the committee to be

constituted by

District Collector,

Vizianagaram.

j) Construction Of Ro

Plant In

Sambhayyapalem,

Sunkurapalem And

Supply Ro Water Free

Of Cost.

SMAL will evaluate the

water quality and

implement the RO

plant if necessary.

Based on the water

analysis if required

SMAL will provide

R.O plants at

Sambhayyapalem,

Sunkurapalem.

Rs. 6.0 Lakhs 3 years

k) Development of

roads, nallas and

other Infrastructure

needs of the village

under CSR activities

SMAL has constructed

2 bus stops, installed

20 Solar lights,

provided culvert

cover of drains of 100

meter etc.

SMAL will continue

infrastructure

development in

future also as per

villager’s

requirement and

withing its CSR

budget.

SMAL will take up

such village

development

activities based on

the

recommendation of

the committee to be

constituted by

District Collector,

Vizianagaram.

SMAL has

spent Rs. 45.0

Lakhs in the

financial year

2021-22

This will be

taken up in

the District

committee

to be

constituted

by District

collector.

SMAL will

provide the

necessary

budget from

the CSR

Funds

-

Rs. 200

lakhs

l) Skill Development

Programs

Under Skill

development project,

SMAL developed

computer education

centre in Kantakapali

panchayat from

which around 85

members got

benefitted to become

employable.

SMAL also developed

2 stitching learning

centres from which 50

members got trained

to become self-

employable.

SMAL will open up

new skill

development

centres in future also

to make villagers

employable based

on the need.


m) Support to rural SMAL has constructed SMAL will support Rs. 15.0 Lakhs Three Year



Report


S.

No.


response

Action Plan/

Activities proposed

Budget

allocation

Timeline

primary education for

weaker sections

4 classrooms and toilet

block at high school

at local village. R.O

water supply

established at school.

SMAL is providing all

required help to

students viz..

distribution of lunch

boxes, water bottles,

compass boxes etc,

rural primary

education for

weaker sections as

part of CSR activity

and as per CSR

budget.

Total = Rs.

7883.5 Lakhs

Note: 1. * These items are part of the EMP budget

2. Out of the total amount of Rs. 7883.5 about Rs. 7500 Lakhs is earmarked for implementation of

Waste Heat Recovery Boiler (WHRB) and Rs. 383.5 Lakhs for various activities to be implemented

as part of public hearing commitments and CSR activities.


demands. Action plan as per MoEFCC O.M. dated 30/09/2020 along

with the list of activities giving physical numbers, time schedule and

Budget is given in Table – 7.2.

TABLE – 7.2

PUBLIC HEARING COMMITMENTS AND ACTION PLAN AND BUDGET (Action Plan as per MoEF&CC OM dated 30/09/2020 for Public Hearing issues)

S.

No.

Activity Year Total

(Rs Lakhs) 2022-23 2023-24 2024-25

1. Land Related Issues

c) Compensation to

the land losers

Physical

Nos

Nil

Already paid to APIIC. Any discrepancies to be

brought to APIIC Notice for resolution

-

@Village -

Budget

Rs Lakhs

-

d) Compensation to

the farmers whose

mango garden was

disturbed during

laying the power

line through

Kothasunkarapalem

village

Physical

Nos

An amount of Rs. 21,51,15032 /- has been paid to

land owners on whose lands the towers were

erected as stipulated by APTRANSCO. Those who

have not received the compensation may

approach SMAL for taking up the issue with

APTRANSCO.

-

@Village

Budget

Rs Lakhs

2. Air Pollution Related issues

c) Impact on black

dust pollution on

mango and

cashew plantation

from the industry

Physical

Nos

Nil *Rs. 16877 lakhs

earmarked

towards air

pollution

control system

and online

monitoring

systems as part

@Village

Budget

Rs Lakhs



Report


S.

No.

Activity Year Total

(Rs Lakhs) 2022-23 2023-24 2024-25

of EMP

d) Option to reduce

coal consumption

to meet COPS

guideline for

reducing CO2

emissions

Physical

Nos

Implementation of WHRB within 3 years

Implementation of Roof top solar panels within 3

years

Rs. 7500 Lakhs

Rs. 10 Lakhs @Village

Budget

Rs Lakhs

3. Water Pollution Related issues

c) Water pollution to

Marrigedda

Physical

Nos

Nil Rs. 20.0 Lakhs

@Village SMAL will construct a sedimentation pit before

monsoon to collect the runoff water. Analysis of

the water will be carried out periodically.

Budget

Rs Lakhs

20

d) Impact of rainwater

being discharged

from the plant site

and joining the

narasapalli Tank.

4. Greenbelt Development Related Issues

c) Avenue plantation

on internal roads

Physical

Nos

1000-1500

Plants

1000-1500 Plants 1000-1500

Plants

Rs. 6.0 Lakhs

@Village Kantakapalli Kotturu Sunkarapalem

Budget

Rs Lakhs

2.0 2.0 2.0

d) Plantation of Fruit

bearing and

medicinal Plants

Physical

Nos

Within the plant site as part of Greenbelt

development program which includes Miyawaki

Plantation

*Rs. 20.0 Lakhs

@Village

Budget

Rs Lakhs

7 7 6

5. Employment related issues

f) Jobs to local and


Preference will be given to locals from the

surrounding villages during the expansion phase

also

-

g) 75 to 80 %

employment should

be given for locals

h) Provide the

employment to the

people who lost the

land

i) Priority to local and

unemployed youth

j) Preference to local

people for petty


works, civil works

etc.,

6. Occupational safety related Issues

c) Monitoring the heat

near furnace

Physical

Nos

Conducting industrial hygiene test and provision

of full body heat retardant suits

Rs. 15.0 Lakhs



Report


S.

No.

Activity Year Total

(Rs Lakhs) 2022-23 2023-24 2024-25

@Village Within the plant

Budget

Rs Lakhs

5.0 5.0 5.0

d) PPE to all the

workers

Physical

Nos

PPE to all workers is provided Rs. 10.5 Lakhs

@Village Nil

Budget

Rs Lakhs

3.5 3.5 3.5

7. Rain water Harvesting Related Issues

a) Rainwater

Harvesting

Physical

Nos

Nil

Done with in the plant site

*Rs. 60 Lakhs as

part of EMP

@Village

Budget

Rs Lakhs

60.0

8. Compliance to Pollution Control Rules and Regulations Issues

a) Comply with

emission standards

and follow the rules

and regulation of

MoEFCC / APPCB

Physical

Nos

Nil Budget for

implementation

of pollution control

equipment (EMP

Budget) already

provided to

comply with

MoEFCC / APPCB Rules and

Regulations Issues

@Village

Budget

Rs Lakhs

9 CSR Related Issues

n) Charging for RO

water

Physical

Nos

SMAL has implemented the RO Plants and the

village panchayat is charging for maintaining the

RO Plant

-

@Village

Budget

Rs Lakhs

o) Medical camps,

Issue of Health

Cards and supply of

medicines

Physical

Nos

4 camps per village per year will be taken up Rs. 30.0 Lakhs


Budget

Rs Lakhs

10 10 10

p) CSR amount is not

spent in the nearby

villages

Physical

Nos

District Collector has advised the govt. Officials to

form a committee which will prioritize the needs

of the villages and coordinate the

implementation of CSR Budgets.

Rs. 200 Lakhs

@Village

Budget

Rs Lakhs

SMAL has earmarked the budget of Rs. 200 lakhs

for this purpose

q) CSR amount should

be 5% of the net

profit

Physical

Nos




implementation of CSR Budgets. @Village

Budget

Rs Lakhs

SMAL has earmarked the budget of Rs. 200 lakhs

for this purpose

r) Formation of

Coordination

committee with

Physical

Nos




Rs. 1.0 lakhs per

year

@Village



Report


S.

No.

Activity Year Total

(Rs Lakhs) 2022-23 2023-24 2024-25

Govt. officials, PCB

Officials and Local

Villagers

implementation of CSR Budgets.

Budget

Rs Lakhs

SMAL has earmarked the budget of Rs. 1.0 lakhs

per year for this purpose

s) Construction of

Hospital

Physical

Nos

SMAL is regularly undertaking the health camps

for the benefit of the local villagers. SMAL has

started a polyclinic in which registered MBBS

Doctor sits for alternate days to give free health

check-up and consultancy. company also

provides free medicines to all the villages as

prescribed by the doctor.

SMAL is providing the ambulance service to

transport in case of emergency to local

Government hospital which located at

Kothavalasa within 6kms.

Rs. 30.0 Lakhs

@Village SMAL will try to contribute more to local health

centers

Budget

Rs Lakhs

10.0 10.0 10.0

t) Construction of

burning shed in

grave yard of

Kantakapalli

Physical

Nos

1 Nos Rs. 10 Lakhs

@Village Kantakapalli

Budget

Rs Lakhs

10.0

u) Construction of

Community Hall

Physical

Nos

This will be taken up in the District committee to

be constituted by District collector. Since the land

has to be identified by the village panchayat.

-

@Village

Budget

Rs Lakhs

CSR Budget

v) Construction of

additional

overhead tank in

kantakapalli,

Sunkurapalem

Physical

Nos

SMAL has upgraded the transformer capacity by

spending Rs 5.0 Lakhs to ensure that 24X7 water

supply in the villages. However, this issue will be

taken up by the committee to be constituted by

District Collector.

-

@Village

Budget

Rs Lakhs

w) Construction of RO

plant in

sambhayyapalem,

sunkurapalem and

supply RO water

free of cost.

Physical

Nos

1 1 1 Rs. 6.0 Lakhs

Water Quality

will be tested @Village Kotturu Sambhayyapalem Sunkurapalem

Budget

Rs Lakhs

2.0 2.0 2.0

x) Development of

roads, nallas and

other Infrastructure

needs of the village

under CSR activities

Physical

Nos

This will be taken up in the District committee to

be constituted by District collector. SMAL will

provide the necessary budget from the CSR Funds

Rs. 200 lakhs

@Village

Budget

Rs Lakhs

y) Skill Development

Programs

Physical

Nos

Tie up with local ITI or Polytechnical Colleges and

sponsoring of students.

Rs. 30.0 Lakhs


Budget

Rs Lakhs

10.0 10.0 10.0

z) Support to rural

primary education

Physical

Nos

Identification of Weaker section students and

providing necessary education aids to ensure

Rs. 15.0 Lakhs



Report


S.

No.

Activity Year Total

(Rs Lakhs) 2022-23 2023-24 2024-25

for weaker sections that they attend the school


Budget

Rs Lakhs

5.0 5.0 5.0

Total = Rs.

7883.5 Lakhs Note: 1. * These items are part of the EMP budget

2. Out of the total amount of Rs. 7883.5 about Rs. 7500 Lakhs is earmarked for implementation of

Waste Heat Recovery Boiler (WHRB) and Rs. 383.5 Lakhs for various activities to be implemented as

part of public hearing commitments and CSR activities.

The proceedings of the Public Hearing are enclosed as Annexure-7B.

The response of the management for the speaker wise, along with

action plan, budget allotment and time of completion are attached

Annexure-7C.

7.2 RISK ASSESSMENT, ON-SITE EMERGENCY PREPAREDNESS & DISASTER

MANAGEMENT PLAN

7.2.1 RISK ASSESSMENT - MAJOR LAWS RELATING TO OCCUPATIONAL SAFETY &

WORKING CONDITIONS MANAGEMENT

There are four main legislations that cover Occupational Safety &

Working Conditions Management at workplace.

i The Factories Act, 1948, covering factories wherein the

enforcement of safety at workplace is by the Chief Inspector of

Factories in the respective states,

ii The Mines Act, 1952 and Mines Rules, 1955 for mining industry

where the enforcement is by the Directorate General of Mines

Safety (DGMS) under Ministry of Labour & Employment,

Government of India,

iii The Dock Workers (Safety, Health and Welfare) Act, 1986 followed

by notification of the Dock Workers (Safety, Health and Welfare)

Regulations, 1990 dealing with the major ports of India and the

enforcement is by the Directorate General of Factory Advice

Service & Labour Institutes (DGFASLI), under Ministry of Labour &

Employment, Government of India, and

iv The Building & Other Construction Workers (Regulations of

Employment and Conditions of Service) Act, 1996, covering

construction workers at construction sites wherein the

enforcement is by the Directorate General Labour Welfare in the



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central sphere and by the Labour Commissioners/Factory

Inspectorates in the States/UTs.

7.2.2 OTHER RELATED LEGISLATIONS ON SAFETY, HEALTH AND ENVIRONMENT

Apart from the four main legislations mentioned above, there are

legislations relating to certain substances, machinery, environment

which also addresses certain issue of Occupational Safety & Working

Conditions. These statutes are applicable to all sectors including the

unorganized sectors:

a) The Indian Boilers Act, 1923 (amended 2007)

b) The Dangerous Machines (Regulation) Act, 1983

c) The Motor Transport Workers Act, 1961 (amended 1986)

d) The Shops and Commercial Establishments Acts

e) The Explosives Act, 1884 (amended 1983)

f) The Petroleum Act, 1934

g) The Inflammable Substances Act, 1952

h) The Insecticides Act, 1968 (amended 2000)

i) The Oil Fields (Regulation and Development) Act, 1948

j) The Petroleum and Natural Gas Regulation Board Act, 2006

k) The Environment (Protection) Act, 1986 (amended 1991)

l) The Water (Preventions Control of Pollution) Act, (Amended 1988)

m) The Water (Prevention & Control of Pollution) Cess Act, 1977

(Amended 2003)

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

1987)

o) The Public Liability Insurance Act, 1991 (Amended 1992)

p) The Motor Vehicles Act, 1988 (Amended 2013)

7.2.3 MAJOR HAZARDS IN STEEL PLANT

Type of Hazard/Risk Major areas where Hazard is faced

Toxic gases (rich in Carbon monoxide) All over the plant

Explosive Gases (Rich in Hydrogen

and Methane)

All over the plant

Harmful Chemicals Coal Chemicals plant, CRM

Liquid metal/ slag (burn, explosions) Blast Furnace, SMS, Continuous casting,

Foundries

Extreme Temperature (-180 OC to 1700 OC)

Coke Ovens, Blast Furnace, SMS,

Continuous casting, Foundries, Rolling Mills



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Type of Hazard/Risk Major areas where Hazard is faced

and Cryogenic Oxygen Plant

Fire All over the plant

Electric Shock, Electrocution, Flash

over

All over the plant and project sites

Rail/ Road Traffic Movement All over the plant and project sites

Moving/ Rotating machines (Hit,

Caught, pressed etc.)

