Telangana State Pollution Control Board Profile Pvt Ltd, Kallakal (V...Title: Figure 3- Author: Figure 3- Subject: 3-5 Created Date: 5/12/2019 6:53:21 PM

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Table of Contents

Contents

1 INTRODUCTION .................................................................................................................... 8

1.1 Background............................................................................................................................... 8

1.2 Details of EIA Consultant /Accreditation .............................................................................. 8

1.3 Information about the Project Proponent ............................................................................. 9

1.4 Importance and Benefits of the Project ................................................................................. 9

1.5 Purpose of the Report ............................................................................................................ 10

1.6 Scope of the Study .................................................................................................................. 12

1.7 Structure of EIA Document .................................................................................................. 12

1.8 Post Environmental Clearance Monitoring ......................................................................... 13

2 PROJECT DESCRIPTION .................................................................................................. 14

2.1 Identification of the Project................................................................................................... 14

2.2 Products and Capacities ........................................................................................................ 16

2.3 Cost of the Project and Time of Completion ....................................................................... 17

2.4 Infrastructure Facilities in Project District ......................................................................... 17

2.5 Raw Materials ........................................................................................................................ 17

2.6 Material Balance .................................................................................................................... 19

2.7 Total Efficiency of Induction Furnace ................................................................................. 20

2.8 Source of Raw Material ......................................................................................................... 20

2.9 Water Requirement ............................................................................................................... 21

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2.10 Manufacturing Process .......................................................................................................... 23

Pickling ..................................................................................................................................... 29

3 SITE DETAILS ...................................................................................................................... 31

3.1 General .................................................................................................................................... 31

3.2 Location of the project ........................................................................................................... 31

3.3 Site Selection ........................................................................................................................... 31

3.4 Topography............................................................................................................................. 31

3.5 Coordinates of the land plot .................................................................................................. 32

3.6 Industries within 10 km Radius of Plant .............................................................................. 36

Figure 3-5 ........................................................................................................................................ 36

3.7 Geo-Hydrological Status ........................................................................................................ 36

3.8 Land Use ................................................................................................................................. 38

Figure 3-7 ........................................................................................................................................ 38

Figure 3-8 ........................................................................................................................................ 38

4 BASELINE ENVIRONMENT STATUS ............................................................................. 39

4.1 General .................................................................................................................................... 39

4.2 Methodology ........................................................................................................................... 39

4.3 Study Area .............................................................................................................................. 39

4.4 Environmental Surveys and Studies ..................................................................................... 39

4.5 Physical Environment ............................................................................................................ 40

4.6 Geomorphology ...................................................................................................................... 40

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4.7 Drainage .................................................................................................................................. 40

4.8 Irrigation ................................................................................................................................. 40

4.9 Geology .................................................................................................................................... 41

4.10 Climate & Meteorology ......................................................................................................... 41

4.11 Test Methodology for Environmental Monitoring & Testing ............................................ 43

4.12 Ambient Air Quality .............................................................................................................. 43

4.13 Ambient Noise Quality ........................................................................................................... 53

4.14 Water Environment ............................................................................................................... 55

4.15 Soil Environment .................................................................................................................... 56

4.16 Flora and Fauna ..................................................................................................................... 65

4.16.1 Forest ............................................................................................................................... 65

4.17 Socio Economic Environment ............................................................................................... 66

5 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES ....... 68

5.1 Introduction ............................................................................................................................ 68

5.2 Air Environment .................................................................................................................... 68

5.3 Impact on Topography and Climate .................................................................................... 68

5.4 Impact on Topography .......................................................................................................... 68

5.5 Impacts on Climate ................................................................................................................ 69

5.6 Air Quality Impact Prediction .............................................................................................. 69

5.7 Model Input Data ................................................................................................................... 70

5.8 Ground Level Concentration ................................................................................................ 71

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6 ANALYSIS OF ALTERNATIVES (SITE AND TECHNOLOGY) .................................. 77

6.1 General .................................................................................................................................... 77

6.2 Analysis of Alternative Site ................................................................................................... 77

6.3 Analysis of Alternate Technology ......................................................................................... 77

6.4 Induction Furnace .................................................................................................................. 77

6.5 Reheating Furnace ................................................................................................................. 79

7 ENVIRONMENTAL MONITORING PROGRAM ........................................................... 80

7.1 Monitoring Schedule during Operational Phase ................................................................. 81

8 ADDITIONAL STUDIES ...................................................................................................... 86

8.1 Public Hearing ........................................................................................................................ 86

8.2 Risk .......................................................................................................................................... 86

8.3 Risk Assessment & an Approach to Emergency Preparedness Plan ................................ 86

8.4 Identification of Hazards ....................................................................................................... 87

8.5 Major Hazards ....................................................................................................................... 87

8.6 Accidents ................................................................................................................................. 88

8.7 Risk Assessment ..................................................................................................................... 89

8.8 Risk Prevention Methods ...................................................................................................... 89

8.9 Disaster Management Plan Including Risk Assessment and Damage Control ................ 90

8.10 On-Site Emergency Plan ....................................................................................................... 90

8.11 Objectives ................................................................................................................................ 91

8.12 Basic Contents of Disaster Management Plan (DMP) ........................................................ 91

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8.13 Purpose & Scope .................................................................................................................... 92

8.14 Preventive Measures & Plans ............................................................................................... 92

8.15 Emergency Management ....................................................................................................... 93

8.16 Infrastructure at Emergency Control Centre ..................................................................... 93

8.17 Health and Safety Measures For The Workers ................................................................... 94

8.18 Safety of Personnel ................................................................................................................. 94

8.19 Emergency Action Plan for Fire ........................................................................................... 94

8.20 Emergency Action Plan For Electric Shock Casualties ...................................................... 94

8.21 First Information .................................................................................................................... 94

8.21.1.1 Declaration of Emergency ......................................................................................... 95

8.21.1.2 Objectives of Onsite Emergency Plan ...................................................................... 95

8.21.1.3 Elements of Onsite Emergency Plan......................................................................... 96

8.21.1.4 Methodology ............................................................................................................... 96

8.21.1.5 Risk Assessment Matrix ............................................................................................ 99

8.22 Heat Stress ............................................................................................................................ 106

8.23 Source .................................................................................................................................... 106

8.24 Occupational Health & Safety ............................................................................................ 108

8.25 Legal Provisions ................................................................................................................... 109

8.26 Role of Management ............................................................................................................ 109

8.27 Accident Record ................................................................................................................... 110

8.28 General Safety at Work ....................................................................................................... 112

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8.28.1.1 Safe Guards, Signals, Signs ..................................................................................... 112

8.28.1.2 Safety Guards ........................................................................................................... 113

8.28.1.3 Electric Safety ........................................................................................................... 113

8.28.1.4 Hoisting, Loading & Handling ................................................................................ 113

8.28.1.5 Safety Training & Drills .......................................................................................... 114

8.29 Occupational Health Monitoring & Record ...................................................................... 115

8.30 Disasters & its Types ............................................................................................................ 117

8.31 Hazards in Steel Industry & its Effects .............................................................................. 117

8.32 Common Hazards in Industry ............................................................................................ 118

8.33 Disaster Management .......................................................................................................... 119

8.34 Risk Assessment ................................................................................................................... 120

8.35 Disaster Management Steps ................................................................................................ 121

8.36 Incident Control and Command ......................................................................................... 123

8.37 Incident Action Plans (IAP) ................................................................................................ 123

8.38 Incident Command Structures (ICS) ................................................................................. 124

9 PROJECT BENEFITS ........................................................................................................ 127

9.1 Tangible Benefits .................................................................................................................. 127

9.2 Intangible Benefits ............................................................................................................... 127

9.3 Other Benefits ....................................................................................................................... 127

10 ENVIRONMENT COST BENEFITS ANALYSIS ........................................................... 128

11 ENVIRONMENTAL MANAGEMENT PLAN ................................................................ 129

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11.1 Environmental Management Cell ....................................................................................... 129

11.2 Environment Management Plan ......................................................................................... 130

11.3 Central Pollution Control Board {CPCB} Guide Lines for Steel Industry .................... 134

12 DISCLOSURE OF CONSULTANTS ENGAGED ........................................................... 136

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1 INTRODUCTION

1.1 Background

M/S Mahalakshmi Profiles Pvt. Ltd., established on Survey. No. 287, 288 & 289 in

Kallakal village, Manoharabad Mandal, Medak District in Telangana state, is already

manufacturing Steel Billets. Presently it has two induction furnaces (one stand by) with 12

tons capacity, with total production of 29,700 tons per Annum. It also has a Strip mill and

Tube mill of 165tonnes per day capacity each. The existing plant is having valid Consent

for Operation from TS Pollution control Board.

Now the company have proposed to expand the existing plant by installing 12TPH x 6

more (total 8 No. 12TPH) Induction Furnaces along with CCM for making 621 TPD

(2,04,930 TPA) of MS Billets and New roughing stand/Modernization activities for

making 534 TPD (1,76,220 TPA) of MS Skelp and installation of 3 new ERW Tube mills

for production of 835 TPD (2,75,550 TPA) of MS Pipes and installation of scaffolding

workshop for production of 50 TPD (16,500 TPA) of Scaffolding. It will also Install

continuous coil Galvanizing unit for manufacturing of 300 TPD (99,000 TPA) of

Galvanized Strips /Coils and installation of Hot Dip Galvanizing unit for manufacturing of

300 TPD (99000 TPA) of Hot Dip Galvanizing of MS ERW Tubes.

As per the Environmental Impact Assessment (EIA) notification S.O. 1533 issued on 14-

09-2006 by Ministry of Environment and Forests (MoEF&CC), New Delhi, the proposed

expansion project for manufacturing MS Billets and TMT Bars is categorized as Category

B project under 3(a) Secondary Metallurgical Industries and is mandated to obtain prior

Environmental Clearance from State Environmental Impact Assessment Authority

(SEIAA), under Ministry of Environment & Forests, Govt. of India. Since the state

committee is not yet formed the case is put up at center.