All over the plant and project sites

Working at Height All over the plant and project sites

Dust, noise, heat and Vibration All over the plant

Material Handling All over the plant and project sites

Confined Space (suffocation/ gas

poisoning)

Furnaces, Tanks, Gas Pipelines, Gas holders,

Sumps, Pits, Oil cellar, Conveyor/ cable

galleries, Silos etc.

High pressure Steam, Water &

industrial gases

All over the plant

Source: Safety Guidelines for Iron and Steel Sector published by Ministry of Steel, Govt of India, 2019.

7.2.4 MAIN PLANT

The SMAL plant is sub-divided into seven divisions viz.

EXISTING PLANTS

1. Power Plant Division

2. Ferro Alloys Division

3. Briquetting plant – 1,05,000 TPA

PROPOSED PLANTS



❖ Mineral fiber plant – 1,50,000 TPA

❖ Captive power plant with PF Boiler - 1X80MW

7.2.5 RISK ANALYSIS OF M/s. SARDA METALS & ALLOYS LIMITED

7.2.5.1 HAZARDS CONSIDERATION

MAJOR HAZARD POTENTIAL ASSESSMENT

The major disasters or emergencies usually occurring in Steel industry

take birth from one or any combination of the following: -

(a) Slow isolated fires.



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(b) Fast spreading fires.

(c) Explosions

(d) High temperature liquid metal handling

(e) Electric Short circuits

(f) Bursting of pipelines/vessels.

(g) Uncontrolled release of toxic/corrosive/flammable liquids.

(h) Uncontrolled release toxic/flammable gases/dust.

(i) Material movement or handling

Depending upon the nature, scale, speed, and impact on

environment each of these may constitute an emergency. The hazard

potential of various plant sections is identified and tabulated.

7.2.5.2 FIRE HAZARD

(a) In Furnace section due to heat and temperature.

(b) In Coal/Oil Storage section.

(c) Cables on galleries and on trays in all plant sections.

(d) From oil handling.

7.2.5.3 EXPLOSION HAZARD

(a) In Submerged Arc Furnace due to excessive Gas Stores.

(b) In the Induction (Charging of scrap & Alloy).

(c) Transformers & Turbo Generator (oil cooled).

(d) Tapping of Melt in the Ladle & Mould.

(e) Compressor and Air Tank.

7.2.5.4 BURSTING OF PIPELINES

(a) Compressed Air Pipes due to high pressure.

(b) Water pipes due to high pressure.

(c) Diesel & FO carrying pipe due to high pressure.

(d) Steam pipes due to high pressure.

7.2.5.5 RELEASE OF GASES / DUSTS

(a) Gases from Furnace, (Induction & SAF) T.G. (due to excessive

heat)

(b) Fumes & CO from the furnace at the time of melting.



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7.2.6 HAZARDOUS MATERIALS STORED IN FACTORY

TABLE – 7.3: HAZARDOUS MATERIALS STORED IN FACTORY

S.

No

.

Name of

Hazardous

Content

Physic

al

State

Max.

Qty.

Stored

Mode of

Storage

Reacts

With

Nature of

Material

Toxic

Corrosive

Explosive

Flammable

Handlin

g

/Conve

ying

Device

Place

Of

Storag

e

Vulne

r-

able

Areas

Control

Measure

s

Reqd /

Provided

01 Sulphuric

Acid

Liquid

/ Gas

300-

400 Lts

FRP Drum

Jerrican

of 40 Lts In

Store

Oxidizin

g

Material

Corrosive By

Pump/

Manuall

y

In FRP

Jerric

an

Yes Provided

02 Turbine /

Transforme

r Oil

Liquid 200 Lts In Drums

In

Storage

Oxidizin

g

Material

Flammable By

Pump

In

Shed

Yes Provided

03 Diesel Oil Liquid 15 Kl In 1x15 Kl

Tank U/G

Oxidizin

g

Material

Flammable By

Pump

U/G Yes Provided

04 Furnace

Oil

Liquid 24 Kl In Tank

2x12 Kl

Oxidizin

g

Material

Flammable By

Pump

In

Yard

A/G

Yes Provided

7.2.7 CONSEQUENCE OF MAJOR HAZARDS FROM STORAGE

I. COAL

1) Fire may possibly occur if coal comes in contact with ignition

source.

2) Spontaneous combustion

II. LIGHT DIESEL OIL, FURNACE OIL & TG/ TRANSFORMER OIL

1) Fire may possibly occur if oil comes directly contact with

ignition source.

2) Due to Fire, explosion of LDO/FO/TG oil storage tank/drum

can occur.

III. SULPHURIC ACID

i. Clear colourless oily liquid. Odorless. Will not burn. Very toxic.

Fatal if inhaled. Can form very hazardous decomposition

products. Highly Reactive. Incompatible with many common

chemicals. Reacts violently with water. Corrosive. Causes

severe skin burns and eye damage. Strong inorganic acid

mists containing sulfuric acid are carcinogenic.

ii. Spillage of these materials due to leakage or collapse of

storage vessels can give out toxic fumes and gases affecting

workers.



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7.2.8 CONSEQUENCE OF MAJOR HAZARDOUS FROM PROCESSING:

1) In the Power Plant Division Mainly Hurt/Burn may possible to the

workers from moving part of m/cs and due to handling of hot

materials.

2) In Casting Division sometimes explosion may occur in ladle at the

time of tapping of hot metal due to difference in temperature.

3) In Coal Fired Furnace CO gas is produced which may be harmful

if inhaled by workers in excess (such situation arises only if it will

not exhaust immediately into the atmosphere).

4) In Switch Yard possibility of Electric Shock to the workers and

possibility of Fire and explosion in Transformer and in circuit

breaker due to short circuiting.

5) In Turbo Generator due to high pressure of steam in boiler tubes,

boiler drum etc. may cause explosion

7.2.9 DESCRIPTION OF HAZARDOUS OPERATION/PROCESS/AREA/ MATERIALS IN

SMAL

The possible hazards are not only due to chemicals but also due to the

other plant and machineries and means to overcome them, in

tabulated form are detailed in Hazard Identification and Risk

Assessment (HIRA) for the following plants

Division Reference

1. Coal Handling Plant

Operations Table - 7.4

2. Ferro Alloys Plant Operations Table - 7.5

3. Power Plant Operations Table - 7.6

4. SMS Plant & CCM Division Table - 7.7

TABLE - 7.4: COAL HANDLING PLANT OPERATIONS

S. No

Operation

Process

Equipment

/Area

Sub Activity Hazard

Description

What is the

Consequen

ce

Hazard control

measures

1

Bunkering

of coal

Positioning of the

coal vehicles on

dump hopper

Collision of

the coal

vehicles

Injury to

personnel

Monitoring the

activity and taking

control measures as

per SOP

2 Handling Breaking of Slip and fall / Injury to Monitoring the



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S. No

Operation

Process

Equipment

/Area

Sub Activity Hazard

Description

What is the

Consequen

ce

Hazard control

measures

of coal

(stacking)

oversize coal on

dump hopper

grizzle

hit by poking

rod

personnel activity and taking

control measures as

per SOP

3

Handling

of coal

(reclaimed

)

Crushed Coal

Reclaimed from

coal shed

through Stacker

Spontaneous

ignition of

coal in shed

Injury to

personnel

Monitoring the

activity and taking

control measures as

per

On site emergency

& response plan in

case of emergency

(ERP)

4

Cleaning

of

conveyor

and

equipment

Cleaning of

conveyor support

structure and tail

& head drums

area

Entanglemen

t rotating

part of the

conveyor

(tail & head

drums)

Injury / ill

health /

fatality

Monitoring the

activity and taking

control measures as

per SOP

5

Un

crushed/

Crushed

Coal

Conveying

through

the Belt

conveyor -

1 2,3,4,5

and Belt

feeder

Breakage of

Conveyor Belt

Weakness of

Belt joint

personal

Injury

Monitoring the

activity and taking

control measures as

per SOP

6

Handling

of coal

(stacking)

Crushed Coal

stacking in coal

shed through

Stacker

Spontaneous

ignition of

stack coal in

shed

Injury of

person

Monitoring the

activity and taking

control measures as

per on site

emergency &

response plan in

case of emergency

(ERP)

7

Cleaning

of

conveyor

and

equipment

Un crushed coal

& Crushed Coal

passing through

the Vibro- feeder

& Belt conveyors,

Crusher House,

TT-1, TT-2, TT-3

Fly coal

accumulate

d

combustion

and

spontaneous

ignition

condition.

Severe burn

injury of

person

Monitoring the

activity and taking

control measures as

per

On site emergency

& response plan in

case of emergency

(ERP))

SMAL has developed a detailed Hazard identification and the

measures to be taken if a Hazard occurs. The following table gives the



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hazards identified. Detailed Standard Operating Procedures (SOPs)

have been developed and personnel are provided internal training,

mock drills for preparing to face any eventuality.

TABLE - 7.5: FERRO ALLOY PLANT OPERATIONS

S. No

HAZARD

(Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable Human

factor, behavior &

capability and

other causes for

hazard

Potential

Consequences

Engineering

controls

(built in safety

controls)

Administrative

& Work Practice

Personal

protective

equipment

1.1 Fall from

height

Corroded

gratings,

opening in

gratings /slip

and fall from

sides

due to missing

side railings

Injury / fatality

Pull chord,

emergency

push buttons,

belt

always

Supervision,

periodic plant

inspections for

unsafe

conditions by

multi-

functional

team

Helmet,

safety

shoes, ear

plugs

1.2 Dragging by

conveyors

Wearing of

loose cloths,

absence of

mind,

unawareness of

work

Injury / fatality

Pull chord,

emergency

push buttons,

belt ways.

Awareness

Training,

Helmet,

safety

shoes, ear

plugs

1.3 Slip and trip

Poor

housekeeping/

illumination

Injury / fatality Hand

railings/lighting

Regular

cleaning

practice

Helmet,

safety

shoes, ear

plugs

1.4 Crushing

injures

Lack of

communication Injury Guarding Supervision

Helmet,

safety

shoes, ear

1.5 Entanglement

Un

consequence

mind

Injury /illness

Hand

railings/lighting

Guarding

Awareness

Training,

Helmet,

safety

shoes

1.6 Engulfment

Un

consequence

mind

Injury /illness

Hand

railings/lighting

Guarding

Awareness

Training,

Helmet,

safety

shoes

2.0 Exposure to

dust

Not using PPE,

transferring dry

material

Respiratory

problem, ill

health

Bins are fully

enclosed

Supervision,

manual water

spray system

for

suppressing

dust

Nose

mask,

gloves,

helmet

3.1 Exposure to

dust

Leaks in system,

Not using the

PPE

Respiratory

problem, ill

health

Screens are

fully closed

Supervision,

Periodic

check for any

dust leaks

and

rectification

Nose

mask,

gloves,

helmet

3.2 Exposure to Unawareness of Hearing Regular Supervision to Ear plugs



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S. No

HAZARD

(Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable Human

factor, behavior &

capability and

other causes for

hazard

Potential

Consequences

Engineering

controls

(built in safety

controls)

Administrative

& Work Practice

Personal

protective

equipment

noise noise hazard,

Not using PPE,

impairment preventive

maintenance

check use of

ear

protection,

Caution

signage

display

/ muffs

4.0 Fall from

height

Not having

railing or fall

protection

Injury Guarding Awareness

Training

Helmet,

safety

shoes,

safety

belt

5.0 Hit by vehicles Break failure,

Hasty operation Injury

Reverse horns,

speed control

of vehicles,

warning horns

provision.

Supervision to

check use of

ear

protection,

Caution

signage

display

Helmet,

safety

shoes, ear

plugs

6.0 Exposure to

dust

Improper

approach, wide

gaps of ladder

causing slip and

fall, hasty

operation

Injury Guarding Awareness

Training,

Helmet,

safety

shoes

7.0

Fall of

conveyor &

dragging by

conveyors

due to

overshooting off

the rails, failure

of mechanical

stoppers

Injury

Provision of

mechanical

stoppers

Shuttle

operated

from Panel

Helmet,

safety

shoes

8.0

Hit by moving

conveyor &

dragging by

conveyor

Unawareness

and standing in

the path of

conveyor

Injury

Conveyor

remotely

operated limit

switches,

mechanical

stoppers.

Caution

display

regarding

remote

operation of

conveyor and

restriction of

unauthorized

entry

Helmet,

safety

shoes

9.0 Exposure to

dust

Not using PPE,

transferring dry

material

Injury

Blowers

arrangement,

ventilation

Awareness

Training,

Helmet,

safety

shoes

9.2 Exposure to

noise

Unawareness of

noise hazard,

Not using PPE,

Hearing

impairment

Regular

preventive

maintenance

Supervision to

check use of

ear

protection,

Caution

signage

Ear plugs

/ muffs



Report


S. No

HAZARD

(Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable Human

factor, behavior &

capability and

other causes for

hazard

Potential

Consequences

Engineering

controls

(built in safety

controls)

Administrative

& Work Practice

Personal

protective

equipment

display

9.3 Exposure to

heat Not using PPE, ill health Guarding Supervision

Helmet,

safety

shoes, ear

plugs

10.1 Crushing

injures lack of guards Injury Guarding Supervision

Helmet,

safety

shoes, ear

plugs

10.2 Entanglement unconscious

mind ill health

Hand

railings/lighting

Guarding

Awareness

Training,

Helmet,

safety

shoes

10.3 Engulfment unconscious

mind ill health

Hand

railings/lighting

Guarding

Awareness

Training,

Helmet,

safety

shoes

S.

No

HAZARD

(Source,

situation or

act with a

potential for

harm in

terms of

human

injury, ill

health or

both)

Probable

Human

factor,

behavior &

capability

and other

causes for

hazard

Potential

Consequences

Engineering

controls

(built in safety

controls)

Administrative

& Work

Practice

Personal

protective

equipment

11

Metal

recovery

Plant

Dragging by

conveyors

Injury, Wearing of

loose clothes,

absence of mind,

unawareness of work

Pull chord,

emergency

push buttons,

belt ways.

Guarding

Awareness

Training

Helmet,

safety shoes,

ear plugs

Slip and trip Poor housekeeping/

illumination, Injury

Hand

railings/lighting

Regular

cleaning

practice

Helmet,

safety shoes,

ear

plugs

Crushing

injures lack of guards, Injury Guarding

signage

boards and

supervision

Helmet,

safety shoes,

ear

plugs

Entanglement Un- consequence Hand Awareness Helmet,



Report


S.

No

HAZARD

(Source,

situation or

act with a

potential for

harm in

terms of

human

injury, ill

health or

both)

Probable

Human

factor,

behavior &

capability

and other

causes for

hazard

Potential

Consequences

Engineering

controls

(built in safety

controls)

Administrative

& Work

Practice

Personal

protective

equipment

mind, Injury/illness railings/lighting

Guarding

Training, safety shoes

Engulfment Un- consequence

mind, Injury /illness

Hand

railings/lighting

Guarding

Awareness

Training,

Helmet,

safety shoes

12.1 Charge

eruption

Water

leakages /

fines content

in charge mix

Injury/ health

impact/fatality

Supervision, trained operator

carrying out the job

Gloves,

goggles,

safety shoes,

Helmet and

heat

retained suit

12.2 Charge

shrinkage

Huge number

of materials

collapsed

into the

furnace

reaction zone

Injury/ health

impact/fatality


carrying out the job

Gloves,

goggles,

safety shoes,

Helmet and

heat

retained suit

12.3 Boiling of

slag

fines content

in charge mix

high moisture

in charge mix

Injury/ health

impact/fatality


carrying out the job, OCP(o)

no5.3,5.2

Gloves,

goggles,

safety shoes,

Helmet and

heat

retained suit

12.4 Hit by

vehicles

Break

failure, Hasty

operation

Injury

Supervision to check use of ear

protection, Caution signage

display

Helmet,

safety shoes,

ear plugs

13.1 Smoke

emissions

Id fan tripping

or failure health impact

Id fan

exhausting to

stack through

gas Cleaning

Plant, auto

opening of

damper in case

of id trips.

Supervision,

remote

control of

furnace

operation,

periodic

check for the

functioning of

id fan and

audio, visual

alarms in

case of id fan

tripping,

Nose masks,

Hand gloves,

goggles,

safety shoes,

heat

retained suit.

13.2

Exposure to

heat

radiation

High

temperatures

during

smelting,

failure of

health impact

cooling of

furnace parts

by water

circulation

system, heat

Supervision,

remote

control of

furnace

operation,

Nose masks,

Hand gloves,

goggles,

safety shoes,

heat



Report


S.

No

HAZARD

(Source,

situation or

act with a

potential for

harm in

terms of

human

injury, ill

health or

both)

Probable

Human

factor,

behavior &

capability

and other

causes for

hazard

Potential

Consequences

Engineering

controls

(built in safety

controls)

Administrative

& Work

Practice

Personal

protective

equipment

water-cooling

system

resistance

material

cladding,

failure of water-

cooling system

trips furnace

operation

temperature

sensing and

alarm

provision

retained suit.

13.3

Failure of

electrical

bus bars

causing

short circuit

and fire

Over heating Injury due to fire

Air blowing

system to cool

the bus bars

Supervision,

alarms at

panel in case

of high

temperature

or failure of

blowers

Nose masks,

Hand gloves,

goggles,

safety shoes,

heat

retained suit.

13.4

Charge

shrinkage &

eruption

and Boiling

of slag

Water

leakage, fines

content

in charge mix

high moisture

in charge mix

Injury/ health

impact/fatality

Dry and low

fines material

used

(permeability

material used)

Supervision,

trained

operator

carrying out

the job,

Nose masks,

Hand gloves,

goggles,

safety shoes,

heat

retained suit.

14.1

Power pack

operation to

adjust

electrodes

Exposure to

high

pressure oil

Possible failure

of tubing /

piping and

connections

Injury

Awarene

ss

Training,

Supervision,

remote

control of

furnace

operation

Gloves,

goggles,

safety shoes

Possibility of

fire

Possible failure

of tubing /

piping and

connections

causing

spraying of oil

on electrical

panel

Injury

due to

fire

Awarene

ss Training,

Supervision,

remote

control of

furnace

operation

Gloves,

goggles,

safety shoes

14.2 Slippery

area

Due to spill of

hydraulic oil Injury

Awarene

ss Training,

Supervision,

cautious

movement at

the area

and periodic

house

keeping

Gloves,

goggles,

safety shoes

15.1 Ladle

Preheating

Exposure to

Oil leakage

/ Hot

Inadvertent

act of touching,

rupture of

Illness/

burn

injury

Use of std

piping /

tubing and

Supervisio

n, periodic

check and

Gloves,

goggles,

safety



Report


surface

contact

tubing / piping connection

s

maintenance

of preheater

unit

shoes,

helmet

15.2 Possible fire

Leakage of LDO

/ presence of

electrical

equipment

nearby

burn

injury

Use of std

piping /

tubing and

connection

s

Supervisio

n, periodic

check and

maintenance

of preheater

unit

Gloves,

goggles,

safety

shoes,

helmet and

face guard,

shoe

16.1

Ladle

Cleaning

Exposure to

hot metal /

sharp

edges of

metal / fly

particles

Not using the

required PPE

Injury/

burn

injury

Awarene

ss Training,

Supervision,

cooling of

ladle before

manual

cleaning

Gloves,

goggles,

safety

shoes,

helmet

16.2 Hot

contact

Not using the

required PPE

Injury/

burn

injury

Awarene

ss Training,

Supervision,

cooling of

ladle before

manual

cleaning

Gloves,

goggles,

safety

shoes,

helmet

16.3

Hit by

hammers/c

hisels

Unawareness of

hazard,

improper

operation

Illness/

burn

injury

Use of

standard

tools

Supervision

and

restriction of

unauthorized

entry

Gloves,

goggles,

safety

shoes,

helmet and

face guard

17

Use of Liq.

Oxygen

lancing for

tap hole

opening

Possibility of

backfire

Leakage of liq.

Oxygen

burn

injury

Use of std

lancer,

Provision of

non-return

valves in

the system

Supervision,

Gloves,

goggles,

safety

shoes,

helmet and

face guard,

shoe

18

Drill bit

operation

for tapping

Possible of

air hose

failure

Improper

operation

Illness/

injury

Use of std

hose and

proper

clamping

Supervisio

n, periodic

check and

maintenance

of air dryers

Gloves,

goggles,

safety shoes

and Helmet

19.1

Tapping

Splashing

of Metal &

Slag

Improper

operation /

spacing of

ladle, leakage

of launder

burn

injury

Heat

Shields

Protection

Supervision,

Caution

display

regarding hot

metal

tapping and

barricading

of the

tapping area,

periodic

check and

maintenance

of launder

and

connected

Apron,

Gloves,

goggles,

safety shoes



Report


system

19.2

Overflow

liquid melts

Improper

heating and

boiling of liquid

melt in ladle

burn

injury

Heat

Shields

Protection

Supervision,

Caution

display

regarding hot

metal

tapping and

barricading

of the

tapping area,

periodic

check and

maintenance

of launder

and

connected

system

Apron,

Gloves,

goggles,

safety shoes

19.3 Expose to

heat/dust

and noise

Not using PPE, Illness/

injury

Switch on

dust

collector

Awareness

Training,

Nose mask,

Helmet,

goggles,

safety

shoes,

aprons and

face mask

19.4

Blasting

Some

moisture is

entrapped

into area Avoiding wet

conditions

Supervision,

periodic check,

and

maintenance of

preheater unit,

Nose mask,

Helmet,

goggles,

safety shoes,

fire heat end

suit, aprons

and face mask

19.5

Hit by tapping

tools/drag/hit by

EOT hook

Unawareness

of hazard,

improper

operation

Providing

Standard

tools,

regular

maintenance

Supervision and

restriction of

unauthorized

entry

Gloves,

goggles,

safety shoes,

helmet and

face guard

19.6

Possibility of

fingers struck in

between crane

hook or launder

groves blocks at

the time of

fixing

Improper

handling /

Improper

awareness

Signal lamp,

Blowing

whistle,

Walkie Talky

Supervision,

Awareness

Training, Apron, Gloves,

goggles,

safety shoes

19.7

Slipped during

slag pushing

from runner

Improper

handling /

Improper

awareness

Heat Shields

Protection

Supervision,

Awareness

Training,

Apron, Gloves,

goggles,

safety shoes

20.0

Mud gun

operation

for tap hole

closing

Splashing of

Metal, Slag and

exposure to hot

metal

Improper

operation /

leakage of

Hydraulic oil

Heat Shields

Protection

Supervision,

Caution display

regarding hot

metal tapping

and barricading

of the tapping

Apron, Gloves,

goggles,

safety shoes



Report


area, periodic

check and

maintenance of

launder and

connected

system

21.1

Hot metal

/slag

handling

Splashing of

Metal, Slag and

exposure to hot

metal

Improper

handling

and tilting of

ladles

Proper Ladle

Tilting

Supervision,

Caution display

regarding hot

metal tapping

and barricading

of the Cast house

area, periodic

check and

maintenance of

connected

system,

Apron, Gloves,

goggles,

safety shoes,

proper

signaling

21.2 Hit by snap of

pulling wire rope

Improper

handling

Tested

quality Wire

ropes

Supervision,

Caution display

regarding hot

metal tapping

and barricading

of the Cast house

area, periodic

check and

maintenance of

connected

system,

Apron, Gloves,

goggles,

safety shoes,

proper

signaling

21.3 Hot contact Not using the

required PPE

Awareness

Training,

Supervision,

Caution display

regarding hot

metal /slag

tapping and

barricading of

the Cast house

area.

Gloves,

goggles,

safety shoes,

helmet

21.4

Skimming of

hot metal

Splashing of

Metal & Slag

Improper

operation /

spacing of

ladle and

skimmed

area

Heat Shields

Protection

Supervision,

Caution display

regarding hot

metal/slag,

barricading of

skimmed area,

preventive check

the skimmed

racker

Apron, Gloves,

goggles,

safety shoes

21.5 Blasting

Some

moisture is

entrapped

into area

Avoiding wet

conditions

Supervision,

periodic check

and

housekeeping

Nose mask,

Helmet,

goggles,

safety shoes,

fire heat end

suit, aprons

and face mask

Flying metal/slag

sprinkle Not use PPE Providing PPE

Supervision,

display signage

Nose mask,

Gloves,



Report


boards, goggles,

safety shoes

Spillage of

Metal

Improper

handling / tilting

of ladle

Burn injury

Supervision,

Awareness

Training,

Apron, Gloves, goggles, safety

shoes

21.6 Return metal

Fall improper coating

Injury /

fatality

Supervision,

Awareness

Training,

Apron, Gloves,

goggles, safety

shoes

21.7 Dragging by

mould chain

Wearing of loose

cloths, absence of

mind, unawareness

of work

Injury /

fatality

Supervision,

Awareness

Training,

Apron, Gloves,

goggles, safety

shoes

21.8 Crushing

injures

Lack of

communication

consequence mind

Injury /

fatality

Supervision,

Awareness

Training,

Apron, Gloves

Goggles, Safety

Shoes

21.9

Leakage of

liquid

metal/ blasting

Improper

handling/operation

Heat

stress/Injury

Supervision,

Awareness

Training,

Apron, Gloves,

goggles, safety

shoes

21.10 Broken of

metal cakes

Improper

handling/operation

Heat

stress/Injury

Supervision,

display signage

boards,

Apron, Gloves,

goggles, safety

shoes

21.11

Slip of the

Metal lifting

hooks/grabs

Improper handling

and lack of

awareness

Injury

Supervision by

experience

persons,

Awareness

Training,

Apron, Gloves,

goggles, safety

shoes

21.12 Spillage of hot

metal lumps

Time to time not

handled Injury

Supervision,

Awareness

Training,

Apron, Gloves,

goggles, safety

shoes

21.13

Exposure to

hot metal /Hot

surface

contact

Inadvertent act of

touching Moisture at

surface area

Illness/ burn

injury

Supervision,

display signage

boards, Training

Nose mask,

Gloves, goggles,

safety shoes

21.14 Boiling of

metal Improper heating burn injury Supervision,

Nose mask,

Gloves, goggles,

safety shoes,

Aprons,

21.15 Splashing of

Metal & Slag

Improper operation /

spacing of ladle burn injury Supervision

Nose mask,

Gloves, goggles,

safety

shoes, Aprons

21.16 Slip and Trip Improper operation /

Electrical failure burn injury Supervision

Apron, Gloves,

goggles, safety

shoes



Report


21.17

Hit by moving

conveyor &

dragging by

conveyor

Unawareness and

standing in the path

of conveyor

Injury

Caution displays

regarding

remote

operation of

conveyor and

restriction of

unauthorized

entry

Helmet, safety

shoes

22.0 Slag

Granulation

Exposure to hot

environment

during Water

boiling and

pungent smell

Improper

operation,

Heat stress

Proper

insulation to

EOT crane

cabin

Supervision,

Apron,

Gloves,

goggles,

safety

shoes,

nose mask

23.0 Casted slag

Exposure to hot

and spillage of

slag pieces

Improper

handling by

tilting of slag

pots causing

burn injury /

Heat stress

Use of

standard slag

pots and

proper slag

pot tilting

Supervision,

and

periodic

slag pot

checking

Gloves,

goggles,

safety

shoes,

Alarms and

Helmet

24.0 Tap holes

maintenance

Exposure to Heat,

paste Smoke/gas

and dust, hit by

hammers/crowbar

Unawareness

of hazard,

improper

operation,

Injury to

personal /

illness

cooling of tap

hole runner by

water and air

blowing,

instructions

Supervision

and

controlling

of tap hole

proper

plugging

Gloves,

safety

shoes and

Helmet

25.0

Lifting of

electrode

paste

bags/cylinders

and fed in

casing

Fall from height

Injury due to

failure of hoist,

improper

hooking of

bag, personnel

standing

below bag

Use of std.

lifting tools

and tackles,

Barricading

the area,

Warning

sign ages

Supervision,

lifting

equipment

certification

by

competent

person

Helmet,

safety

shoes

25.1

Exposure to Heat,

paste Smoke/gas,

stuck in clamp in

the casing

Injury due to

failure of hoist,

improper

hooking of

bag,

Use of std.

lifting tools

and tackles,

Barricading

the area

Supervision,

lifting

equipment

certification

by

competent

person

Helmet,

safety

shoes,

Gloves,

goggle

26.0 Possible hit by

hoist

Oscillation of Hoist

due to improper

operation

Injury to

personal

Use of std.

lifting tools

and tackles,

Warning sign

ages

Supervision, Helmet

27.0

Exposure to

heat and

dust,

Electrode

Breakage

time hit the

particles

Improper handling injury

Ventilators

provided, stay

away from the

area,

Supervision,

Safety suit,

Helmet,

nose mask,

safety

shoes and

PPE



Report


28.0

Exposure to

heat / flame,

hit with

objects.