Accordingly EIA studies in and around 10 Km range of project site has been carried out by

NABET Accreditated Global Management & Engineering Consultants International,

Jaipur, Rajasthan as per the terms of reference stated above and the EIA report has been

compiled based on the data collected during the study and details about the project

provided by the proponents.

1.2 Details of EIA Consultant /Accreditation

The EIA consultants have accreditation with Quality Control of India (QCI)/National

Accreditation Board of Education and Training (NABET) as per office memorandum dated

26th December 2009 of MoEF&CC. Disclosure of the Consultant is given in Chapter 12.

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Table 1-1: Brief Information about Consultant

EIA Consultant Organization Global Management and Engineering

Consultants International

Saharan Tower, 308, Officers Campus Extension,

Sirsi Road, Khatipura, Jaipur-302012

Environmental coordinator Dr. Meena Bhaduri

Contact Information E-mail: [email protected]

QCI/NABET NABET Accredited EIA Consultant

Organization

Certificate No. NABET/EIA/1619/IA007

An ISO 9001:2008 Certified company

Laboratory Engaged in EIA Project Nakshatra Enviro Services 66/40, Heera Path,

Mansarovar, Jaipur Certificate Number:- 2018-

12-08

Status of Laboratory NABL Accredited Laboratory

An ISO 9001:2008 Certified Laboratory

1.3 Information about the Project Proponent

M/S Mahalakshmi Profiles Pvt. Ltd. is a Private Limited Company. The Directors of the

company are as under:

Directors: The company is promoted by: Mr. Ramniranjan Agarwaland Mr. Vinod Kumar

Agarwal.

Address: Mahalakshmi Profiles Pvt. Ltd. Private Limited has its registered office at 1-9-8,

I.D.A, Azamabad, Hyderabad, Telangana.

1.4 Importance and Benefits of the Project

Iron and Steel industry forms the backbone of the economy. Iron and steel helps to

manufacture machines that support other producing units. The level of per capita

consumption of steel is treated as one of the important indicators of socio-economic

development and living standard of the people in any country.

India is the third largest steel producer in the world. The Indian Steel industry is organized

in three categories i.e., main producers, other major producers and the secondary

producers. The main producers and other major producers have integrated steel making

facility with plant capacities over 0.5 MT and utilize iron ore and coal/gas for production of

steel. The main producers are Tata Steel, SAIL, and RINL, while the other major producers

are ESSAR, ISPAT and JVSL etc. The secondary sector is dispersed and consists of: (1)

Forward linkage with about 120 sponge iron producers that use iron ore and non-coking

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coal, providing feedstock for steel producers; (2) Approximately 650 mini blast furnaces,

electric arc furnaces, induction furnaces that uses iron ore, sponge iron and melting scrap to

produce steel; and (3) backward linkage with about 1,200 re-rollers that roll out semis into

finished steel products for consumer use. In 2015-16, production of finished Steel is 90.98

million tones. The share of secondary steel producers is 67% of total steel production in the

country. Due to its growing demand, India has been identified as one of the hottest

destination of steel exports from all over the world.

Secondary steel producers play vital role in reaching end customers in the country.

Induction steel melting and rolling mills are growing at rapid rate due it’s accessibility to

small and medium users, housing sector, infrastructure, transportation etc., This demand is

further boosted by the demand from foreign countries. The Indian Market is exporting the

steel products to more than 51 countries and earning valuable foreign exchange to the

country. In view of the above, the proposed expansion project would contribute in meeting

the increasing demand for steel in both domestic and export markets.

The project would provide direct employment and indirect business and service

opportunities in the region. Also the project contributes to economic development in the

region and revenues to Government.

The Company has its registered office at 1-9-8, I.D.A, Azamabad, Hyderabad, Telangana.

The Company is engaged in Manufacturing of Hot Rolled Strip, MS ERW Pipes & Tubes.

MPL stands on a foundation of skill and enterprise with experience of over five decades.

The founder Late Shri Mohanlal Agarwal is the first promoter of the steel industry in

Andhra Pradesh. Over the last fifty years we have combined technology with expertise to

manufacture a wide range of steel products geared to serve a variety of needs. With a

modest turnover of Rs. 13.97 Crores for the year ended March 2002, the Company has

registered a turnover of around Rs. 269.85 Crores and net profit of 5.02 Crores for the year

ended March 2018, and has targeted a turnover of Rs. 500 Crores for the year 2020. The

company has manufacturing at Kallakal village, Manoharabad Mandal, Medak Dist,

Telangana. The company now proposes expand the existing plant by modernization of

Strip mill and Induction Furnace in existing plant premises, setting up of new tube mill

division along with strip galvanizing and hot dip galvanizing facilities.

They are committed to bring around a major change in the society through its quality

products and by implementing global best practices, adopting efficient technologies,

developing R&D and promoting CER activities.

1.5 Purpose of the Report

M/S Mahalakshmi Profiles Pvt. Ltd., established on Survey. No. 287, 288 & 289 in

Kallakal village, Manoharabad Mandal, Medak District in Telangana state, is already

manufacturing Steel Billets. Presently it has two induction furnaces (one stand by) with

12 tons capacity, with total production of 29,700 tons per Annum. It also has a Strip mill

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and Tube mill of 165tonnes per day capacity each. The existing plant is having valid

Consent for Operation from TS Pollution control Board.




making 534 TPD (1,76,220 TPA) of MS Skelp and installation of 3 new ERW Tube

mills for production of 835 TPD (2,75,550 TPA) of MS Pipes and installation of

scaffolding workshop for production of 50 TPD (16,500 TPA) of Scaffolding. It will also

Install continuous coil Galvanizing unit for manufacturing of 300 TPD (99,000 TPA) of

Galvanized Strips /Coils and installation of Hot Dip Galvanizing unit for manufacturing

of 300 TPD (99000 TPA) of Hot Dip Galvanizing of MS ERW Tubes.

As per the Environmental Impact Assessment (EIA) notification S.O. 1533 issued on 14-

09-2006 by Ministry of Environment and Forests (MoEF&CC), New Delhi, the proposed

expansion project for manufacturing MS Billets etc. categorized as Category B project

under 3(a) Secondary Metallurgical Industries and is mandated to obtain prior

Environmental Clearance from State Environmental Impact Assessment Authority

(SEIAA), under Ministry of Environment & Forests, Govt. of India.

Since the State Appraisal Committee was dissolved hence, Project proponent has

submitted application in the prescribed Form-I along with Pre- Feasibility Report and

other required documents, to obtain Terms of Reference (TOR) for conducting

Environmental Impact Assessment study for the proposed expansion project to EAC,

Ministry of Environment and Forests (MoEF&CC), New Delhi.

The Proposal No IA/TG/IND/96524/2019 was considered by the “Re constitute Expert

Appraisal Committee (Industry-I) “meeting held between 27th – 29th March, 2019 .After

detailed deliberations, the Committee recommended specific ToR on 3rd May 2019, for

undertaking detailed EIA and EMP study in addition to the generic ToR enclosed at

Annexure I read with additional ToRs at Annexure-2, for the project proposal, the same

is attached in the report. The committee also desired that public consultation should be

done by the SPCB and final outcome of the same be incorporated at the time of final EIA

report. Accordingly this final EIA report has been prepared by incorporating Public

Hearing outcomes.

Accordingly EIA studies in and around 10 Km range of project site has been carried out

by NABET Accreditated Global Management & Engineering Consultants International,

Jaipur, Rajasthan as per the terms of reference stated above and the EIA report has been

compiled based on the data collected during the study and details about the project

provided by the proponents.

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1.6 Scope of the Study

M/S Mahalakshmi Profiles Pvt. Ltd. received the terms of reference issued by the

“Reconstitute Expert Appraisal Committee (Industry-I)” on 3rd May 2019.

For undertaking detailed EIA and EMP study the committee issued Specific ToR in

addition to the generic ToR enclosed as Annexure I read with additional ToRs at

Annexure-2 the same is attached in the report. The committee also desired that public

consultation should be done by the SPCB and final outcome of the same be incorporated

at the time of final EIA report. Accordingly this final EIA report has been prepared by

incorporating Public Hearing outcomes.

Accordingly the scope of the work includes detailed characterization of various

environmental components such as micro-meteorology, air, noise, water, land and socio-

economy within 10 km radius from the proposed plant. The main objectives of the study

are:-

To identify and quantify significant impacts due to various operations of the

proposed steel unit on various environmental components through prediction of

impacts.

To assess the existing baseline status of air, water, noise, land and socio-

economic environment

To evaluate and implement the Environmental Management Plan (EMP)

detailing control measures and its efficiency to minimize the pollution levels

within the permissible norms. To evaluate the beneficial and adverse impacts of

the proposed plant.

To design an occupational health & safety plan for the employees.

To design post project monitoring plan for regulating the environmental quality

within the limits and help in sustainable development of the area.

To assess the probable risks, likely to occur in unit and suggest appropriate

measures to avoid the same.

1.7 Structure of EIA Document

The objective of the EIA study is to prepare Environment impact assessment report

based on the guidelines of the Ministry of Environment and forests (MoEF) and CPCB.

In terms of the EIA notification of the MOE&F dated 14th September 2006 and

subsequent amendments on 01.12.09 and 04.04.2011, the generic structure of EIA

documents is as follows.

Executive Summary

Introduction

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Project Description

Description of the Environment

Anticipated Environmental Impact & mitigation Measures

Analysis of Alternatives (Technology & Site)

Environmental Monitoring Program

Additional studies

Project benefits

Environmental Cost Benefits Analysis

EMP

Disclosure of Consultant Engaged

1.8 Post Environmental Clearance Monitoring

Half yearly compliance reports will be provided on 1st June and 1st December of each

calendar year.