Improper

operation or

raking with

improper tools or

bamboo pipes

instead of sticks

Heat stress /

burn injury

Instructions,

Warnings

Supervision,

use of

bamboo

sticks for

raking

Apron,

Gloves,

goggles,

safety

shoes

29.0

Possible short

circuit and

systems

hanging

Not using PPE Injury due to

fire

Providing

insulating mats

and fire

protection

Supervision,

PEP talk

Electrical

mats,

Safety

shoe

30.0 Puncture of

Furnace shell

Spillage of Hot

metal/slag and

hot water.

Injury to

personal

Monitoring

temp, through

thermo

couples,

through

controlled

water cooling

supervision

and

maintain

ground

levels

Safety suit,

Helmet,

safety

shoes,

nose mask

and PPE

31.0 Electrical short

circuit

Possible failure of

breakers in

electrical panels

Injury due to

fire

Electrical fire

extinguishers

and proper

earthing

Supervision,

Electrical

mats,

Safety

shoe

32.0

Hot contact,

hit by moving

object,

exposure to

Smoke and

dust

Unawareness of

hazard, improper

operation

Injury to

personal /

illness

Monitoring,

warnings sign

ages,

Machine

guards,

fencing,

covers

provided.

Supervision,

Nose mask,

Gloves,

goggles,

safety

shoes

33.0

Exposure to

hot

environment

during hot

gases

Unawareness of

hazard, improper

operation

Injury to

personal /

illness

water nozzles

arrangement

and Air

blowing

system and

silo

arrangement

Supervision,

Nose mask,

Gloves,

goggles,

safety

shoes

Fall from

height

Poor

housekeeping/

illumination

Injury / fatality Proper

illumination

Supervision,

Awareness

Training,

Nose mask,

Gloves,

goggles,

safety

shoes

34.0 CO explosion

Unawareness of

hazard, improper

operation

Injury / fatality CO

monitoring

Supervision,

Awareness

Training,

Nose mask,

Gloves,

goggles,

safety

shoes

35.0

Ladles and

slag pots

improper

tilting and Hit

by humans or

moving object

Unawareness of

hazard, improper

operation

Injury to

personal /

illness

Ac chamber

provided EOT

crane, and

regular crane

maintenance

Supervision,

Nose mask,

goggles,

safety

shoes



Report


and exposure

to heat.

36.0

Improper

arrangement

of ladles with

hook. In PCM

area improper

arrangement

splash of liquid

melt by jerk of

lifting/failure

of crane wire

rope.

Unawareness of

hazard, improper

operation

Injury to

personal /

illness

Preventive

and periodical

maintenance

and siren

during crane

operation

Supervision,

Nose mask,

Gloves,

goggles,

safety

shoes

37.0 Cabin short

circuit

Poor

housekeeping,

Possible of fire in

electrical panels

Injury / fatality

Preventive

and periodical

maintenance

during crane

operation

Supervision,

Awareness

Training,

Nose mask,

Gloves,

goggles,

safety

shoes

38.0 Failure of

break

Possible hot metal

spillage Injury / fatality

Preventive

and periodical

maintenance

and siren

during crane

operation

Supervision,

Awareness

Training,

Nose mask,

Gloves,

goggles,

safety

shoes

39.0

Improper

operation of

Furnace and

un

consistence of

periodic

tapping and

using of

different sizes

of raw

materials and

water

leakages.

Unawareness of

hazard, improper

operation

Injury to

personal /

illness/fatality

Periodical

maintenance

of furnace

and

consistence of

furnace

operation

Supervision,

Consistence

of raw

materials.

OCP(o) no

5.4

Nose mask,

Gloves,

goggles,

safety

shoes,

aprons

40 Fall from

height

Unawareness of

hazard, improper

operation

Injury

Hand railings,

Proper flat

forms

Supervision

and

improve

awareness

Safety

belts, Nose

mask,

Helmet,

goggles,

safety

shoes,

aprons

41 Hit by

hammers Improper handling Injury

Use of std.

lifting tools

and tackles,

Warning sign

ages

Supervision

and

improve

awareness

Nose mask,

Helmet,

goggles,

safety

shoes,

aprons

and face



Report


mask

42

Cut injury by

sharp brick

edges

Improper handling Injury Unawareness

of hazard

Supervision

and

improve

awareness

Nose mask,

Helmet,

goggles,

safety

shoes, and

face mask

43 Exposure

heat/flame

Leaks in system,

Not using the PPE burn injury

Monitoring,

warnings sign

ages, fencing,

covers

provided.

Supervision

and

improve

awareness

Nose mask,

Helmet,

goggles,

safety

shoes,

aprons,

and face

mask

44 Exposure to

dust/noise

Leaks in system,

Not using the PPE Injury

Monitoring,

warnings sign

ages,

Machine

guards,

fencing,

covers

provided.

Supervision

and

improve

awareness

Nose mask,

Helmet,

goggles,

safety

shoes,

aprons

and face

mask

45 Hit by moving

object

Unawareness of

hazard, improper

operation

Injury to

personal /

illness

Monitoring,

warnings sign

ages,

Machine

guards,

fencing,

covers

provided.

Supervision

and

improve

awareness

Nose mask,

Helmet,

goggles,

safety

shoes,

aprons

and face

mask,

46 Fall from

height

Not having railing

or fall protection Injury / fatality

Monitoring,

warnings sign

ages,

Machine

guards,

fencing,

covers

provided.

Supervision

and

improve

awareness

Nose mask,

Helmet,

goggles,

safety

shoes,

aprons

and face

mask and

safety belts

47 Expose to

heat

Unawareness of

hazard, not

closing doors

Heat stress

Provide closed

doors and sin

ages board

Supervision

and

improve

awareness,

Nose mask,

Helmet,

goggles,

safety

shoes,

aprons

and face

mask

48

Exposure to

glare due to

open arc

Unawareness of

hazard, not

closing doors

Injury to

personal /

illness

Provide closed

doors and sin

ages board

Supervision

and

improve

awareness,

Face mask

and,

chrome

specs.



Report


49

Expose to

noise

Unawareness of

hazard, not

closing doors

Injury to

personal /

illness

Provide closed

doors and sin

ages board

Supervision

and

improve

awareness

Nose mask,

Helmet,

goggles,

safety

shoes, to

use ear

plugs and

face mask

50 Fall from

height

Corroded

gratings, opening

in gratings /slip

and fall from sides

due to missing

side railings

Injury / fatality

Pull chord,

emergency

push buttons,

belt

always

Supervision,

periodic

plant

inspections

for unsafe

conditions

by multi-

functional

team

Helmet,

safety

shoes, ear

plugs

51 Dragging by

conveyors

Wearing of loose

cloths, absence of

mind,

unawareness of

work

Injury / fatality

Pull chord,

emergency

push buttons,

belt ways.

Awareness

Training,

Helmet,

safety

shoes, ear

plugs

52 Slip and trip

Poor

housekeeping/

illumination

Injury / fatality Hand

railings/lighting

Regular

cleaning

practice

Helmet,

safety

shoes, ear

plugs

53 Crushing

injures

Lack of

communication Injury Guarding Supervision

Helmet,

safety

shoes, ear

plugs

54 Entanglement Un consequence

mind Injury /illness

Hand

railings/lighting

Guarding

Awareness

Training,

Helmet,

safety

shoes

55 Engulfment Un consequence

mind Injury /illness

Hand

railings/lighting

Guarding

Awareness

Training

Helmet,

safety

shoes

56 Exposure to

dust

Not using PPE,

transferring dry

material

Respiratory

problem, ill

health

Bins are fully

enclosed

Supervision,

manual

water spray

system for

suppressing

dust

Nose mask,

gloves,

helmet

57 Exposure to

dust

Leaks in system,

Not using the PPE

Respiratory

problem, ill

health

Screens are

fully closed

Supervision,

Periodic

check for

any dust

leaks and

rectification

Nose mask,

gloves,

helmet

58 Exposure to

noise

Unawareness of

noise hazard, Not

using PPE,

Hearing

impairment

Regular

preventive

maintenance

Supervision

to check

use of ear

protection,

Caution

signage

Ear plugs /

muffs



Report


display

59 Fall from

height

Not having railing

or fall protection Injury Guarding

Awareness

Training

Helmet,

safety

shoes,

safety belt

TABLE – 7.6 POWER PLANT OPERATIONS

S. No Sub

Activity

HAZARD

Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable

Human

factor,

Behavior &

capability,

and other

causes for

hazard

Potential

Conseque

nces

Engineerin

g controls

(built in

safety

controls)

Administrat

ive & Work

Practice

Personal

protective

equipmen

t

1

Startup

of fuel

oil

pump

Bursting of line

causing hot

oil spill

Line getting

weak /

undue high

pressure in

line due to

faulty

operation

injury due

to

splinters /

burn

injury due

to hot oil

spill

pressure

indication

and re-

circulation

control

valve /

manual

isolation

valve,

Safety relief

valves

Trained

persons

carrying

out the

operation,

periodic

check for

mechanica

l integrity of

lines.

Safety

helmet

Gloves,

goggles,

safety

shoes

2 Startup

of fans

Entanglement

/ hit by

running fan

blades or

rotating parts

of fan

Unawarenes

s, slip and

fall on fan

while

Inspection

nearer to

fan, missing

guards .

Injury to

personnel

Coupling

guards

Trained

persons

carrying

out the

operation,

check for

proper

guarding

on rotating

parts

Safety

helmet

Gloves,

goggles,

safety

shoes

3 Light up

with oil

Furnace

(Combustion

chamber)

explosion

Improper

draught

across

furnace

causing

flame failure

and

subsequent

start up

without

purging,

improper /

no purging

before

starting of

burner after

flame failure

burn

Injury/

fatality

Furnace

tripping in

case of

flame

failure.

Furnace

Purging to

be done

every time

on flame

failure

system

inbuilt.

Nil



Report


S. No Sub

Activity

HAZARD

Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable

Human

factor,

Behavior &

capability,

and other

causes for

hazard

Potential

Conseque

nces

Engineerin

g controls

(built in

safety

controls)

Administrat

ive & Work

Practice

Personal

protective

equipmen

t

Possible fire

oil leakage

due to lines

damage or

gaskets

failure and

catching

fire

Injury to

personnel

/Burn

Injury

Use of std.

gaskets

safety relief

valve in

case of line

high

pressure,

re-

circulation

control

valve

Periodic

inspection

of lines for

integrity,

fire

extinguishe

rs for

smaller fires

Gloves,

goggles,

safety

shoes

4

Steam

venting

/

Poppin

g of

SRV

Noise

pollution

Missing

silencer, not

using the

PPE

Hearing

impairme

nt

Silencers

periodical

maintenan

ce of

silencers.

Ear plugs

Steam

drainin

g /

venting

Splash of

condensate

Improper

operation /

condensate

outlet

having

obstruction

or improper

routing

burn

injury

Common

header/

flash tank

Training,

operating

with

authorised

persons

Gloves,

goggles,

safety

shoes

5

Coal

Mill

operati

on

Exposure to

hot air

Improper or

missing

guarding /

insulation

Illness/

burn

injury

Proper

insulation /

guarding

Training,

operating

with

authorised

persons

Gloves,

goggles,

safety

shoes

Exposure to

Reject spill /

spillage

/leakage of

coal powder

Improper

operation /

Leaks in

system

Burn

injury /

eye

irritation /

illness

Remote

operation

Periodic

checking

of and

rectificatio

n of leaks,

communic

ating with

field

operator

while

opening of

the reject

gates.

Goggles,

safety

shoes,

nose

masks.



Report


S. No Sub

Activity

HAZARD

Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable

Human

factor,

Behavior &

capability,

and other

causes for

hazard

Potential

Conseque

nces

Engineerin

g controls

(built in

safety

controls)

Administrat

ive & Work

Practice

Personal

protective

equipmen

t

Mill fire /

explosion

Fine powder

catching

fire due to

high

temperatur

e of hot air,

friction

between

metallic

component

s, static

charges

burn

Injury/

fatality

Earthing of

the system,

controlling

of mill

temperatur

e by cold

air. Tripping

of mill in

case of

high

temperatur

e.

Trained

persons

carrying

out the

operation,

periodic

check for

the

condition

of earthing

system

Safety

shoes,

Helmet

Spillage of Mill

reject

Improper

operation /

Leaks in

system

Burn

injury

Double

gate

system

Training,

operating

with

authorized

persons

Safety

shoes,

Helmet

6

Chargi

ng of

Drum

Level

gauge

glass

Steam

leakage /

condensate /

contact with

hot surface

Improper

charging of

steam,

damaged

gland

packing /

gaskets,

inattentiven

ess in

operation,

missing or

damaged

insulation

Injury /

burning

Use of std.

gaskets,

gland

packing

Trained

persons

carrying

out the job,

Periodic

check for

insulation

condition,

Caution

display

Gloves,

goggles,

safety

shoes, ear

plug

7

Soot

blowing

operati

on

Steam leaks

near glands

damaged

gland

packing

Burn

injury

Remote

operation

Co-

ordination

with field

operators

during

operation

Safety

helmet

Gloves,

goggles,

safety

shoes

8

Boiler

operati

on

Explosion /

implosion of

furnace

Furnace

pressure high

,flame failure

and

subsequent

start up

without

purging /

Failure of

tripping of ID

in case, FD

fan trips

burn

Injury/

fatality

Boiler trips

when

furnace

reaches

draft high /

Flame

failure /

protections

Provision of

interlock for

FD & ID trip.

Trained

Manpower,

Authorised

persons will

operate.

Safety

helmet

Gloves,

goggles,

safety

shoes



Report


S. No Sub

Activity

HAZARD

Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable

Human

factor,

Behavior &

capability,

and other

causes for

hazard

Potential

Conseque

nces

Engineerin

g controls

(built in

safety

controls)

Administrat

ive & Work

Practice

Personal

protective

equipmen

t

Explosion due

to Flame

failure./

backfire

Improper

draught

across

furnace, FD

/ ID fan

tripping or

failure

Injury to

personnel

Boiler Trips

When

flame

failure

occurs,

alarms for

FD / ID fans

tripping

and

pressure

indication

Trained

Manpower,

Authorised

persons will

operate.

Safety

helmet

Gloves,

goggles,

safety

shoes

steam drum

Manhole

gaskets

leakages due

to high

pressure

Faulty

Gaskets,

instrumentat

ion, SRV

failure in

popping up,

poor

mechanical

integrity of

steam drum

Injury to

personnel

Use of

standard

gaskets &

instruments

Periodic

check for

instrument

functioning

, Boiler

certificatio

n by

authorities

annually

during shut

down

Safety

helmet

Gloves,

goggles,

safety

shoes

Drum level

low

Improper

operation,

faulty

Instrumentat

ion

Injury due

to tube

failure

and

explosion

Boiler Trips

when Drum

level

reaches

low.

Trained

Manpower,

Authorized

persons will

operate.

Safety

helmet

Gloves,

goggles,

safety

shoes

Startup

vent

operati

on

Noise

pollution /

spillage of

condensate

No silencer,

not using

the PPE

Burn / Ear

problems

Silencer,

Drain

rooting to

flash tank.

Periodic

check for

silencer

Gloves,

safety

shoes,

goggles,

ear plugs

Checki

ng of

Flame

conditi

on

through

peep

hole

Hitting of

Flame

Improper

operation

Burn

Injury

Draft

controlling

in DCS

Trained

Manpower,

Authorised

persons will

operate.

Gloves,

safety

shoes,

goggles

9

Proper

isolatio

n of

balanc

e leak

of line

Major injury to

surrounding

manpower

Improper

identificatio

n /operation

Injury to

personnel

Proper

identificati

on

Trained

operators

Hand

gloves,

Safety

Helmet,

Safety

shoes



Report


S. No Sub

Activity

HAZARD

Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable

Human

factor,

Behavior &

capability,

and other

causes for

hazard

Potential

Conseque

nces

Engineerin

g controls

(built in

safety

controls)

Administrat

ive & Work

Practice

Personal

protective

equipmen

t

during

BFP

mainte

nance

10

Movem

ent of

Persons

at

Furnac

e floor

Fall due to slip

Improper

housekeepi

ng, in

attentive

movements

Injury

Authorized

persons

only

allowed

Proper

House

keeping

Safety

shoes,

Helmet

11

Bottom

Header

drains

operati

on

Fall from

height

Improper

approach /

platform

Injury Safety belt

required

Supervision,

Work at

Height

permit,

arranging

proper

work

platform /

scaffold

Safety

helmet ,

belt

Operating in

odd posture

Improper

fixing of

valves /

operation

Muscular

pain

Using of

proper F

rod

Supervision,

arranging

proper

work

platform /

scaffold

Safety

helmet

Gloves,

goggles,

safety

shoes

Expose to Hot

surface

No / missing

insulation,

hasty or

inattentive

operation

Burn

injury Insulation

Periodic

checking

of

Insulation

gloves

12

Chargi

ng of

PRDS

Steam leaks/

contact with

hot surface

Improper

operation /

damaged

gaskets /

undue line

pressure / in

attentivenes

s

Burn

injury

Insulation /

safety

valve / use

of std.

gaskets

Trained

operators

carrying

out the job

hand

gloves,

Safety

helmet,

Safety

shoes,

Goggles

13

Chargi

ng of

Steam

tracing

line

Steam leaks/

spillage of

condensate

Improper

operation /

damaged

gaskets

Burn

injury

Use of std.

gaskets

Trained

operators

hand

gloves,

Safety

helmet,

Safety

shoes,

Goggles



Report


S. No Sub

Activity

HAZARD

Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable

Human

factor,

Behavior &

capability,

and other

causes for

hazard

Potential

Conseque

nces

Engineerin

g controls

(built in

safety

controls)

Administrat

ive & Work

Practice

Personal

protective

equipmen

t

14

Manual

operati

on of

Soot

blowing

steam

valve

Hard to

operate

Improper

maintenanc

e, valve

persuaders

Muscular

pain

proper 'F '

Rod,

periodic

maintenan

ce of

valves

periodic

maintenan

ce

hand

gloves,

Safety

helmet,

Safety

shoes

15

Steam

Sample

chargin

g

Hard to

operate/

Exposing to

Hot surface

Improper

maintenanc

e, valve

persuaders,

missing / no

insulation

Burn

injury/Mu

scular

pain

proper 'F '

Rod,

periodic

maintenan

ce, and

lubrication

of valves

periodic

maintenan

ce

hand

gloves,

Safety

helmet,

Safety

shoes

16

Coal

Mill

Cleanin

g

Expose to

coal dust,

oxygen

deficiency

Improper

ventilation,

not using

PPE

Eye

irritation/

respirator

y system

problem

provision of

proper

ventilation/

oxygen

level

measurem

ent

Confined

space

entry

permit,

supervision

to check

use of PPE

Standard

nose

masks to

prevent

RSPM

17

Main

steam

line

chargin

g up to

stop

valve.

Line

hammering /

Exposure to

hot surface /

burning

Improper

operation,

missing / no

insulation,

hasty

operation

Injury /

burns

Insulation ,

steam traps

/ drains

Trained

manpower

carrying

out the job,

sop

gloves,

goggles,

safety

shoes

18

Chargi

ng of

steam

from

Turbine

Stop

valve

to ESV.

Valves hard to

operate.

Improper

maintenanc

e / lack of

lubrication

Muscular

pain

Use of

proper F

rod

Periodic

maintenan

ce and

lubrication

Ear plugs,

gloves,

goggles,

safety

shoes

19 Lube oil

system

Slippery area

due to oil spill

Improper house

keeping

Injury due

to fall

Parapet

wall

SOP good

housekeepi

ng,

periodic

check for

oil spills

Gloves,

safety

shoes,

goggles

Fire due to oil

leaks

damaged

lines /

gaskets

burn

injury

Use of std

gaskets,

Deluge

system

Supervision,

Training,

sop,

periodic

check for

Gloves,

safety

shoes,

goggles



Report


S. No Sub

Activity

HAZARD

Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable

Human

factor,

Behavior &

capability,

and other

causes for

hazard

Potential

Conseque

nces

Engineerin

g controls

(built in

safety

controls)

Administrat

ive & Work

Practice

Personal

protective

equipmen

t

lines

condition

Oil fire at

MOT

Oil leaks /

unauthorize

d hot work /

smoking or

naked fire /

defective

electrical

equipment

burn

injury

Deluge

system

/Extinguish

ers

Supervision,

Trained

manpower,

hot work

with permit,

No smoke

zone

displays

and

vigilance,

check and

rectificatio

n for

defective

electrical

equipment

Gloves,

safety

shoes,

goggles

Oil Fire at

COT

Oil leaks /

unauthorize

d hot work /

smoking or

naked fire /

defective

electrical

equipment

burn

injury

Fire

extinguishe

rs

Supervision,

Trained

manpower,

hot work

with permit,

No smoke

zone

display and

vigilance,

check and

rectificatio

n for

defective

electrical

equipment

Gloves,

safety

shoes,

goggles

20

Turning

gear

operati

on

Oil leaks Joint leaks Fire /

burn

Proper

gaskets /

Fire

Extinguisher

s

Periodic

check and

rectificatio

n

Gloves,

safety

shoes,

goggles

21

Steam

Jet

Ejector

chargin

g

Valve hard to

operate /

Expose to

heat

Improper

maintenanc

e / lack of

lubrication

Muscular

pain /

burn

injury

Periodic

maintenan

ce of valve

Insulation,

proper F

rod,

periodic

maintenan

ce

Gloves,

safety

shoes,

goggles



Report


S. No Sub

Activity

HAZARD

Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable

Human

factor,

Behavior &

capability,

and other

causes for

hazard

Potential

Conseque

nces

Engineerin

g controls

(built in

safety

controls)

Administrat

ive & Work

Practice

Personal

protective

equipmen

t

22

Warm

up vent

operati

on

Noise

pollution /

spillage of

condensate

No/Missing

silencer, not

using the

PPE

Burn / Ear

problems

Silencer,

Drain

rooting to

flash tank.

Periodic

check for

silencer

Gloves,

safety

shoes,

goggles,

ear plugs

23

Turbine

operati

on

Main steam

line rupture

Undue high

pressure of

line,

damaged

lines

Injury to

personnel

/ Burn

injury

Safety relief

valves /

30% Dump

control

valve,

Startup

vent valve

& line

condition

checking

periodically

.

Trained

Manpower,

Periodic

checking

of Safety

valves and

operation

Dump

valves

whenever

required.

Nil

Bursting of

Turbine due to

high vibrations

and excessive

speed

Improper

operation,

faulty

Instrumentat

ion

,chances of

wet steam

entering the

turbine and

causing

pitting of

blades /

malfunction

of governor

and

protection

system

failure.

Injury due

to

bursting/F

atality

turbine

high

vibrations

trip / over

speed

tripping

Trained

Manpower,

Authorised

persons will

operate.

Turbine

vibrations

monitoring

from DCS,

and alarms

provided.

Nil

24

Air

Cooled

Conde

nser

(ACC)

Bundle

cleanin

g

through

system

Hit by Trolley &

High-pressure

water

Hasty / in

attentive

movement

of personnel

/ use of

damaged

equipment

for handling

high

pressure

water

Injury

due to

impinge

ment of

high-

pressure

water /

trolley

Proper

Hose pipe

fittings, free

movement

of trolley &

Standard

pressure

gauges.

Supervision,

Authorised

trained

persons for

operating,

Gloves,

safety

shoes,

goggles,

ear plugs



Report


S. No Sub

Activity

HAZARD

Source,

situation or act

with a potential

for harm in

terms of human

injury, ill health

or both)

Probable

Human

factor,

Behavior &

capability,

and other

causes for

hazard

Potential

Conseque

nces

Engineerin

g controls

(built in

safety

controls)

Administrat

ive & Work

Practice

Personal

protective

equipmen

t

25

Boiler

feed

pump

start up

Suction/Disch

arge valve

hard to

operate,

Improper

maintenanc

e / lack of

lubrication

Muscular

pain /

burn

injury

Use of

proper F

rod

Periodic

maintenan

ce and

lubrication

Ear plugs,

gloves,

goggles,

safety

shoes

Bursting of

pump

Improper

operation

causing

high

pressure

Injury to

personnel

/Fatality

Auto re-

circulation

line,

balance

leak off &

standard

Pressure

gauges.

supervision,

Authorised

training

persons for

operating

the

equipment,

Nil

26

Conde

nsate

system

Suction/Disch

arge valve

hard to

operate,

Contact with

hot water

Improper

maintenanc

e / lack of

lubrication

Muscular

pain /

burn

injury

Insulation,

proper F

rod

supervision,

periodic

lubrication

of valves

Gloves,

safety

shoes,

goggles

27

Lube oil

centrifu

ge

operati

on

Exposure to oil

spill

Hasty/Impro

per

operation

Eye injury float to trip

supervision,

Authorised

train g

persons for

operating

the

equipment,

Gloves,

safety

shoes,

goggles

28

Deaera

tor

Vent

Operati

on

Contact with

hot surface

Improper

operation,

missing / no

insulation,

hasty

operation

burn

injury Insulation

Trained

operators,

periodic

check for

insulation

condition

and

rectificatio

n in case of

damage

Gloves,

safety

shoes,

goggles

Spillage of hot

condensate

Improper,

hasty

operation

burn

injury

Silencer,

Drain

rooting

supervision,

Authorised

training

persons for

operating

the

equipment,

Gloves,

safety

shoes,

goggles



Report


TABLE – 7.7: STEEL MELTING SHOP (SMS)

S.

NO.

OPERATION/

PROCESS

EQUIPMENT/AREAS

POSSIBLE

HAZARDS

PRECAUTIONARY

MEASURES

MEASURE TO BETAKEN IF

HAZARDS OCCURS

1 Induction CCM and

submerged Arc

and Reheating

Furnace LRF/ Ladle

Preheater

Fire hazard

caused by

flames. Burns

may occur if

directly

come in

contact.

1. Emergency Kit is kept

ready and nearer to

the Furnace.

2. Fire Fighting

Equipment, powder/

foam type

extinguishers on

vehicles and mounted

on walls are kept

readily available.

3. Hydrant system

provided at

conspicuous places.

4. Fire Fighting man is

employed.

a) Switch off the system.

b) Information is delivered

to the AGM -EHS and

DMD present in the

Factory.

c) First aid is given to the

victim and carrying to

Hospital for further

treatment.

d) In case of any

malfunction Furnace

get switched off

automatically and

can be restarted only

after removing the

faults.

2 Charging of RM,

scrap and other

material in

Induction, SA

Furnace and

moving parts of

CCM Roller table

and other M/Cs

Cut/Burnt &

hazards are

possible

1. Workers are provided

with gloves & proper

equipment to handle

& feed the scrap.

2. Workers charging the

material in the furnace

are equipped with

Fireproof dress &

proper equipment to

handle the scrap and

material.

3. Fireproof system made

available. Firefighting

equipment like

extinguisher and water

hydrant with sufficient

No. of points easily

accessible.

4. Furnace is operated

by trained and

qualified person.

5. Entry of other person is

prohibited, and proper

watch is kept by shift

in-charge.

a) If any worker is hurt/

burnt during the

process, information is

delivered to the

Director/ Manager

available in Factory.

b) Information given to

the Doctor fix up by

the Management.

c) First Aid is given to the

victim by shift in-

charge / trained

person and then refer

to the Doctor for

further treatment.

3 Tapping of Molten

metal in the Ladle/

mould/ CCM

process of

continuous casting.

Burn due to

Hot metal is

possible and

sometime

explosion

may possible.

1. Fireproof system made

available.

2. Whole process is

operated by trained

and qualified person.

3. During tapping entry

of another person/

a) Complete process is

taken up in presence

of shift in-charge and

by his

b) Even after if any

worker gets hurt then

immediately first aid is



Report


S.

NO.

OPERATION/

PROCESS

EQUIPMENT/AREAS

POSSIBLE

HAZARDS

PRECAUTIONARY

MEASURES


HAZARDS OCCURS

worker is prohibited.

4. During the process of

heating & drying entry

of another person/

worker is prohibited.

given & then referred

to Doctor / Hospital

for further treatment.

04 Shifting of Ladle/

MOULDS by crane

Serious injury

may occur

due to

movement of

MOULDS

ladle by

crane if

moulds are

not fastened

carefully.

1. Ladle / mould are

placed where tapping

is done and after

taping shifted to

cooling place.

2. Proper watch is kept by

shift In-charge during

the process.

3. Fastening & loosing of

MOULDS from the crane

is done by trained

person under the

guidance of shift in-

charge.

4. Crane Is not run till line

clear is given.

a) The crane movement

is done only after

obtaining the line

clearance.

b) If any injury may

cause then after

giving first aid to

person/ worker refer

for further treatment

to Doctor/ Hospital.

05. FO, Diesel Oil etc.

Storage & pumping

to equipment.

Fire hazard

may occur if

the oil comes

in direct

contact

source of

ignition

A Fireproof system made

available like Foam,

Extinguishers and

Hydrant system etc.

keep accessible.

B Stored in MS cylinder

tank & kept away from

any type of fire

causing things.

Proper care to be taken

in storing and keeping

the drum of oil.

Precautions should be

adopted and taken as

mentioned as per SOP

06 Welding Gas like

Oxygen, Acetylene

LPG etc.