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2 PROJECT DESCRIPTION

2.1 Identification of the Project

M/S Mahalakshmi Profiles Pvt. Ltd., is already manufacturing Steel Billets. Presently it

has two induction furnaces (one stand by) with 12 tons per hour (TPH) capacity, with

total production of 90 tons per day (TPD). It also has a Strip mill and Tube mill of

165tonnes per day capacity each.




making 534 TPD (1,76,220 TPA) of MS Skelp and installation of 3 new ERW Tube

mills for production of 835 TPD (2,75,550 TPA) of MS Pipes and installation of

scaffolding workshop for production of 50 TPD (16,500 TPA) of Scaffolding. It will also

Install continuous coil Galvanizing unit for manufacturing of 300 TPD (99,000 TPA) of

Galvanized Strips /Coils and installation of Hot Dip Galvanizing unit for manufacturing

of 300 TPD (99000 TPA) of Hot Dip Galvanizing of MS ERW Tubes.

M/S Mahalakshmi Profiles Pvt. Ltd.is situated at village Kallakal village, Manoharabad

Mandal, Medak District in Telangana state , Latitude 17° 41' 54.3408"N and Longitude

78°29'4.8192"E. The project falls under the Manoharabad Mandal.

The land area of the plant is 19 Acres and 17 Guntas (78,610.256 sq m) out of which

13.675 acres is being used for the Industrial processes and 5.75(33.0% )Acres has been

allocated for green belt.

The total project cost is Rs 150.00 Crores (after addition of proposed

machinery).Proposed Employment Generation from proposed project will be around 600

persons out of which 500 persons will be having direct employment and 100 persons

will have indirect employment.

The electricity load of 15500 KVA will be procured from Telangana Electricity supply

board. Fresh water consumption for the proposed project will be 75 KLD and recycle

water 115 KLD; proposed project is based on zero discharge, 15 KLD of waste water

will be generated and treated in septic tank.

The unit obtained CFO for Furnace on 16-08-2017 (valid up to 31-01- 2022) from State

Pollution Control Board to manufacture 90 T/Day of MS Ingots ,60TPD MS Pipes and

70TPD hot Rolling strips . The unit obtained the respective Consent Orders accordingly

and started its operations

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Salient features of the project are given in Table2-1.

Table 2.1-1: Salient Features of the Site

Name of Project Mahalakshmi Profiles Pvt. Ltd.

Proponent( Director) Mr. Ramniranjan Agarwaland Mr. Vinod Kumar

Agarwal.

Nature of the Project Secondary Metallurgical Process based industry

Latitude and Longitude S.

NO.

LATITUDE LONGITUDE S.

NO.

LATITUDE LONGITUDE

1 17°42'3.22"N 78°29'1.19"E 14 17°41'56.60"N 78°28'47.00"E

2 17°41'57.66"N 78°29'0.91"E 15 17°41'56.50"N 78°28'47.00"E

3 17°41'57.60"N 78°28'55.80"E 16 17°41'55.90"N 78°28'42.00"E

4 17°41'52.50"N 78°28'55.60"E 17 17°41'56.20"N 78°28'41.90"E

5 17°41'52.50"N 78°28'55.40"E 18 17°41'56.80"N 78°28'46.70"E

6 17°41'54.20"N 78°28'50.00"E 19 17°41'57.60"N 78°28'46.70"E

7 17°41'54.20"N 78°28'49.60"E 20 17°41'57.50"N 78°28'48.20"

8 17°41'54.10"N 78°28'49.10"E 21 17°42'0.80"N 78°28'48.50"E

9 17°41'55.30"N 78°28'48.80"E 22 17°42'0.70"N 78°28'50.60"E

10 17°41'55.40"N 78°28'49.40"E 23 17°42'2.00"N 78°28'50.90"E

11 17°41'56.60"N 78°28'49.40"E 24 17°42'2.30"N 78°28'56.20"E

12 17°41'56.70"N 78°28'49.60"E 25 17°42'2.20"N 78°28'56.20"E

13 17°41'56.90"N 78°28'49.70"E 26 17°42'2.79"N 78°29'0.25"E

Site Location Survey. No. 287, 288 & 289 in Kallakal village,

Manoharabad Mandal, Medak District in Telangana state

Total land area 78,610.255 sq. m

Total area of green belt developed 2,594.22 sq. m (33.0%)

Nearest High way The plant site approached by small road which connect

NH-7 and Industry

Nearest Rly Stn Dabilpur Rail Way Station is 2.8 Km from the site

Nearest Air Port Rajiv Gandhi International Airport, Shamshabad,

Hyderabad is 70 km from the site

Nearest fire station Narsapur 21 km (North –West)

Nearest village Kallakal Village North 1km

Nearest surface water bodies Pond near Gomaram 9.0 km (West-North West)

Water body near Meenjipeta 5.5 km(North East)

Water body near Tunki Makta 8.0 km (NE)

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Medchal Lake 8.63 km (South)

Nearest Reserve Forest Ellampet Reserve Forest 2.0 km South –South West

Any ecologically sensitive areas None

Fresh Water Requirement Industrial: 16 KLD; Domestic: 3.6 KLD (Existing)

Industrial: 57KLD; Domestic: 16 KLD (Proposed)

Source of Water Telangana: Gram Panchayat and tanker supply

Man Power 500 Members to be employed directly and around 100

people may be employed indirectly

Power Demand 15500 KVA and is supplied by Telangana Electricity

supply board

DG Set Existing one DG set of 380 kVA

Project Cost The cost of the project is Rs 150 crores (15000 lakhs)

along with all the accessories

2.2 Products and Capacities

The existing project was small scale and did not required prior Environmental Clearances

but complied fully to all the legislations required in case of Air, Water (Acts), hazardous

waste handling rules and regulations. The land area of the plant is 19 Acres and 17 Guntas

(78,610.256 sq m) out of which 13.675 acres is being used for the Industrial processes and

5.75(33.0% )Acres has been allocated for green belt.

Six Induction furnaces having capacity 12 TPH has been proposed. The existing capacity

of the unit is 90 TPD of Billets .The capacity of the unit after expansion is given in Table

2-2 .

Table 2-2: Existing and Proposed Capacities

S. No. Product Capacity

Existing Expansion After Expansion

1 MS Billets though Induction Furnace

90 TPD 621 TPD 711TPD

2 MS Skelp through Strip mill

165 TPD 534 TPD 699 TPD

3 Pipes through Tube Mill 165 TPD 835 TPD 1000 TPD

4 Scaffolding -- 50 TPD 50 TPD

5 Galvanized Strips/Coils -- 300 TPD 300 TPD

6 Hot Dip galvanizing of -- 300 TPD 300 TPD

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MS ERW Tubes

2.3 Cost of the Project and Time of Completion

The total project cost is Rs 150.0 Crores (after addition of proposed machinery). The time

schedule required for the expansion will be within 5-6 months after getting necessary

statutory approval.

2.4 Infrastructure Facilities in Project District

Site is well connected to the Kallakal village road. Medchal is the Nearest Town to

Kallakal village. Medchal is 8 km from Veerlapally. Road connectivity is there from

Medchal to Kallakal. Dabilpur Rail Way Station is 2.8 Km from the site. However

Hyderabad Deccan Railway Station is major railway station 80 km.

2.5 Raw Materials

The steel manufacturing industry requires variety of raw material which is presently being

supplied locally /foreign market/both. The existing unit is using the MS Scrap; Sponge Iron

and Alloying metals for the MS Ingots and Billets. It is proposed to increase the production

capacity of MS Ingots/Billets from 27,000 TPA to 213,300 TPA, thus the raw material

requirement will also increase which is mentioned below in Table 2-3.

Table 2-3: Raw Materials Requirement for Existing Unit

S.N

o

Raw

Material

Source Transportation Quantity

TPD TPA

For Existing (90 TPD)

1 Sponge Iron Local/adjacent States By Road 63.54 19,062

2 Iron Scrape Local/Imported By Road 9.9 2,970

3 Pig Iron Local/adjacent States By Road 18.63 5,589

4 Ferro Alloys Local/adjacent States By Road 0.81 243

Strip mill

1 Billets In plant generation and

purchased from Market

Conveyors and

By Road

(Covered trucks)

165TPD

2 High grade

coal thermal

Imported/Purchased from

Traders

By Road

(Covered trucks) 9 TPD

Tube Mill

1 MS Skelp In plant generation By Road


Material Balance for Existing

Billets 90 27,000

Slag 2 600

Cutting& Scaling 1.5 450

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Table 2-4: Raw Materials Requirement for Existing Unit

S.No. Raw Material Consumption Source of Raw

Materials

Method of Transport

Induction Furnaces with concast

1 Sponge Iron 551 TPD From Sponge iron

plants By Road (covered trucks)

2 Scrap 164 TPD Local By Road (covered trucks)

3 Ferro Alloys 6 TPD Local By Road (covered trucks)

Strip mill

1 Billets 587 TPD In plant generation Conveyors

2 High grade coal

thermal 32 TPD

Imported/Purchased

from Traders By Road (Covered trucks)

Tube Mill

1 MS Skelp 699 TPD In plant generation By Road (Covered trucks)

2 HR Coil 354 TPD

Purchased from

SAIL/TATA/JSW/

Other Manufacturers

By Road (Covered trucks)

Scaffolding

1 MS Tubes 47 TPD In plant generation By Road (Covered trucks)

2 Accessories/

Components 3 TPD

Purchased from local

Manufacturers By Road (Covered trucks)

Continuous Coil Galvanizing


2 HR Coils 150 TPD Purchased from

SAIL/TATA/JSW By Road (Covered trucks)

3 Zinc Hindustan Zinc/ Other

reputed Manufacturers By Road (Covered trucks)

Hot Dip Galvanizing

1 MS ERW Tubes 300 TPD In plant generation By Road (Covered trucks)

19



2.6 Material Balance

Figure 2.6-1: Material Balances for (Existing) M.S. Billets to the tune of 27,000TPA

20

Figure 2.6-2: Material Balances for (Proposed) M.S. Ingots and Billets to the tune of

213,300 TPA

2.7 Total Efficiency of Induction Furnace

Efficiency of induction furnace is estimated after deducting electrical and heat transfer

losses. Electrical losses consist in transformer, frequency converter, condenser, wiring,

cable, coil, etc. Loss in coil is essential factor, on which the furnace capacity depends. Heat

losses in induction furnace consist of conduction loss of heat escaping from furnace wall to

coil side, radiation loss of heat released from melt surface, absorption loss in ring hood,

slag melting loss, etc.

Heat efficiency of high-frequency furnace (60- 78%) is slightly larger than that of low-

frequency furnace (58 - 71%). Low-frequency furnace is larger in heat loss, while high-

frequency furnace is larger in electrical loss. This is explicable from the fact that low-

frequency furnace has lower power density at melting and larger heat loss due to long

melting time, while high-frequency furnace has higher power density, heat loss is small due

to short melting time and primary electrical loss is large due to frequency conversion.

Table 2-5:Total Power Consumption in Induction Furnace per Hour

Heat Item

PERCENTAGE MWH

Heat

Input

Transformer Primary I/P Power

100

5.4

Heat Content of

Heat

Output

Metal 39.6 2.6136

Slag 8.5 0.561

Heat Content of

Walls

Waste Gases

Water Cooling

Electrical Losses

Miscellaneous Heat Losses

9.72

10.5

9.2

10.9

11.58

0.64152

0.693

0.6072

0.7194

0.76428

Total

100.00 6.6

Note: Energy balance is done considering 600 kWh/t – steel

Source: Specific Energy Consumption of Induction Crucible Furnace/ Intensive Programme “Renewable Energy Sources”,

May 2011, UWB, CZ

2.8 Source of Raw Material

The raw material required for the unit is M.S. Scrap; Sponge Iron & alloying materials

(Silico-Mn, Ferro-Silicon etc.) will be purchased from domestic market. The raw material

is sufficiently available in the domestic as well as in international market. The raw material

supply to the site will be carried out by trucks.

21

2.9 Water Requirement

The existing daily fresh water demand of the unit is 15 KLD out of which 11.4 KLD is

required for industrial purpose and 3.6 KLD for domestic purpose. The waste water

generated from the industrial process like blow down and quenching water is being treated

in settling tank baffle type and the treated water is being recycled in the process (23 KLD)

and reused for plantation (4KLD). Similarly, the domestic waste water is being routed to

septic tank followed by soak pit. Thus, the unit is maintaining zero discharge. After

expansion additional water will be required as new units will be installed. After expansion

the daily fresh water demand will be 75 KLD out of which the 60 KLD will be required for

industrial purpose and 15 KLD for the domestic purpose. The total recycle water will be 45

KLD and 10 KLD will be reused for plantation. The water is being met from Rural water

supply Scheme and same will be maintained after expansion. The detailed existing water

balance along with after expansion water balance is given below in figure 2-3 and 2-4:

The details of total water consumption, it's breakup is shown in Table below.

Table 2-6: Water Requirement

SOURCE Existing

in KLD

Expansion

in KLD

After expansion

in KLD

Cooling water make up for SMS 3 20 23

Cooling water make up for Strip mill 4 13 17

Cooling water make up for Pipe mill 4 13 17


Hot Dip Galvanizing

Domestic consumption 3.6 12.5 16.1

Total 14.6 say 15 59.5 say 60 74.1say 75

22

Figure 2.9-1: Existing Water Balance

Figure 2.9-2: Water Balance after Expansion

23

2.10 Manufacturing Process

INDUCTION FURANCE [STEEL MELTING SHOP]

In Steel Melt Shop (SMS) Sponge Iron will be melted along with melting scrap and fluxes

to make pure liquid steel and then to mould it in required size billets. The shop consists of

following equipment and subassemblies:

Induction Furnaces: Induction Furnace is a device to melt the charge material using

electrical power. It consists of Crucible lined with water cooled induction coils, Electrical

system to give controlled power to induction coil, Hydraulic tilting system, Heat exchanger

to cool the circulating water, water softener for generating soft water, furnace transformer,

Power Factor improvement system and surge suppressor.

Ladles: Ladles are pots with refractory lining inside to withstand 1600 deg C temperature.

It has side arms so that it can be lifted with the help of crane. Ladles are used to stores the

liquid steel from Induction Furnace and take it for further processing. Ladles are with

bottom nozzle and pneumatically operated gate for discharge of liquid.

Cranes: Electric Over-head (EOT) cranes of various capacities are used to carry the

ladles/materials at different places. Cranes are used in Melting hall to charge melting scrap,

remove the ladles to the LRF, further to place it over the Tundish of the Continuous Caster,

to remove billets from the cooling bed and store at designated places, and also for other

petty use. Accordingly the sizes, capacity and number of cranes are decided.

Continuous Casting Machine (CCM): CCM is used to continuously cast the liquid steel

in required cross section and in length. It consists of Tundish, Mould, Bow with

Withdrawal mechanism, straightening mechanism and cooling bed, hydraulic system for

withdrawal mechanism, water sumps and cooling towers for water spray on the withdrawn

section as well as on the cooling bed. Dummy bar is provided to start the casting. Tundish

is a rectangular vessel, lined with refractory and having discharge nozzle with

pneumatically operated gate. A stand is erected over it where the ladle is stationed for

discharging the liquid in it. Mould is of copper with water cooled jacked. Its cross-section

in the bottom is of the size of which billet is to be drawn. Initially the dummy for of the

same size is kept inserted. When the liquid steel is poured in the mould the dummy bar is

drawn slowly, so that the liquid steel in partially frozen state comes out of the mould.

Water spray nozzles are installed to spray water over the just drawn billet to cool it further

and to harden the skin of the drawn billet.

B) STRIP MILL

The primary function of the Hot Strip Mill is to reheat semi-finished steel slabs of steel

nearly to their melting point, then roll them thinner and longer through 8 successive rolling

mill stands driven by motors totalling 10,000 HP and finally coiling up the lengthened steel

strip for transport to the next process. The Hot Mill rolls billet pieces weighing up to 600

24

kg between 100*100 and 160*160mm. Steel billet of up to 160mm thickness is rolled into

strip as thin as 1.2mm up to 400 feet in length.

Raw Material Handling:

The raw material for making strip is MS square billets/MS Slabs. The billets are then cut

using liquid oxygen and LPG into smaller lengths as per the desired dimension of strip to

be produced. The cut-to-length billets are placed on a charging grate. With the help of a

hydraulic arrangement the billets are fed onto the conveyor and in turn conveyed to the

pusher top.

Reheating Furnace:

Critical to the Hot Strip Mill is its pusher-type reheat furnace nominally rated to produce

30 tons-per-hour. Heating this much steel from room temperature to 1150-1200°C

consumes around 32 MT of coal each day. The cut length billets are placed on a roll line.

When space is available in the furnace, large hydraulic ‘pusher arms’ are engaged to move

the billets into the furnace. Much of the preheating of the steel is achieved by the hot

exhaust gases rushing past the billets on the way to the ‘recuperates’ above the charge door.

Whatever heat is left in the exhaust gases preheats the incoming combustion air to over

450°C in these massive heat-exchangers. Conversely, in the heating zone the steel is

primarily heated by the glowing-hot furnace walls. In the soak zone, numerous smaller

burners seek to maintain a uniform temperature within the zones to equilibrate any cold

spots in the billets. Refractory dividers help to physically distinguish the zones, and

thermocouple temperature sensors throughout the furnace. When the billet reaches the

‘discharge door’ at the exit end of the furnace, the billet has been sufficiently heated, the

door opens and the ejector billet pushes the hot piece out of the furnace. The intensely hot

billet is placed on a roller table which carries it into the roughing mill.

Direct feeding of HOT Billets /slabs from CCM

Descaling:

After exiting the reheat furnace, the Billets/slabs passes through a descaling unit, an

enclosure employing two pairs of spray headers that blast the intensely hot billet with

pressurized water to remove the scale of oxidized iron that forms at the surface of the slab

in the oxygen-rich atmosphere of the reheat furnace. Shortly after descaling, a (relatively)

small 2-hi rolling mill called a scale breaker breaks up any scale that remains.

Roughing:

The roughing mill is made up of 5 rolling mill stands, two of which incorporate small

vertical rolling mills called edgers. Billets are heated in the furnace until they glow bright

orange-yellow are rolled through one stand at a time to produce so-called transfer bars

suitable for finish rolling. High-pressure water-jet nozzles clean the oxidized iron, or scale,

from the surface along the way. The two vertical stands, each incorporate edgers for width

25

control and roll the bar from five to six inches thick incrementally down to around an inch

and a quarter, depending on the customer’s ordered width, gauge, and steel grade.

Edging:

At the very high temperatures at which the steel is rolled in the roughing mill, it is very

plastic and ‘flows’ easily like cookie dough beneath a rolling pin. Consequently, as the

Billets/slab is reduced from five to six inches thick to the final bar thickness of few

millimetres; bars tend to spread width-wise by a few inches at their extremities, and by as

much as an inch through the body. The edgers serve to hold a uniform width through the

bar’s length, and are powerful enough to squeeze the bar as much as an inch narrower than

the slab’s original dimension.

Finishing:

The Hot Strip Mill includes three finishing stands, which reduce the thickness of the

transfer bar down to the gauge required by the customer or the next process. The rolling

speed is set to allow the last stand to perform the final reduction at the finishing

temperature, between 850° to 1000°C, specified to reach certain mechanical properties. By

now, the steel has been rolled into a flat strip as long as 200 feet. In contrast to the

roughing mills, the finishing mills roll the transfer bar in tandem, meaning each bar will be

rolled through all three stands at once. The hot steel is quite fragile as it is rolled and

tension between the finishing mill stands must be closely controlled at very low levels in

order to avoid stretching or tearing the strip.

Coiling

The strip is passed through a pinch roll and the head end is mounted on a horizontal coiler.