Fire hazard

caused by

flames &

leakage on

inhalation

cause

damage of

nasals system

& lungs.

1. Emergency kit is kept

ready and nearer to

the storage of

cylinders.

2. Fire Fighting

Equipment, powder/

Foam type

extinguishers on

vehicle and mounted

on walls are kept

readily available.

3. Hydrant system

provided at

conspicuous places.

4. Fire Fighting man is

employed.

5. Precautions to ensure

that cylinders are not

allowed to clash with

each other.

6. Cylinders are handled

Emergency kit is kept

ready which consisting

of:-

1. Tools for stopping

leakage through

storage tank/

pipeline.

2. Self-contained

breathing apparatus

must be provided.

3. Detector solution to

detect percentage of

leakage (available at

site).

4. Installation of inert gas

(Nitrogen CO2)

equipment to take

care of Fire hazards in

the factory is being

installed.

5. Hydrant point has



Report


S.

NO.

OPERATION/

PROCESS

EQUIPMENT/AREAS

POSSIBLE

HAZARDS

PRECAUTIONARY

MEASURES


HAZARDS OCCURS

carefully without

dropping or rolling.

7. Sand bed cushion

available for the

purpose of unloading

cylinders and point of

transferring.

8. Periodic inspection

done to avoid

accident of any kind.

been provided at the

proximity of gas

cylinders and also be

kept outside the

factory too.

08 Lab chemical like

Ammonia,

Sulphuric acid, etc.

In case of

breakage

cause burns

and damage

to respiratory

system.

A. Proper care taken to

store / handle

chemicals.

B. Firefighting equipment

like extinguishers, sand

bucket etc. keep

available.

C First aid box keep

available at site and

first aid personnel are

employed.

Instructions are to be

displayed for the

knowledge other man to

take care of the situation

in the event of

occurrence

09 Control Rooms Electrical

shock

Possible due

to leakage.

A. Earth leakage circuit

breaker is installed.

B. Shock precaution &

treatment chart are

displayed.

C. Operator should be

provided with

insulated shoes.

D. All instruments are

properly earthed.

E. Electrification Layout &

diagram is displayed.

In the event of electric

leakage main supply

should be immediately

shut off.

Shock treatment &

medical aid shall be

immediately provided.

10 E.O.T. Crane Hoist Rope

Breakage

possible.

A. No movement of

strange people in

crane bay will be

permitted.

B. Frequent check of the

rope and other load

bearing material shall

be done.

C. Light indication

movement of crane

shall be provided.

D. Prescribed load shall

only be allowed.

E. Crane operator to

give alarm before

movement.

Weak rope shall be

immediately replaced.

11 Conveyor belts,

Storage hopper

Fire hazards

are possible

a. Fire extinguishers are

provided in the area.

In case of fire, water

hydrants and fire



Report


S.

NO.

OPERATION/

PROCESS

EQUIPMENT/AREAS

POSSIBLE

HAZARDS

PRECAUTIONARY

MEASURES


HAZARDS OCCURS

with diverter b. Water hydrants are

provided near the

area

c. No smoking zone

declared

extinguishers can be

immediately used to

extinguish fire.

Fire alarm is activated.

7.3 ON SITE & OFFSITE EMERGENCY PREPAREDNESS AND RESPONSE PLAN

SMAL has prepared a detailed Onsite & Off-Site Emergency

Plan/Disaster Control Plan as per statutory requirement and in

compliance to ISO 9001:2015, IS0140012015 and ISO 45001 :2018.

An Emergency Preparedness and Response Plan envisages developing

an emergency response plan to handle natural disasters and

accidents which occur during the functioning of the industry. It also

provides the detailed methodology in the form Standard Operating

Procedures including training to the employees for handling identified

emergencies to ensure that the loss to human life & property is minimal.

Key components of this emergency plan identify the following:

a. Pre-emergency planning including coordination with outside

stakeholders

Emergency situations

b. Response plan for natural and human caused emergencies

c. Roles. lines of authority, training and communication

d. Site security and control

e. Safe evacuation

f. First-aid and emergency medical treatment

Emergency handling equipment.

OBJECTIVE

The objective of the Emergency Response Plan is:

1. To appreciate emergency and/or situations and the effect it will

have on the employees, property etc.

2. To lay down steps to handle such emergencies



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3. To lay down arrangements for first aid/ medical help for the

affected persons.

4. To nominate trained manpower to mobilize for handling of

emergency

➢ From within the factory

➢ From outside sources

5. To appreciate and designate likely area of influence and lay down

actions for moving and evacuation of employees/ public at large, if

required.

6. To identify officials from district administration/civil authorities

responsible for execution of off-site emergency plan including relief

operations.

SMAL will integrate the existing Emergency Response plan by including

the new facilities. The current Emergency Response Plan is given in

Annexure- 7D.

7.4 TRAFFIC STUDY – IMPACT DUE TO TRANSPORTATION OF RAW MATERAILS

AND FINISHED PRODUCTS

The traffic impact assessment study was conducted by prof. M. N Sree

Hari to identify the impacts due to expansion on the traffic.

The salient aspects of the study are given below and the detailed

reports is enclosed as Annexure – 7E.

The total traffic generated in the post expansion is as follows:

PROPOSED RAW MATERIALS TRUCK LOAD AFTER EXPANSIONS

S.No. Raw Materials Trucks per day

1 Ferro Alloys 110

2 SMS 38

3 MFP 16

4 Briquetting plant 10

5 Power plant 108

Total trucks per day 282



Report


FINISHED GOODS TRAFFIC LOAD

S.No. Product No. of truck/Day

1 Ferro alloys 10

2 Ferro alloys 27

3 Steel 28

4 Mineral fibre 16

Total trucks per day 71

SOLID WASE TRAFFIC LOAD

S. No Solid waste Trucks/day

1 Si-Mn Slag 32

2 Ash 16

Total Trucks per day 48

MOVEMENT OF RAW MATERIALS TO THE PROJECT SITE

It is estimated that the raw materials will arrive to the plant based on

the requirement and also from the transportation mode like goods

transport, road transport which come from two ports. 18 hours traffic

count is also measured and considered as the raw materials will use the

part of highways.

There are 3 sources from which the raw materials will reach the plant

❖ From Kantakapally railway siding (40%).

❖ From Vizag port (30%).

❖ From Gangavaram port (30%).

The below map indicates the Google image of the site along with the

different roads which connects to the project site.



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The figure also points the places from where the raw materials were

imported i.e., Kantakapally railway siding, Vizag port and Gangavaram

port.

The raw materials from both the Gangavaram port and Vizag port will

be carried through NH-5 and SH-39 mainly to the project site. And the

Kantakapally railway station siding is very near to the project site and

the raw materials will be carried easily through the Kotturu road.

TRAFFIC AND TRANSPORTATION MEASURES

1. Proposal is there from State government for the widening of SH-

39 being State Highways.

2. Merging of vehicles will be performed only to left traffic from the

exit gates, this ensures safety.

3. To establish smooth entry & exit of vehicles, bell mouth shape

geometry is provided at the merging locations. This ensures

smooth transition for merging of vehicles.

4. All gates are manned with efficient security who can guide the

entry and exit of vehicles.

5. All precautionary measures are ensured for the safety of laborers

while working at loading and unloading yards.

6. Drivers must be well instructed to no to overtake vehicles

especially for loaded trucks.

7. Amber blinker lights will be used at the gate to caution vehicles

which are moving out. Sign boards will also to be installed to this

effect. Security personnel manning the entry and exit gate

should be well trained for guiding the trucks entering and leaving

the facility.

8. Adequate sign & guide posts for traffic as per IRC (Indian Road

Congress) or ITE (Institute of Transportation Engineers USA) to be

installed along study roads.

9. Road marking, STOP lines etc. must be clearly painted so as to

guide the drivers along study roads.

CONCLUSION

1. The existing roads can sustain without any change in the LoS and

Performance of the road as the number of trucks carrying the



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raw material is also reasonably less on daily and hourly basis

(considering loaded trucks to the plant and unloaded trucks

from the plant to the railway station as well as to port).

2. All these loaded trucks must be well covered to prevent any

spillages as well as losing the materials and causing dust

nuisances.

3. The vehicles must be in good condition for movement to prevent

frequent stoppage as well as congestion on the roads. They

should have valis emission test certificates.

4. Hence it is concluded that the proposed expansion does not

have any adverse impact on the transportation of raw materials

and finished products.

CHAPTER - 8

PROJECT BENEFITS



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CHAPTER – 8 : PROJECT BENEFITS


As per the Government of India’s push for Atmanirbhar Bharat and also

as per the National Steel Policy 2017, India’s Steel capacity is expected

to increase from current ~125 Million MT to ~330 Million MT by 2030. The

COVID-19 pandemic has strained the economies across the globe and

has severely affected MSME’s leading to high level of unemployment.

In order to bring back the economic activity to pre-pandemic levels

and reduce unemployment, Government’s across the world are relying

on investment in public infrastructure. This will give a major boost to

Steel and Ferro Alloys production in India. Currently India is one of the

largest producers and exporters of Ferro Alloys from India and it will

maintain its position going forward.


ENVIRONMENTAL

❖ The project has implemented Briquetting Plant. Dust from Ferro

alloy plant along with Mn Ore fines & Coke fines are currently

being recycled at briquetting plant to manufacture hard

briquette by mixing with binders & additives. In this process the

waste material generated in the entire plant is being recycled in

the briquetting plant and used as a feed material for Ferro Alloy

Plant. After commissioning of the SMS the fugitive dust collected

will also be recycled into the Briquetting Plant.

❖ Slag from ferro alloy plant will be used as raw material in Mineral


briquetting Plant.

❖ The dust from SMS will be sent to Briquetting Plant. Mill Scales will

be sent to Ferro Alloy Plant for recycling. The slag will be used for

road construction.

❖ Solid waste like waste cottons, empty bags, rejected gaskets,

empty bottles band Jerry canes, steel structures and rejected

spares of process equipment etc, generated may have scrap

value and shall be disposed of with price realization.





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❖ The project is implementing the Mineral fiber plant which will

convert the slag to value added product- mineral wool. The

technology for the same is being sourced from Peking University,

China.

❖ The project will implement the Flue Gas Desulphurization systems

for both the Captive power plants as per the notification from




consumption.

SOCIAL








FINANCIAL



exchange

8.2 SOCIAL WELFARE MEASURES

SMAL has implemented the following CSR activities aimed at

strengthening the bond between the project authorities and the local

population in the vicinity of project area.

S. No CSR ACTIVITIES

1. Health – Polyclinic

General physician attends for 2-hr on alternative days. Doctor

consultation and medicine provided for free to villagers

2. Health - Mega medical camps

Mega Medical Camp arranged every 6 months. Specialist doctors

of Orthopedic, Ophthalmology, Gynecology, Pediatric, Dental &

Eye Care attended this camp. About 0685 persons have benefited

due to conduct of periodical medical camps since 2016.



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S. No CSR ACTIVITIES

3. Drinking water – RO plant

SMAL set up 2 RO water treatment plants (each 1000 ltr capacity)

in Katakapalli & Kantakapalli Panchayat

4. Drinking water – Borewell

We have provided borewells at 4 villages

5. Drinking water & Yoga class at ZPH school

Started water supply to school children from RO Plant. YOGA

classes arranged every Friday in ZPH School, Kothuru attended by

around 180 students.

6. COVID Pandemic – Initiatives

Sanitization done in 11 villages with hypo and bleaching powder

on alternate days. Provided kit containing food grains, nose masks

and soaps to villagers during Lockdown.

7. SKILL Development – Computer center

Month course per batch training on computer skills to make

trainees industry ready, employable, self-dependant, which

enabled them to earn their own livelihood

8. SKILL Development – Tailoring center

A tailoring centre with a trainer and sewing machines is set up at

Katakapalli village to impart training to women of the villages.

Each batch consists of 8 members are trained for 4 months.

9. Education

Constructed 4 classrooms at ZPH School, Kothuru village. Students

were earlier attending classes under the sky without any roof

10. Clean & Green India

Improved the living standards by creating awareness about health

and cleanliness, and to inculcate the habit of hygienic living

amongst nearby villagers. Undertook many drives to educate and

sensitize villagers and students. Provided sapling to villagers and

school students. 500 avenue plantations on both sides of the R&B

road.

11. Awards & appreciations for CSR activities

Awarded Best Partner at the State level in the SMART VILLAGE

program by the Chief Minister of Andhra Pradesh.



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The implementation of CSR measures carried out by SMAL is given in Table

- 8.1 and photographs are shown in Fig-8.1.

TABLE – 8.1: IMPLEMENTATION OF CSR MEASURES

S.No Contributions Details Image

1 Construction of School

Building

* 4 Class Rooms

Constructed 4 class rooms

at ZPH School, Kothuru,

240 students got

benefited.

2 Polyclinic in

Kantakapalli

Panchyat * 240

paticents are

getting benefited

every month

Provided Poly clinic

facility to nearby villagers

with free consultancy and

medicine.

3 2 No of RO plants of

Drinking water

@ Kantakapalli

@ Katakapalli

Provided 2 RO water

treatment plants (each

1000 ltr capacity) in 2

Panchayats of

Katakapalli &

Kantakapalli. 150 families

get benefited daily.

4 Computer Training

Center at Kantakapalli

Panchayat

* 150 students

trained * 16

members got jobs in

different

organizations

Provided certificate

course in computer

learning center to

develop the skill in village

youth. As of now 150

members have been

trained and out of which

16 members have got

jobs.



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5 Started Two Tailoring

learning Centers

@ Kantakapalli

@Katakapalli

Sewing Machines

provided to develop skill

of women in stiching.

Each batch consisting of

8 members and each

batch having training for

4 month

6 Construction of 2 Bus

shelters

@ Kantakapalli

@ Kotha

Sunkarapalem

Constructed 2 Bus shelter

at Kantakapalli and

Kotha Sunkarapalem

7 Construction of

Washrooms for School

Children

Constructed washrooms

for ZPH School at Kothuru,

240 students got

benefited

8 Installation of Solar

Street Lights

Rs. 3,00,000/-

Donated 20 no solar

street lights for

Kantakapalli pantchyat

(4 villages).

9 Donated Electrical

Transformer facilitating

24x7 drinking water

supply

Installed 3-phase

transformer at

Kantakapalli Panchayat

to provide 24 hrs power

supply, so that public can

have drinking water 24x7.

By this initiation 4 villages

of Kantakapalli Panchyat

got benefited.



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10 Mega Medical Camps

Yearly 300-600

Villagers get

benefitted

Mega Medical Camp

usually arranged once in

6 months in an year with

panel of doctors like

Orthopedic,

Ophthalmology,

Gynecology, Pediatric,

and Dental. Each time on

an average 300 patient's

to be get benefited.