The coil build up takes place until the desired weight of the coil is achieved. The coil is

conveyed on conveyors to the point of storage or use for the next process.

C) TUBE MILL

The coil as per desired width and thickness is received from the stock yard and loaded onto

decoiler. The end of the strips are sheared and butt-welded and fed into a storage cage. The

strip is passed through the forming section of the pipe mill and then into the Fin-pass

section. In this process, it gradually takes the shape of a round tube. Using the process of

High Frequency Induction Welding, the edges of the strip are heated and welded. The extra

metal on the weld seam is removed using a scarfing tool. The tube which becomes hot in

the process is cooled in the cooling chamber. The sizing section adjusts any deviation in the

shape and size of the tube as per desired levels. The tube is then cut to suitable lengths

using a circular flying saw driven by rack & pinion system. The cut-length tubes are then

conveyed to a rack where they are bundled and stored in the stock yard for dispatch.

26

D) CONTINOUS COIL GALVANIZING

Coils to be processed on either galvanizing line are charged, or loaded, onto one of two

Pay-Off Reels. The head of the coil being charged is welded to the tail of the coil being

processed by a lap seam welder. Between 1/32” and 1/4” of the two coils are over-lapped

onto one another, and a pair of high-voltage copper wheels, one above and one below, roll

from one edge to the other, melting the laps and pressing them into one another. The

resulting weld is nearly flattened to the gauge of each coil, but with a slight bulge in the

center of the seam. The voltage applied between the two dies and the speed at which they

roll across the width of the strip are pre-programmed in a computer as various recipes that

are called up according to the gauges and grades being processed.

After welding, the strip travels into the ‘Entry Loop Car’, or accumulator section, where

enough material is stored to allow the entry section to shut down for at least a minute and a

half while another coil is charged without slowing the process (annealing and zinc pot)

section. The Loop Cars for the #1 CGL travel horizontally, while the newer line employs

multi-strand, vertical accumulators.

Cleaning & Preheating

Before heat treating, the strip is cleaned of rolling oils and iron fines with rotating brushes

and diluted sodium hydroxide (caustic soap). The steel is preheated in the process section

to a relatively low temperature to further clean the strip surface and minimize the time

needed for the reducing zones to bring the steel up to its annealing temperature.

Burners in the Preheat section combust natural gas in open air to maintain zone

temperatures as high as 2250° Fahrenheit. Under normal operating conditions, the steel is

in this section for only a few seconds and never actually reaches this furnace temperature.

Producing ‘full hard’ galvanized steel requires striking a delicate balance between cleaning

the surface adequately for good zinc adherence and not sacrificing the strength desired by

the customer by allowing the steel grains to recrystallize. Costly low-carbon steel grades

with small additions of titanium are sometimes used because they anneal at relatively high

temperatures and can be thoroughly cleaned prior to coating.

Heat Treatment

Because most of feed-stock for the galvanizing lines is Full Hard from the 5-Stand, both

units incorporate processing steps to remove rolling oils, iron fines and surface oxides from

the strip to ensure good zinc adherence, and to anneal the material to achieve the

combination of formability and strength sought by the customer.

Immediately after the preheat section, the strip enters the ‘reducing zone’ where it is

annealed to achieve the customer’s physical requirements for formability in a heated

atmosphere of 1 part hydrogen, 3 parts nitrogen. The atmosphere prevents the growth of

scale during heat-treatment, actually ‘reducing’ light surface oxide back to iron. Heat is

supplied by burning natural gas inside sealed tubes above and below the strip, with the heat

produced radiating from the walls of the tubes out into the reducing zones. These zones are

27

held at temperatures up to 1650° Fahrenheit, and, under normal operating conditions, the

product is annealed for less than a minute. Thin strip at the #2 CGL may spend only 10

seconds in the reducing zones, while heavier gauges at the #1 CGL may take a couple of

minutes to reach the necessary temperature. The steel is heated to temperatures typically in

the range of 1300° to 1500° Fahrenheit.

Because the furnace is cannot achieve abrupt changes in temperature, specific limits are

placed on the scheduling of coils to ensure smooth transitions between products with

different annealing requirements. Since the annealing process depends on both time and

temperature, operators can ease the transitions by adjusting the speed of the line.

Immediately after annealing, the strip travels through cooling zones incorporating air jets

and recirculating fans before being directed down the ‘snout’ to the zinc pot. The objective

is to cool the steel to a temperature that roughly matches that of the molten zinc; too warm

and the coating’s adherence will be compromised by an overly thick zinc-iron transition

layer; too cool and the aluminum can begin to precipitate (freeze) out of the molten zinc

and get picked up by the pot roll, marking the steel.

Galvanizing

The facilities for coating steel are of the ‘hot-dip’ type, as opposed to electro-galvanizing,

which is a plating process comparable to chroming. After the steel has been thoroughly

cleaned, annealed, and cooled to a temperature that roughly matches that of the molten zinc

bath, the strip enters the zinc pot and travels around a ‘pot roll’ which redirects it up

through an ‘air knife’ system. Coating thickness is controlled by blowing off excess molten

zinc; the air pressure applied to a tapered gap in the knife lips, as well as the distance

between the knives and the strip, regulate how much zinc is carried out of the pot on the

steel’s surface. The height of the air knives above the zinc pot is adjusted according to strip

speed. Additional blow-offs called edge baffles serve to prevent the excess zinc coating

inherent to the edges from resulting in a condition called ‘edge build-up’ that causes the

coil to flare up at the sides, stretching the material to the point that it will not lay flat during

further processing.

The thickness of the zinc applied to the steel is specified by CSI’s customers as a coating

weight, in the unit of hundredths of ounces per square foot. An order for ‘G-60’ seeks 0.60

ounces of zinc on every square foot of steel, which, when evenly distributed, equates to a

coating thickness of about one-half of one thousandth of an inch (0.0005”) per surface.

Since the heavier coating weights add as much as 0.004” (for G-235) to the overall

thickness of the coated steel, aim gauges at the rolling mills provide for this so the finished

product will meet the customer’s gauge requirements. The thickness of the zinc coating is

measured with a Gamma-ray and fed back into the computer which in turn adjusts the air

knives to optimize the coating weight. Changes in required coating weight, steel thickness,

and even line speed are rapidly compensated for automatically.

28

The ‘pot’ is replenished periodically with 1-ton ingots of 99.9% pure zinc. Massive

induction heaters in the basement maintain the pot at temperatures about 50 above the 800-

degree Fahrenheit melt point of the zinc. Small additions of aluminum improve the

adherence of the zinc to the base metal by inhibiting the growth of the brittle zinc-iron

transition layer.

The strip travels more than ten stories straight up into the air out of the pot to allow time

for the zinc to solidify against the steel. Large fans in the cooling tower air-cool the freshly

coated steel before it is sent through a water-quench ‘shock roll’ tank.

Galvannealing

Products designated by an ‘A’ in their coating weight (for instance A-40) are

‘Galvannealed’, a process wherein the just-coated steel’s surfaces are immediately reheated

by open-air burners. The zinc is baked into the steel until the two are alloyed, or

metallurgically blended, with one another at the surfaces of the strip. The finished product

has a dull gray appearance due to the large proportion of iron that has diffused to the

surface.

Galvannealed product corrodes more readily than galvanized steel and is intended for end-

uses that will be painted, such as computer brackets and appliance panels. While hot-dip

galvanize must be chemically treated before painting, galvanneal does not. The alloyed

layer is relatively brittle and will tend to fracture and flake off (‘powdering’) if flexed

significantly by a paint line or roll-former.

Reheating is accomplished for this operation with a short, vertical, natural-gas furnace that

is positioned above each line’s zinc pot. Because of the limitations of these furnaces, line

speeds are slowed considerably when producing galvannealed steel and available coating

weights are normally limited to A-60 or lighter to ensure that ‘free zinc’ does not remain at

the steel’s surface.

Flatness Correction

Situated after each pay-off reel is a small uncoilerLeveler that flattens the head-end of the

steel by removing its coil-set, or memory of having been coiled up.

After the steel has been through the cooling tower and is roughly room temperature again,

it passes through a Tension Leveler much like that at the Pickle Line where the strip is

tightly worked up and down by a series of roll cassettes. Shape defects are removed from

the strip as its thickness is reduced by around one-half of one percent.

The #2 Galvanizing line includes a 4-hi skin-pass mill stand situated just in front of the

tension leveler to reduce strain marks and impart a uniform surface texture on the coated

product, subject to the customer’s specifications.

29

Final Processing

When required by the customer, a thin coat of rust inhibitor is applied to the strip as it

travels through the chem treat section after the tension leveller. A solution is squeegeed

onto both surfaces and then air-dried, inhibiting the formation of ‘white rust’ (water-stained

zinc) for six months or longer.

Just before final inspection, the product passes into the stamping area where, when

indicated on the schedule, the strip is printed periodically with the product’s specifications.

The older line uses four 16” diameter ink drums, while the #2 CGL incorporates an ink-jet

printer for improved print quality and greater flexibility.

When indicated by the customer, the strip is oiled after inspection. A spreader roll at the #1

CGL squeegees oil evenly across the top surface of the steel shortly before it is recoiled,

while the newer line uses an electrostatic oiler. Oil is less expensive than Chem Treat, but it

is not as durable and is more difficult for the customer to clean from the strip. Typically,

galvanize products that will be painted are oiled, while end-uses calling for exposed zinc

receive Chem Treat.

Inspection

Before recoiling, the strip is inspected to ensure it is dimensionally sound, and that any

surface or shape defects are acceptable, based on customer- and end-use-specific criteria.

Each line has a small laboratory used to monitor the process on an ongoing basis. Rockwell

Hardness tests are performed on each parent coil to evaluate the annealing heat treatment

and feedback is normally given to the operator in time to adjust for the next coil.