11 During Pandemic

donated 15 Oxygen

Cylinders & 1

Ventilator

(Rs. 15,00,000/-)

1.Donated 5 Oxygen

Cylinders at Collector

Office.

2.10 Oxygen Cylinders

donated at MIMS

Hospital

3.One Ventilator donated

at Gaytri Hospital.

4. 500 PPE Kits (Face

Shield, Nose Mask, Hand

Gloves and Hand

Sanitizers) donated to

Govt. Primary Health

Center at Jammil,

Vizianagaram

12 Initiatives During

COVID

Pandemic

(Food graings

distributed to 4700

families worth over Rs.

3,00,000/-)

Distributed groceries to

4700 families during the

time of lock down of

Covid pandemic.



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13 Initiatives During

COVID

Pandemic

Disinfection done in 11

villages during

pandemic

Disinfection with hypo

solution at

Kantakapalli, Kothuru,

Kothuru

Goppu, Kotha

Sunkarapallem,

Katakapalli & Gollapeta

villages once in a week.

Sanitized 11 villages with

bleaching powder on

alternate days.

14 Avenue Plantation

along the road side

* Planted 500 no

plants

To create awareness

among the public on their

health, greenery and

environment, provided

500 nos of avenue

plantation with safe

guards.

FIG – 8.1: PHOTGRAPHS SHOWING IMPLEMENTATION OF CSR MEASURES

Borewell Computer Polyclinic

Medical Camps



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Fruit Tree Plantation in School RO Plant In Kantakapalli

Inauguration ZP High School Block Tailoring Training Center

Supply of Oxygen Cylinders and Sanitization in Vehicles During Covid-19

Pandemic

The Details of CSR expenditure incurred year wise by SMAL is given below:

FIG – 8.2 CSR EXPENDITURE



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SMAL has consolidated the various issues raised during the public

hearing and has prepared an action plan with necessary budget for

implementation as per MOEFCC Office Memorandum F.NO 22-

65/2017-IA.III dated 30th September, 2020 and amendments.

The District Collector, Vizianagaram during the public hearing has

advised the govt. official to constitute a committee comprising of all

the relevant Govt. officials and local sarpanches and SMAL

representatives. This committee will be responsible to identify the




CHAPTER - 9

ENVIRONMENTAL COST BENEFIT ANALYSIS



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CHAPTER – 9: ENVIRONMENTAL COST BENEFIT ANALYSIS

Not applicable as it is not recommended at the Scoping stage.

CHAPTER - 10

ENVIRONMENTAL MANAGEMENT PLAN



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CHAPTER – 10: ENVIRONMENAL MANAGEMENT PLAN


The details of the Environmental Management Cell, its objectives for

effective implementation of mitigation measures recommended for

the proposed expansion project along with the Occupational Health

care of the workmen and facilities provided is detailed in this chapter.

10.2 ORGANISATION STRUCTURE OF EHS DEPARTMENT

SMAL already has a well-constituted Health, Safety & Environment,

(SHE) department under the administrative control of AGM (EHS) The

organizational Structure of EHS Department to deal with the

environmental issues and ensure compliance with the stipulations is

presented in Fig-10.1. The fire department is headed by Manager (Fire

& Security). The Safety Department is headed by Manager Safety.

Environment department is headed by Asst. Manager Environment and

looks into environmental, sustainability & horticultural issues of the plant.

Fig - 10.1

The main responsibilities of EHS would cover the following:

o Supervising the environmental performance (EP) test of pollution

control Equipment /systems



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o Monitoring the EP of the pollution control equipment/ systems on

daily basis

o Environmental data generation, compilation and monthly report

preparation

o Initiation and implementation of corrective measures as and

when required

o Dealing with the stakeholders on the desired EP of the plant

o Conducting environmental audit and check the legal

compliance

o Tree plantation and Garden maintenance

o Occupational health monitoring and implementation of

occupational health care programme

o To maintain health statistics of the employees

o Safety surveillance and safety audit

o Training of operation and maintenance personnel in EHS by

expert EHS personnel for effective implementation of policy &

guidelines.

10.3 ENVIRONMENTAL POLICY

SMAL already has framed Environmental Policy and is committed to

preserve the environment in an integral manner. The environmental

policy is presented in Fig -10.2 and this would be applicable for the

proposed expansion.

Environment department would be responsible for the compliance of

the environmental conditions in adherence to the Environmental Laws

and Regulations. Six monthly compliance report to the conditions

imposed by MoEFCC is submitted regularly to the statutory agencies. In

case of violation of any statutory conditions, the same is reported to

Dy. Managing Director and appropriate corrective as well as

preventive actions are taken.

10.3.1 TRANSPARENCY IN THE IMPLEMENTATION OF ENVIRONMENTAL POLICY

Monitoring will be conducted periodically as per relevant norms

framed by APPCB/MoEF&CC or any other concerned authority to

drive accountability and transparency and for providing learning

to implement.



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FIG – 10.2: ENVIRONMENTAL POLICY



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SMAL is implementing a monitoring mechanism by its defined

organizational structure with clear roles & responsibilities for every

operational unit and project by creating a register specifying all the

regulatory compliances and clearance conditions that have been

defined by the Ministry or other statutory authorities.

10.3.2 AUDIT & REVIEW

SMAL is regularly conducting review and audit at the operational

level for verification and feedback on the effectiveness of

organization system and environmental performance. The audit

covers:

❖ Line management system

❖ Awareness and training

❖ Procedures: standards, targets

❖ Plans: Waste, contingency, pollution control compliance

❖ Review the implementation of mitigation measures as prescribed

in the EIA Studies/audits.

❖ Reporting and communication

❖ Documentation

❖ Feedback

INTERNAL AUDIT

SMAL undertakes Internal Audit at each unit by involving trained

internal and external auditors. In addition, auditing will ensure

compliance with all the applicable legislations and also bring out any

gaps in the implementation of mitigation measures.

AUDIT TYPE FREQUENCY

❖ Internal - 6 months basis

❖ External - yearly basis

The results of monitoring and auditing are regularly reported through

the senior management team to ensure that action items are

addressed.



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10.3.3 NON-CONFORMITY, CORRECTIVE ACTION AND PREVENTIVE ACTION

As per the Environmental Policy of SMAL, non-conformities,

corrective actions and preventive actions are managed in

accordance with Non-conformance, Preventive and Corrective

Action Procedure. This procedure relates to all activities of SMAL for

identification of non-conformances, application of appropriate

corrective actions(s) to address non-conformances and

establishment of preventive actions to avoid non-conformances.

The key elements of the process include:

❖ Identification of Non-conformance and /or Non-compliances

❖ Recording of Non-conformance and/or Non-compliance

❖ Evaluation of the Non-conformance and/or Non-compliance to

determine specific corrective and preventive actions

❖ Corrective and preventive actions to be assigned to responsible

persons and

❖ Management Review of corrective actions to ensure the status

and effectiveness of the actions

10.3.4 MANAGEMENT REVIEW

A comprehensive review of the objectives and targets associated

with the individual units of SMAL are undertaken on an annual basis.

These reviews, which include involvement of senior site

management and other key personnel, assess the performance of

the plant over the previous year and develop goals and targets for

next year.

10.4 BUDGET FOR IMPLEMENTATION OF ENVIRONMENTAL MANAGEMENT PLAN




with annual recurring cost of Rs. 1719.4 Lakhs (17.19 Crores).

The budget has been formulated in the following Table – 10.1:



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TABLE 10.1: PROPOSED BUDGET ALLOCATION FOR ENVIRONMENTAL

MANAGEMENT PLAN (Rs. In Lakhs)


Per Annum


Chimney) 8880 884

2



3


2Nos) 1260 126






3002 300


Furnace – 3, 4 & 5 120 12


CPP 40 4


SMS 40 4


(1 No). $ 60 6












and NOx control will be provided in the expansion.

CHAPTER - 11

SUMMARY & CONCLUSIONS


APIIC Industrial Park, Kantakapalli (V), Kothavalsa (M), Vizianagaram (Dist.), A.P.

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241 B.S. Envi-Tech (P) Ltd., Sec bad

CHAPTER – 11 : SUMMARY AND CONCLUSIONS

11.1 PROJECT DESCRIPTION

M/s Sarda Metals & Alloys Ltd. (SMAL) is promoted by Raipur, CG based

Sarda Group. The Groups’ flagship company Sarda Energy & Minerals

Ltd. (SEML) is listed on BSE and NSE with interests in Steel, Ferro Alloys,

Power (hydro and thermal), Mining, Investments and Horticulture. SMAL

is a 100% wholly owned subsidiary of SEML.

SMAL is operating a Ferro Alloy Plant and Captive Power Plant near

Kantakapalli Village, Kothavalasa Mandal, Vizianagaram district,

Andhra Pradesh having the following units.

a) Ferro Alloys - 1,00,000 TPA

b) Captive Power Plant 1x80 MW

c) Briquetting Plant-1,05,000 TPA

SMAL proposes to undertake expansion of the facilities by adding the

following units.



❖ Mineral Plant – 1,50,000 TPA




26.11.2009 and subsequently amendment to the same on 04.06.2015.

The Configuration of the Plant as per the approved Environment

Clearance is as below:

CONFIGURATION OF THE PLANT AS PER THE APPROVED ENVIRONMENT CLEARANCE


Unit 1


(75,000 TPA)

1x 33 MVA

(75,000 TPA)

---

2 Sinter Plant 1X24 M2

(1,25,000 TPA)

------ ---

Unit -II



Charging

2,00,000 TPA -- 2,00,000 TPA

5 Sponge Iron Plant -- 2 x 500 TPD --



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(3,00,000 TPA)

6 Blast Furnace (1x350 m3) --- --- 2,50,000 TPA


Induction Furnace

(5x15T)


--- --- 2,50,000 TPA

2,50,000 TPA



10 Pellet Plant --- --- 6,00,000 TPA



amendment from MoEF&CC. MoEF&CC issued amendment dated

02.07.2018.

SMAL has implemented the following facilities and commenced the

operation in the year 2013.

S. No Facilities Configuration Amendment Capacity



Briquetting Plant does not require the Environmental Clearance and is

now categorized as Green Category as per CPCB guidelines. Hence

CFE for the Briquetting Plant of capacity 1,05,000 TPA was obtained by

SMAL.

The summary of the Production capacities (Post Expansion) is given

below.

PRODUCTION CAPACITY (Post Expansion)


Proposed

Total capacity

after expansion

1 Ferro Alloys

TPA

1,00,000 1,50,000 2,50,000

2 Steel Melting Shop (Induction

Furnace (IF), Continuous

Casting Machine (CCM), Re-

Heating Furnace, TMT & Wire

Rod Mill (WRM)

-- 3,00,000 3,00,000

3 Mineral Plant -- 1,50,000 1,50,000


5 Coal Based Captive Power

Plant

MW 1 x 80

1 x 80

2 x 80



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The major raw material required for different products are Manganese

Ore, Coal, Coke, Fe, Mn Slag, Quartz, Dolomite, Coal, Scrap, DRI, Ferro

Alloys, Aluminum, Fluxes, GCP Dust, Mn Ore Dust, Binder, Additive, Coke

Fines, SiMn Slag.

The proposed activities will be within the existing project site. The total


No.179/4,181,182,183/1to20,185,186,187,188/1&2,190,191,192/1to3,193,1

94,195,196, 197,198,199,200,201,202 & 203.



additional land is required for the expansion project.





Lr.No.53/2012-13/E.II (WS-M) dated 16.01.2013.




2 X 250 kVA diesel fired DG sets was installed as standby power supply

units. These DG sets will be operated only when there is a normal power

supply failure. HSD will be used for power generation in DG Sets.










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workers.


FERRO ALLOYS PLANT





composition of alloy. To produce FeMn/SiMn Manganese ore,

reductants like Coke & Coal and fluxes like Dolomite & Quartz are

blended in suitable proportion and fed into submerged arc furnace.

The energy required for smelting is provided from electricity passing

through three Soderberg electrodes that are submerged in the raw

material charge. The Electrical energy is converted into heat energy

and smelting will take place in the furnace with a bath at the

temperature of 1600°C-1700°C.

STEEL MELTING SHOP WITH CCM AND HOT CHARGING ROLLING MILL:



300000 TPA.






❖ Induction Furnace

❖ Continuous Casting

❖ Direct rolling



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BRIQUETTING PLANT

The objective of setting up the briquette plant is to fully recycle

Baghouse Dust from Ferro alloys plant and Steel Melting shop along

with Manganese ore fines & Coke fines to form hard briquettes with

some use of binders like cement, bentonite by the process of extrusion.

In this process first fine material is mixed manually on ground and fed

by payloader onto the hopper. From hopper material is conveyed

through belt conveyors to Pug mill. Binders are added before raw

material is taken into pug sealer to increase the strength and plasticity

of the extruded product.


and binders such as cement bentonite 20mm diameter solid briquette

is extruded. It is cured for 3-4 days in an open area after which it

becomes strong, gaining enough mechanical strength to withstand the

impact during transferring through belt conveyors to furnace.

MINERAL FIBER PLANT






Mineral fiber wool is a name for fiber materials that are formed by

spinning or drawing molten minerals such as SiMn slag.

CAPTIVE POWER PLANT











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The power generated from Captive power plant is consumed by

various units of SMAL.

The flyash and bottom Ash is disposed to local vendors.

11.4 DESCRIPTION OF ENVIRONMENT







below:







Pedda Gedda is a nalla located at a distance of 8.7 km in SE. This is









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with minimum of 11.30C in the month of December. The predominant

wind direction is from NE-ENE-E Sector accounting to 33.51 % with calm

wind for 9.44 % and wind from other directions accounting to 57.05%.

Ambient air quality monitored at eight locations showed all values well

within the limits of NAAQ standards specified for Industrial, Rural,

Residential & Other areas. The overall 98th percentile values of ambient

air quality in the study area are given below:

AIR QUALITY IN THE STUDY AREA (All the values are in g/m3)

S. No Pollutant Range of values

(98th percentile)

NAAQ Standards

for Residential areas

1 PM10 43.7 – 65.6 100

2 PM2.5 25.6 – 32.3 60

3 SO2 13.4 – 16.2 80

4 NOx 15.6 – 17.4 80 Note: CO values are observed less than 1 ppm during study period.


equivalent noise levels of 71.8 dB (A) and 67.4 dB (A) respectively

which are within the limits of National Ambient Air Quality Standards

w.r.t Noise for industrial area.






of vehicles.

Water samples collected from 8 ground water samples showed all

parameters of ground water samples well within the acceptable limits

of IS 10500:2012 except for Total Dissolved Solids, but they are well

within the permissible limits of IS 10500:2012.







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area and analysed to study the fertility.


Organic carbon content along with other parameters.



❖ Soil of Sunkarapalem and Relli, indicated medium fertility




with stunted growth.

Two types of forest were observed in the study area namely Southern

Tropical Dry Deciduous Forest and Dry Deciduous Shrub Forest.

The study area is part of Vizianagaram District in Andhra Pradesh and

the list of forest areas around the project within study area is given

below.

DETAILS OF FOREST AREAS IN STUDY AREA

S.

No

Location


Distance from

project site

(in km)

Direction

from project

site

1 F1 Advanapalem RF 1.3 E

2 F2 Muchcherla RF 6.9 ESE




species observed or reported in the study area. There are no

endangered species in study area as per IUCN Red Listed Categories.

There are no Schedule - I species in the study area as authenticated by

DFO, Visakhapatnam.

Socio economic status of the study area is found to be moderate. The

primary survey has brought out the following issues which helps in








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• Drainage system




11.5 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES




emission. Air pollution emissions from all the units of proposed expansion

are quantified to estimate the impact in the study area.

The Overall Scenario with predicted concentrations over the baseline is

shown below.

OVERALL SCENARIO WITHIN STUDY AREA (g/m3)

CUMULATIVE GROUND LEVEL CONCENTRATIONS OF FERRO ALLOY PLANT AND

CAPTIVE POWER PLANT WITH FGD

24-Hourly Concentrations Particulate

Matter (PM10)

Sulphur dioxide

(SO2)

Oxides of

Nitrogen (NOx)




Overall Scenario 73.16{100} 20.69{80} 21.89{80}

NOTE: 1. Values in parenthesis are National Ambient Air Quality (NAAQ) standard limits specified for

Industrial, Residential, Rural and other areas.

2. The above Overall Scenario is based on post implementation of expansion without FGD

The ambient air quality values are not exceeding the stipulated

standards due to the expansion when the predicted values are

superimposed on the baseline value i.e., when the contribution of

expansion is added to the background air quality.

11.5.2 AIR POLLUTION CONTROL MEASURES


phase are described below



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conveying, transporting, stacking etc), vehicular movement,










water sprinkling.

5. The reductants coal storage is stored in the Coal storage shed.

The other fugitive dust emission sources such as material transfer

points, etc., will be equipped with dust extraction systems of

adequate capacity.


system only.

DUST EXTRACTION SYSTEM


1

Raw material

handling area,

Material Transfer

points

Dust suppression system comprising of spray

nozzles, piping network, valves pumps,

instrumentation and controls, electrics,

water tank etc.


Gas Cleaning Plant






etc

3 Ladle furnace Gas

Cleaning Plant






etc



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Fugitive emissions-

Installation of

secondary de-

dusting facilities.

One bag filter proposed to install to reduce

fugitive emissions at steel melting area.

Water sprinkling will be done to suppress the

fugitive dust at raw material handling area,

pulverizing area, raw material feed area,

cooler discharge area and the product

processing area.

5 Captive Power Plant Dust extraction system comprising of pulse

jet type bag filter, Fly Ash Silo, Bottom Ash

handling system, Electro Static Precipitator,

centrifugal fan and motor, duct work


stack, dust hopper, rotary air lock valves,

etc.

ASH HANDLING SYSTEM





where the ash will be disposed off by road trucks for brick




through belt conveyor. The same will be crushed in the clinker crusher

to reduce the size high dense ash in to small particles. These small

particles transferred to Dry bottom ash silo through post cooler chain

belt conveyor. The bottom ash is disposed to local vendors

FUGITIVE EMISSION CONTROL









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transportation in order to arrest dust



planted in close vicinity.

WATER SPRINKLING









POWER PLANT



be implemented as part of the expansion plan. MOEF & CC stipulated

has revised standards for Thermal Power Plants as per the Gazette






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SOx : 100 mg/Nm3

NOx : 100 mg/Nm3









Dampers.



option.

FUGITIVE DUST PROTECTION FOR WORKERS




dust generation

area

Dust protection

technology proposed

for workers



Raw material

unloading area,

handling area

Nose mask, face


ear plugs


handling of fines, and

dropping of raw materials,

wind break, sheet cover

Stock house, day

bins

Nose mask, face


ear plugs



Work shop and

other confined work

area inside plant

Nose mask, face


ear plugs


exhaust fans, proper

illumination

Internal roads -- Concrete roads, daily

sweeping



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noise

NOISE POLLUTION CONTROL MEASURES



barricades to keep the sound level of 85 to 90 dB. This includes

selection of packaged equipment with acoustic enclosures,

intake and outlet silencers, etc.















during operation.





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generating sources.



MEASURES TO PROTECT WORKERS FROM HIGH NOISE LEVELS

The following measures are implemented to protect the workers from








The total water requirement post expansion will be 2700 m3/day.







generation is minimal from the process. The waste water from the Ferro

Alloy Division and captive power plant will be sent to an ETP.



CPCB/APPCB standards. Hence no treated waste water is discharged

outside the plant premises

RAIN WATER HARVESTING





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Rain water Storage


RWH POND 185 125 15 5.71 3,46,875

SMAL will ensure containment of 100% rainwater and reuse in the plant.


The following is the solid waste management plan.





of Silico Manganese




GCP Dust 3,000 As a raw material for Briquetting Plant

in making Briquettes.


Type of Waste

Quantity,

TPA Mode of Disposal

Slag from


Manganese

1,80,000 SiMn Slag will be provided to brick manufacturers

/ Raw material for Mineral Fiber Plant.

GCP Dust 4,500 Recycled and used as feed material for

Briquetting Plant.


Slag from Induction

Furnace Quantity (TPA) Mode of Disposal


Primary FES


Briquetting Plant.


Secondary FES


Briquetting Plant.


rolling Mill


Alloys plant

Slag from Induction

Furnace


material.



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CAPTIVE POWER PLANT




Manufacturers.




Manufacturers.



MINERAL FIBER PLANT

The SiMn slag will be used to create s used as an insulation material

called Slag wool. SMAL had collaborated with Environment Studies


convert the Silico Manganese Slag into mineral fiber.


maintain the properties of the slag at 14000C through which a stream of

air is blown in to specialized furnaces. The molten material falls into the

fiberization devices which are in form of rotors and distributed in a thin

film on the surfaces by centrifugal force and form into Fiber.

BRIQUETTING PLANT

Dust from Ferro alloy plant & Steel melting shop along with Mn Ore fines








balance, is being sold to authorized agency as per APPCB.



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HAZARDOUS WASTE GENERATION

S.

No.

Type of Hazardous

Waste

Hazardous

Waste Category

Quantity Disposal

1. Waste Oil/Spent Oil 5.1 224 ltrs/Month Stored in covered HDPE

Drums, used for

lubrication purpose &

will be given to APPCB

approved vendors.

11.5.6 GREENBELT DEVELOPMENT













11.6 ENVIRONMENTAL MONITORING PROGRAMME

SMAL has budgeted an amount of Rs. 20.0 lakhs per annum for carrying

out regularly the monitoring of environmental parameters by a reputed

third party NABL Accredited Laboratory.

PROPOSED BUDGET FOR IMPLEMENTATION OF ENVIRONMENTAL MONITORING

PROGRAM (COST IN Rs. LAKHS)




Water quality 2.0


Soil Quality 0.5

Noise Levels 0.5




10

TOTAL 20.0



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with annual recurring cost of Rs. 1719.4 Lakhs (17.19 Crores). The budget

has been formulated in the following table:

PROPOSED BUDGET ALLOCATION FOR ENVIRONMENTAL MANAGEMENT

PLAN (Rs. In Lakhs)


Per Annum


Chimney) 8880 884

2



3


2Nos) 1260 126






3002 300


Furnace – 3, 4 & 5 120 12


CPP 40 4


SMS 40 4


(1 No). $ 60 6












and NOx control will be provided in the implementation.



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ENVIRONMENTAL

❖ The project has implemented Briquetting Plant. Dust from Ferro alloy

plant along with Mn Ore fines & Coke fines are currently being

recycled at briquetting plant to manufacture hard briquette by

mixing with binders & additives. In this process the waste material

generated in the entire plant is being recycled in the briquetting

plant and used as a feed material for Ferro Alloy Plant. After

commissioning of the SMS the fugitive dust collected will also be

recycled into the Briquetting Plant.

❖ Slag from Ferro Alloy Plant will be used as raw material in Mineral


briquetting Plant.

❖ The dust from SMS will be sent to Briquetting Plant. Mill Scales will be

sent to Ferro Alloy Plant for recycling. The slag will be used for road

construction.

❖ Solid waste like waste cottons, empty bags, rejected gaskets, empty

bottles band Jerry canes, steel structures and rejected spares of

process equipment etc, generated may have scrap value and shall

be disposed of with price realization.



❖ The project is implementing the Mineral fiber plant which will convert

the slag to value added product- mineral wool. The technology for

the same is being sourced from Peking University, China.

❖ The project will implement the Flue Gas Desulphurization systems for

both the Captive power plants as per the notification from




consumption.

SOCIAL




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FINANCIAL



exchange

SMAL has implemented the CSR activities aimed at strengthening the

bond between the project authorities and the local population in the

vicinity of project area.

11.9 PUBLIC HEARING




– 7A.





Pollution Control Board. Summary of public hearing issues and response

of SMAL along with budget are given in Table – 7.1, Chapter – 7.

❖ Compensation to the land losers

❖ Compensation to the farmers whose mango garden was

disturbed during laying the power line through

Kothasunkarapalem village

❖ Impact on black dust pollution on mango and cashew

plantation from the industry

❖ Option to reduce coal consumption to meet COPS guideline for

reducing CO2 emissions



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❖ Water pollution to Marrigedda

❖ Impact of rainwater being discharged from the plant site and

joining the narasapalli Tank.

❖ Avenue plantation on internal roads

❖ Plantation of Fruit bearing and medicinal Plants

❖ Jobs to local and surrounding villages

❖ 75 to 80 % employment should be given for locals

❖ Provide the employment to the people who lost the land

❖ Priority to local and unemployed youth

❖ Preference to local people for petty contracts like earth works,

civil works etc.,

❖ Monitoring the heat near furnace

❖ PPE to all the workers

❖ Rainwater Harvesting

❖ Comply with emission standards and follow the rules and

regulation of MoEFCC / APPCB

❖ Charging for RO water

❖ Medical camps, Issue of Health Cards and supply of medicines

❖ CSR amount is not spent in the nearby villages

❖ CSR amount should be 5% of the net profit

❖ Formation of Coordination committee with Govt. officials, PCB

Officials and Local Villagers

❖ Construction of Hospital

❖ Construction of burning shed in grave yard of Kantakapalli

❖ Construction of Community Hall

❖ Construction of additional overhead tank in kantakapalli,

Sunkurapalem

❖ Construction Of Ro Plant In Sambhayyapalem, Sunkurapalem

And Supply Ro Water Free Of Cost.

❖ Development of roads, nallas and other Infrastructure needs of

the village under CSR activities

❖ Skill Development Programs

❖ Support to rural primary education for weaker sections


demands. The District Collector, Vizianagaram during the public

hearing has advised the govt. official to constitute a committee

comprising of all the relevant Govt. officials and local sarpanches and



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SMAL representatives. This committee will be responsible to identify the




11.10 CONCLUSION

The proposed expansion will have significant benefits on the

environmental, social and financial aspects.






SMAL has developed greenbelt in an area of 93.23 acres which is

33.18% of the total plot area.

SMAL has implemented air cooled condenser system in the existing

power plant to save water and the same will be planned for new

power plant

An area of 5.71 acres will be developed to harvest the entire rain

water.

The treated wastewater from the plant will be utilized within the project.

The solid waste from Ferro Alloy Plant, SMS is converted to briquettes in

the briquetting plant and reused.

SMAL is implementing the value addition project for utilization of SiMn

slag in the Mineral Fibre Plant to produce slag wool which is used for

insulation purposes.

Saving in operation cost due to sharing of existing infrastructures

No additional Land acquisition is required for the proposed expansion,

since adequate vacant land is available in the existing project site.



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A budget of Rs. 170.47 Crores towards capital cost and 17.19 Crores

towards recurring cost is planned for implementation of Environmental

Management Plan.

SMAL is carrying out various CSR activities in the areas of health, rural

infrastructure, education, skill development and tree plantation. A total

10685 persons have benefited due to conduct of periodical medical

camps since 2016.

With the implementation of pollution control equipment, greenbelt,

rainwater harvesting and CSR activities will have positive impact on the

surroundings of project site with respect to Environment and Social

Welfare after expansion.

CHAPTER - 12

DISCLOSURE OF CONSULTANTS



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CHAPTER – 12: DISCLOSURE OF CONSULTANTS

Environmental Impact Assessment (EIA) for proposed expansion of M/s

Sarda Metals & Alloys Ltd. (SMAL) at Kantakapalli Village, Kothavalasa

Mandal, Vizianagaram district, Andhra Pradesh. for obtaining

Environmental clearance has been prepared by B. S. Envi-Tech (P) Limited,

Hyderabad.

B. S. Envi-Tech (P) Limited is accredited as Category “A” Consultant by

National Accreditation Board for Education and Training (NABET), Quality

Council of India (QCI).

The EIA report has been prepared by B. S. Envi-Tech (P) Limited with the

qualified professionals having experience of more than 20 years in the field

of Environmental Engineering and Management.

B. S. Envi-Tech (P) Ltd extends the Consultancy Services in the following

fields:

➢ Environmental Impact Assessment studies for Environmental Clearance

➢ Obtaining Consent For Establishment/Operation from SPCB’s

➢ Monitoring of Environmental Parameters as per Statutory requirements.

➢ Performance Testing Of Emissions/Pollution Control Equipment

➢ Environmental Audits

(1) Third Party Environmental Audit

(2) Environmental Statement (Form – V)

➢ Preparation of Mining Plans (Registered as Qualified Person (RQP) by

Indian Bureau of Mines (IBM))

(1) Preparation of Mining Plans

(2) Monitoring of Environmental Parameters for Mines as

Per IBM and DGMS Guidelines.

➢ Providing Analytical services through NABL accredited and MoEFCC

recognized Laboratory.

Accreditation of Consultant and its validity during the collection of

baseline is enclosed as Annexure – 12A.

NABL Accreditation along with scope of accreditation and MOEFCC

recognition of Laboratory is enclosed as Annexure – 12B and Annexure –

12C.

Documents

M/s. SARDA METALS & ALLOYS LIMITED