Additional tests are performed to evaluate the coating quality; weighing a sample,

chemically removing the zinc, then reweighing the coupon confirms the coating weight;

creasing a sample with a tight bend tests the adherence of the zinc to the base metal.

Periodic checks are performed to monitor the cleaner’s detergent levels, the molten zinc

bath’s aluminum and lead content, and the chem treat solution’s make-up. Tensile test

coupons to qualify Physical Quality steel are sent to the main lab for evaluation.

The finished strip is recoiled and cut to the weight required by the customer.

E) HOT DIP GALVANIZING

Hot dip galvanizing is the process of coating pipe and fitting with a layer of zinc alloy in a

bath of molten zinc at temperature around 450 °C.

As ISO 1461, ASTM A123, and EN10240, the galvanizing process has its own built-in

means of quality control because zinc does not react with an unclean steel surface. So

Surface Preparation is a critical step.

Degreasing

A hot alkali solution, mild acidic bath removes organic contaminants such as dirt, paint

markings, grease, and oil from the metal surface.

Pickling

30

A dilute solution by heated sulfuric acid or ambient hydrochloric acid, removes mill scale

and iron oxides (rust) from the steel surface.

Figure 2.10-1 : Galvanized Sheets

Fluxing

A zinc ammonium chloride solution, removes any remaining oxides and deposits a

protective layer prior to dip steel in bath.

According to ISO 1461, zinc coating thickness follows below form:

Steel

thickness

mm

Local coating

thickness

(minimum)

μm

Average coating

thickness

(minimum)

μm

Average coating

mass

(minimum)

g/m²

steel ＞6 70 85 610

3＜ steel ≤6 55 70 505

1.5≤ steel ≤3 45 55 395

steel ＜1.5 35 45 325

31

3 SITE DETAILS

3.1 General

The anthropogenic activities specifically related to industrial sector are expected to cause

impacts on environmental quality in and around the project location. However, the intensity

of environmental impacts from a specific project depends on several factors such as type of

process physical, chemical, fuel combustion etc. involved in the project, processing

capacity (scale/size of the project), type and extent of pollution control measures, project

location surrounding geomorphology etc. To assess environmental impacts from proposed

expansion project at a specific location, it is essential to monitor the environmental quality

prevailing in the surrounding area prior to implementation of the proposed expansion. The

environmental status within the study zone is used for identification of significant

environmental issues to be addressed in the impact assessment study. The impacts from an

existing industrial project on its surrounding environment are mainly regulated by the

nature of pollutants, their quantities discharged to the environment, existing environmental

quality, assimilative capacity of the surrounding environment and topography and terrain of

the project site (its location) as well as the surrounding area.

3.2 Location of the project

M/S Mahalakshmi Profiles Pvt. Ltd.is situated on Latitude 17° 8' 53.48"N and Longitude

78°13'38.28"E. Location map is given in Fig 3-1. The existing land area of the unit is

29338.28 Sq. m.

The expansion will take place in the existing unit by installing six more additional

induction furnace of capacity 12 T capacity. The proposed installation will take place in the

existing shed area. Thus, the land use of the site will not change after expansion.

Project site is near to Kallakal village. It is located 49 KM towards East from District

headquarters Sangareddi. 14 KM from Tupran. Jeedipalle ( 5 KM ) , Kothur ( 6 KM ) ,

Muppireddipally ( 6 KM ) , Rangaipalle ( 6 KM ) , Sikindlapur ( 7 KM ) are the nearby

Villages to Kallakal. Kallakal is surrounded by Tupran Mandal towards North, Shivampet

Mandal towards North , Wargal Mandal towards East , Mulug Mandal towards East .

Hyderabad , Sangareddy , Medak , Singapur are the near by Cities to Kallakal.

Hyderabad is the Nearest Town to Kallakal. Hyderabad is 38 km from Kallakal. Road

connectivity is there from Hyderabad to Kallakal. Kuchavaram Rail Way Station , Dabilpur

Rail Way Station are the very nearby railway stations to Kallakal.

3.3 Site Selection

The Proposed project is expansion project so no alternative sites are considered.

3.4 Topography

The topography of the area is plain. Study area has been taken as 10 km radius around the

project site. Map showing study area of the project on 1:50,000 scale of Topo Sheet No 56

32

K /5, 6,9, 10 of the survey of India map is given in Fig 3-2. No National Parks/ Wildlife

Sanctuaries/ Biosphere Reserves exist within 10 km radius of project site.

3.5 Coordinates of the land plot

The 26 corners of Mahalakshmi Profiles Pvt. Ltd. are shown in Fig 3-3 on Google

Imagery. Figure 3-4 shows the layout of the plant site.

Figure 3.5-1: Location Map

33

Figure 3.5-2: Topography Map of the Project Site

Figure 3.5-3: Google Imagery with Latitude and Longitude of the Corners

34

Table 3.5-1: Coordinates of Mahalakshmi Profiles Pvt. Ltd.

S. NO. LATITUDE LONGITUDE

1. 17°42'3.22"N 78°29'1.19"E

2. 17°41'57.66"N 78°29'0.91"E

3. 17°41'57.60"N 78°28'55.80"E

4. 17°41'52.50"N 78°28'55.60"E

5. 17°41'52.50"N 78°28'55.40"E

6. 17°41'54.20"N 78°28'50.00"E

7. 17°41'54.20"N 78°28'49.60"E

8. 17°41'54.10"N 78°28'49.10"E

9. 17°41'55.30"N 78°28'48.80"E

10. 17°41'55.40"N 78°28'49.40"E

11. 17°41'56.60"N 78°28'49.40"E

12. 17°41'56.70"N 78°28'49.60"E

13. 17°41'56.90"N 78°28'49.70"E

14. 17°41'56.60"N 78°28'47.00"E

15. 17°41'56.50"N 78°28'47.00"E

16. 17°41'55.90"N 78°28'42.00"E

17. 17°41'56.20"N 78°28'41.90"E

18. 17°41'56.80"N 78°28'46.70"E

19. 17°41'57.60"N 78°28'46.70"E

20. 17°41'57.50"N 78°28'48.20"

21. 17°42'0.80"N 78°28'48.50"E

22. 17°42'0.70"N 78°28'50.60"E

23. 17°42'2.00"N 78°28'50.90"E

24. 17°42'2.30"N 78°28'56.20"E

25. 17°42'2.20"N 78°28'56.20"E

26. 17°42'2.79"N 78°29'0.25"E

35

Figure 3.5-4: Plant Layout after Expansion

36

3.6 Industries within 10 km Radius of Plant

Figure 58-5: Location Water Industries in 10 km Range of the Project Site

3.7 Geo-Hydrological Status

In Medak district there are two major hill ranges-one extending from Ramayampet in the

North to Tupran in the south, other from Narayankhed in the northwest to the Gajwel in the

east in the district. Precambrian rocks, such as, granite adamellite, tonalite, amphibolites,

hornblende biotite schist occupy a major part of the district. These formations were

subjected to tectonism and greenschist facies metamorphism. Except for a portion in the

western part of the district, most of the area is occupied by granites. Based on mineral

composition they were further classified as alkali feldspar granite, migmatite granite

gneiss, adamellite, granodiorite, tonalite and trondjhemite. A few patches of amphibolites

and pyroxene granulites are seen around Siddipet.

All these rock formations are traversed by NE-SW and N-S trending dolerite dukes and

vein quartz. The area experienced volcanism at the time of eruption of the Deccan Traps.

The Deccan Traps and intertrappeans are seen north and west of Jogipet, extending upto

the northern and western border of the district. A small portion of Deccan Traps is seen

37

south of Sangareddy. The laterite cappings are seen extensively around Zahirabad. Two

major lineaments trending E-W and N-S appear to cross each other between Medak and

Narsapur; the N-S lineament is also in part occupied by dyke rocks. There are two major

dykes one in central part, trending in N-S direction, the other one encountered at

Kowdipally trending in a NE-SW direction.

The Medak district is covered by hard rock except for 0.2% of the alluvium area. Ground

water occurs under unconfined to confined conditions in hard rock (Archaean and Deccan

traps ages) and recent alluvial formations. The common ground water abstraction structures

are dug wells, dug-cum-bore wells and bore wells and their yields mainly depending on the

recharge conditions in the area. Yield potential of the aquifers in the consolidated rocks

varies widely from 3 to 7 lps. Due to indiscriminate drilling of bore wells, the yields have

fallen drastically, lack of recharge to fracture confined aquifer and existing bore wells

becoming to defunct and even leading to failure. Ground water is one of the important

sources both for domestic and irrigation purposes in the District and is being exploited

through large diameter dug wells, dug-cum bore wells and bore wells. In the Archaeans,

ground water occurs under phreatic conditions, but it is desaturated and under semi-

confined conditions in the fractured zones. Figure 3-6 shows the drainage pattern around 10

km zone of the site.

Figure 3-6: Direction of Drainage in the Project area

38

3.8 Land Use

Land use in the 10 km radius around the project is studied from the proposed land use

zoning of Hyderabad for the year 2031 as in Figure 3-7. The project site falls within the

Metropolitan and various Land uses are mentioned. The plot falls under category of Pre

Urban Land use. The land was purchased by the project proponent and was converted by

the Revenue Divisional Officer Medak District for non-Agricultural use as in Annexure

3.1. The land use pattern within plant area is shown in Figure 3-8.

Figure 3-7: Land Use Zoning of Metropolitan Hyderabad -2031

Figure 3-8: Land Use Pattern within plant area

39

4 BASELINE ENVIRONMENT STATUS

4.1 General

This section describes the existing environmental baseline of the study area around the

project. It includes relevant components of physical, biological and socio- economic

environment.

The purposes of describing the environmental settings of the study area are:

• To understand the project needs and environmental characteristics of the area; and

• To assess the quality of the existing environment, as well as the

environmental impacts of the future developments being studied.

The baseline environment for the EIA was studied through primary survey, information

collected from secondary sources and discussion with local stakeholders.

The baseline environmental scenario of the study area was monitored during October to

December season 2018 and is carried out for 10 km radius from the plant site.

4.2 Methodology

4.3 Study Area

Project Influence Area (PIA): In accordance with MoEF&CC’s EIA Guidelines Manual

for industry and as per guidelines of EIA Notification-2006, the Project Influence Area has

been defined as 10 km Arial radius from boundary of Plant. Collection of secondary

data, including likely i m p ac t s due to other activities like, material storage, disposal

areas, etc. are done within this influence area.

4.4 Environmental Surveys and Studies

The baseline information on physical, chemical, biological, social and economic aspects

of the project area is the most important reference for conducting environmental impact

assessment studies. Thus, for conducting EIA, existing environmental conditions around

the project have been obtained by primary data collection, monitoring, sampling and

secondary data collection from published source and various government agencies. The

primary studies focused on the Project Influence Area but the sensitivities in the project

influence area have been collected through secondary literature.

To assess the baseline environmental status of the Project Influence Area, monitoring of

40

various environmental attributes were conducted by the consultants during February to

April 2019. Primary data for ambient air quality, ambient noise status, water quality

(Ground and surface) and soil quality was generated through NABL approved laboratory.

4.5 Physical Environment

4.6 Geomorphology

The present day landforms in the district are the products of different geomorphic

processes such as erosion, deposition, crustal movements coupled with climatic changes

operating on the surface. The specific geomorphic groups are (i) Residual hills (ii) Plateau

(Deccan traps) (iii) Pediment Inselberg complex (iv) Pediplain and (v) Flood plain.

i) Residual Hills: These geomorphic forms occur as massive hills comprising of

forest areas in Kulakacherla, Manchal and in Yacharam mandals with a maximum

elevation of 691 m amsl. The residual hills occurring around Ghatkesar,

Shamirpet and Rajendernagar mandals , the soil cover is thin and devoid of

vegetation except with low trees, thorny bushes and shrubs. Other forms in the

area include Mesa/Butt, having flat topped hills comprising of laterite and basalts.

ii) Plateau (Deccan traps): This geomorphic unit is characterized by elevated uplands

with steep slope and dissected by deep and narrow valleys occupied by different

flows.

iii) Pediment Inselberg Complex: Pediment inselberg complex is a gently undulating

plain abounding with a number of small hills, mounds, tors etc.

iv) Pediplain: Pediplains are characterized by flat or gentle sloping surface which is

the end product of coalescence of several pediments at the foot of hill slopes.

Pediplains are characterized by the vast area of low lying flat terrain with gentle

slopes covered by red brown and black clayey soils ranging in thickness from 20

cm to 60 cm.

v) Flood plain: Alluvial deposits occur along major river courses mostly derived

from catchments, transported and deposited.

4.7 Drainage

Manjira, a tributary of River Godavari is an important drainage flowing in the district. The

important Nizam Sagar dam is constructed on this river. The other important streams are

Haldi and Kudalair flow in the Eastern half of the district.

4.8 Irrigation

The chief sources of irrigation in the district are tanks, wells and canals. The major

irrigation projects are shown in Table below:

41

Table 4.8-1: Irrigation Projects in the District

4.9 Geology

The rock formation in the district is of the oldest type (Archaen gneisses) and consists

principally of Peninsular granite complex i.e. pink and grey granites and their metamorphic

variations. Minor inliers of Dharwar rocks occur as narrow bands in the granite and

consists of horn blend schists, chlorite schists and banded or massive ferruginous

quartzites. A few such exposures are seen due North and North-East of Siddipet. A part of

the Sangareddy taluk in the South-West of the district is covered by the Deccan traps

(Basalt flows) formation.

4.10 Climate & Meteorology

Climate: Medak district is situated at a considerable distance from the sea-coast, the

climate is tropical and is characterized by hot summer and dry except during the South-

west monsoon season. As per the climate conditions of the district, the year may be divided

into four seasons. The hot (summer) season is from March to May. From March onwards

the temperature continues to rise and May is generally the hottest month in the year. The

period from June to September constitute the South-west monsoon (SW rainy) season,

while October and November form the post monsoon (NE rainy) season. The cold (winter)

season is from December to February.

Winds: Winds are generally light to moderate with some increase in force during May and

South-west monsoon season. During the post-monsoon season winds are very light and

variable in direction in the mornings and mostly North-eastern in the afternoons. During

the latter half of the cold season and in March and April morning, winds continue to be

light and variable in direction, while the afternoon winds are being mostly Eastern to

South-western. Winds from Western direction begin to blow from May and in the South-

west monsoon season; winds are mainly from Western to North-western direction.

42

Temperature: The days are intensively very hot and on individual days the temperature

may go up to about 46°C. The maximum temperature of 45.3°C during the decade is

recorded during the year 2001 in the hottest month of May. With advance of South-west

monsoon by about middle of June there is an appreciable drop in temperature. By October

the day temperature begins to increase slightly, but the night temperature steadily

decreases. After November, both day and night temperature decreases rapidly.

Rainfall: Most of the rainfall is by the South-west monsoon with a normal rainfall of 680

mm; followed by the North-east monsoon with a normal rainfall of 133 mm. Rainiest

month is July. The least normal rainfall of 10 mm is from the winter season; followed by

50 mm of normal rainfall from hot weather season. During the later part of summer and

post monsoon season, the rainfall is sometimes in the form of thunder showers. The

maximum of 896 mm rainfall is recorded during the year 2005-2006 as against the normal

rainfall of 873 mm with a rainfall variation of 2.63 % on the positive side (an increase of

23 mm of rainfall). However, the total rainfall recorded during the decade is 7,160 mm as

against the normal rainfall of 8,730 mm; giving rise to a rainfall variation of -17.98 % on

the negative side (a reduction of 1570 mm of rainfall).

Figure 4-1: Wind Rose at the Project Site

The predominant wind directions are mainly from Western to North-western direction.

sector accounting to about 7.45 % of the total time with calm winds of less than 1.0 kmph

for about 5.80 % Wind speeds during this period were varying between 2.5-12 kmph and

during some of the times the wind speed was recorded more than 12 kmph. The summary

of the wind pattern is given below:

Table 4.10-2: Wind Speed and Direction

43

4.11 Test Methodology for Environmental Monitoring & Testing

Table 4.11-3: Sampling Methodology

S.NO Parameter Methodology Equipment used

1. Particulate Matter

( PM2.5 and PM10)

Collection of Particulate

Matters on Filter Papers

Fine Particulate Matter

Sampler and Respirable

Dust Sampler

2. Sulphur Dioxide

(SO2)

Absorption of Gases in

Liquid Absorbent

RDS with Gaseous

Sampling Attachment

3. Oxides of Nitrogen

(NOX)

Absorption of Gases in

Liquid Absorbent

RDS with Gaseous

Sampling Attachment

4. Carbon Monoxide

(CO) Detection Method CO Meter

5. Noise Instrumental Method Noise Meter with Data

Logger

Analysis

S. NO Parameter Methodology Equipment used

1. Particulate Matter

( PM2.5 and PM10) Gravimetric Method Analytical Balance

2. Sulphur Dioxide

(SO2)

Improved West and

Gaeke Method

UV/VIS

Spectrophotometer

3. Oxides of Nitrogen

(NOX)

Modified Jacob &

Hochheiser (Na-

arsenite) Method

UV/VIS

Spectrophotometer

4.12 Ambient Air Quality

4.12.1 Monitoring Location

Eight locations were selected for ambient air quality monitoring in and around

Mahalakshmi Profiles Pvt. Ltd.as in Figure 4.5 and Table 4.3. Monitoring was done for 24

hours twice a week for ambient air and noise quality at each location. The baseline status of

44

the air quality in the study area was assessed though a scientifically designed ambient air

quality monitoring network. The selection of monitoring network was based on the

following aspects:

Topography / terrain of the study are,

Populated area within the study area,

Residential and sensitive areas within the study area,

Magnitude of the surrounding industries,

Representation of regional background levels,

Representation of cross sectional distribution in downward direction.

Table 4.12-4: Sampling Locations

Station

Code

Name of the

Station

Latitude Longitude Distance

w.r.t.

site (km)

Direction Environmental

Setting

AAQ1 Project Area 170 41' 54.34" 780 29 '4.82" - - Mixed Area AAQ2 Banda Mailaram 170 41' 53.43" 780 30 '21.00" 1.3 S-SW Cross wind AAQ3 Baswapur 170 42' 20.36" 780 32 '31.57" 6.4 E Cross wind AAQ4 Rawalkole 170 39' 29.53" 78 0 30' 26.20" 4.22 SE Down wind AAQ5 Medchal 170 37' 15.77" 78 0 28' 54.6" 1.8 SW-W Down wind AAQ6 Nuthankal 170 41' 21.95" 780 26' 56.56" 5.7 S-SW Cross wind AAQ7 Sikindlapur 170 44' 6.62" 780 25' 31.62" 5.8 NE-E Cross wind AAQ8 Koochavaram 17 0 43 '47.69" 780 28' 12.52" 9.3 S Cross wind

Source: Primary Surveys

Figure 4.12-2: Ambient Air Monitoring Locations

45

Table 4.12-5: Air Quality Monitoring Data

Project Name : Mahalakshmi Profiles Pvt. Ltd. Season : Winter - 2019

Location Name :Project Site (AAQ1) Sampling Duration 24 hrs period

Date PM10

µg/m3

PM2.5

µg/m3

NOX

µg/m3

SO2

µg/m3

CO

µg/m3

I II III

Standards 100.0 60.0 80.0 80.0

February-2019

04.02.2019 88 36 25 21.0 0.81 1.49 0.72

07.02.2019 65 30 11 19.5 0.92 1.46 0.76

11.02.2019 83 38 14 20.7 0.85 1.49 0.74

14.02.2019 73 33 12 18.5 0.96 1.51 0.78

18.02.2019 69 32 12 23.1 0.82 1.54 0.76

21.02.2019 77 35 13 21.4 0.80 1.48 0.72

25.02.2019 57 26 10 18.6 0.83 1.44 0.73

28.02.2019 61 28 10 20.4 0.90 1.42 0.79

March-2019

04.03.2019 88 36 25 10 0.92 1.53 0.78

07.03.2019 67 27 14 8 0.96 1.59 0.80

11.03.2019 85 40 21 12 0.82 1.55 0.75

14.03.2019 75 30 15 9 0.85 1.59 0.78

18.03.2019 71 28 15 8 0.90 1.60 0.76

21.03.2019 79 32 16 9 0.98 1.66 0.80

25.03.2019 58 23 12 7 0.86 1.63 0.79

28.03.2019 62 25 13 7 0.80 1.61 0.71

April-2019

01.04.2019 90 36 18 10 0.90 1.70 0.79

04.04.2019 72 29 15 8 0.98 1.78 0.82

08.04.2019 92 37 19 11 0.92 1.65 0.80

11.04.2019 81 32 17 9 0.84 1.80 0.76

15.04.2019 76 31 16 9 0.99 1.72 0.82

18.04.2019 85 34 18 10 0.90 1.85 0.81

22.04.2019 63 25 13 7 0.85 1.76 0.80

25.04.2019 67 27 14 8 0.83 1.70 0.78

Mean 74 31 15 8 0.99 1.85 0.82

Minimum 57 23 10 5 0.80 1.42 0.70

Maximum 92 40 25 12 0.81 1.61 0.77

98th percentile 91 39 25 11 0.81 1.47 0.72

46


Location Name : Banda Mailaram ( AAQ2 ) Sampling Duration 24 hrs period

Date PM10

µg/m3

PM2.5

µg/m3

NOX

µg/m3

SO2

µg/m3

CO

µg/m3

I II III

Standards 100.0 60.0 80.0 80.0

February -2019

04.02.2019 64 26 12 9 0.85 1.52 0.70

07.02.2019 98 29 22 8 0.79 1.46 0.65

11.02.2019 72 29 14 11 0.92 1.63 0.80

14.02.2019 68 27 13 10 0.86 1.40 0.72

18.02.2019 76 31 15 11 0.90 1.58 0.78

21.02.2019 56 23 11 8 0.87 1.42 0.62

25.02.2019 60 24 11 9 0.76 1.65 0.66

28.02.2019 87 35 17 13 0.80 1.43 0.60

March-2019

04.03.2019 69 28 13 10 0.90 1.80 0.72

07.03.2019 97 32 23 11 0.81 1.62 0.68

11.03.2019 78 31 15 11 0.98 1.78 0.76

14.03.2019 74 30 14 11 0.85 1.69 0.70

18.03.2019 83 33 16 12 0.80 1.53 0.65

21.03.2019 61 24 12 9 0.81 1.62 0.62

25.03.2019 65 26 12 10 0.92 1.69 0.73

28.03.2019 86 34 19 13 0.96 1.71 0.78

April-2019

01.04.2019 69 27 16 10 0.98 1.71 0.80

04.04.2019 93 41 23 15 0.92 1.68 0.76

08.04.2019 77 31 17 11 0.78 1.86 0.69

11.04.2019 73 29 17 11 0.89 1.79 0.70

15.04.2019 81 33 18 12 0.82 1.92 0.66

18.04.2019 60 24 14 9 0.93 1.86 0.75

22.04.2019 64 26 15 10 0.86 1.69 0.72

25.04.2019 98 42 20 13 0.99 1.85 0.85

Mean 75 29 16 11 0.99 1.92 0.85

Minimum 56 21 11 8 0.76 1.40 0.60

Maximum 98 36 23 15 0.81 1.66 0.71

98th percentile 98 35 23 14 0.79 1.44 0.62

47


Location Name : Baswapur ( AAQ3) Sampling Duration 24 hrs period

Date PM10

µg/m3

PM2.5

µg/m3

NOX

µg/m3

SO2

µg/m3

CO

µg/m3

I II III

Standards 100.0 60.0 80.0 80.0

February -2019

04.02.2019 96 37 18 13 0.86 1.58 0.70

07.02.2019 85 28 20 17 0.79 1.52 0.68

11.02.2019 94 37 16 12 0.93 1.66 0.73

14.02.2019 80 30 14 11 0.78 1.50 0.62

18.02.2019 91 35 19 8 0.94 1.69 0.71

21.02.2019 95 38 18 12 0.87 1.59 0.68

25.02.2019 92 32 19 9 0.75 1.49 0.60

28.02.2019 83 29 13 8 0.81 1.51 0.65

March-2019

04.03.2019 90 28 11 10 0.90 1.75 0.74

07.03.2019 85 29 22 8 0.99 1.64 0.81

11.03.2019 98 37 19 10 0.85 1.90 0.72

14.03.2019 89 30 15 11 0.78 1.79 0.65

18.03.2019 75 20 16 9 0.82 1.68 0.68

21.03.2019 89 38 13 8 0.95 1.86 0.76

25.03.2019 91 32 17 12 0.79 1.78 0.65

28.03.2019 83 22 16 13 0.91 1.84 0.78

April-2019

01.04.2019 93 37 21 14 0.98 1.84 0.95

04.04.2019 74 30 17 11 0.96 1.97 0.73

08.04.2019 95 38 21 14 0.85 1.86 0.61

11.04.2019 83 33 19 12 1.05 1.90 0.82

15.04.2019 79 31 18 12 0.89 1.78 0.70

18.04.2019 88 35 20 13 0.96 1.86 0.69

22.04.2019 65 26 15 10 1.10 1.99 0.81

25.04.2019 69 28 16 10 0.98 1.81 0.72

Mean 86 32 17 11 1.10 1.99 0.95

Minimum 65 20 11 8 0.75 1.49 0.60

Maximum 98 38 22 17 0.90 1.74 0.72

98th percentile 97 38 22 16 0.78 1.51 0.63

48


Location Name : Ravalkole (AAQ 4) Sampling Duration 24 hrs period

Date PM10

µg/m3

PM2.5

µg/m3

NOX

µg/m3

SO2

µg/m3

CO

µg/m3

I II III

Standards 100.0 60.0 80.0 80.0

February-2019

04.02.2019 81 33 16 11 0.83 1.42 0.68

07.02.2019 65 26 13 9 0.85 1.36 0.72

11.02.2019 98 39 19 13 0.98 1.56 0.80

14.02.2019 73 29 15 10 0.90 1.48 0.78

18.02.2019 69 28 14 9 0.82 1.55 0.70

21.02.2019 77 31 15 10 0.80 1.46 0.68

25.02.2019 57 23 11 8 0.86 1.58 0.71

28.02.2019 61 24 12 8 0.81 1.54 0.74

March-2019

04.03.2019 88 35 17 12 0.96 1.65 0.79

07.03.2019 99 41 27 9 0.89 1.48 0.70

11.03.2019 90 36 18 12 0.99 1.62 0.78

14.03.2019 79 32 16 11 0.86 1.56 0.72

18.03.2019 75 30 15 10 1.01 1.60 0.82

21.03.2019 83 33 17 11 0.98 1.44 0.80

25.03.2019 61 25 12 8 0.96 1.59 0.77

28.03.2019 66 26 13 9 0.81 1.48 0.69

April-2019

01.04.2019 75 34 13 6 0.99 1.80 0.74

04.04.2019 60 28 10 5 1.02 1.64 0.80

08.04.2019 90 41 15 8 0.94 1.73 0.72

11.04.2019 67 31 12 6 0.85 1.82 0.68

15.04.2019 64 29 11 5 0.90 1.68 0.75

18.04.2019 71 33 12 6 0.82 1.76 0.70

22.04.2019 52 24 9 4 0.96 1.69 0.80

25.04.2019 56 26 10 5 1.02 1.80 0.82

Mean 73 30 14 8 1.02 1.82 0.82

Minimum 52 23 9 4 0.80 1.36 0.68

Maximum 99 37 19 13 0.92 1.59 0.75

98th percentile 98 36 19 13 0.82 1.45 0.68

49


Location Name : Medchal (AAQ 5) Sampling Duration 24 hrs period

Date PM10

µg/m3

PM2.5

µg/m3

NOX

µg/m3

SO2

µg/m3

CO

µg/m3

I II III

Standards 100.0 60.0 80.0 80.0

February-2019

04.02.2019 97 35 17 8 0.98 1.68 0.75

07.02.2019 84 26 18 10 1.05 1.80 0.82

11.02.2019 88 29 15 4 0.89 1.58 0.70

14.02.2019 81 34 20 7 0.96 1.60 0.76

18.02.2019 95 35 18 8 1.10 1.86 0.86

21.02.2019 73 22 16 5 0.99 1.69 0.80

25.02.2019 90 38 20 8 1.08 1.80 0.92

28.02.2019 88 28 14 8 0.96 1.62 0.85

March-2019

04.03.2019 85 30 16 6 1.08 1.71 0.99

07.03.2019 92 32 18 7 0.98 1.58 0.82

11.03.2019 87 21 11 9 1.12 1.78 0.70

14.03.2019 91 37 15 9 1.06 1.72 0.87

18.03.2019 84 23 7 9 0.99 1.58 0.77

21.03.2019 81 26 19 9 0.90 1.46 0.72

25.03.2019 78 22 15 11 0.92 1.49 0.77

28.03.2019 89 31 11 6 1.01 1.71 0.86

April-2019

01.04.2019 85 33 15 11 1.05 1.66 0.90

04.04.2019 75 25 17 8 1.13 1.80 0.95

08.04.2019 90 35 16 7 0.99 1.65 0.78

11.04.2019 80 24 18 12 1.02 1.78 0.82

15.04.2019 84 26 19 9 0.96 1.60 0.74

18.04.2019 93 28 16 9 1.06 1.86 0.86

22.04.2019 76 20 19 5 0.94 1.69 0.70

25.04.2019 89 32 15 7 1.00 1.83 0.80

Mean 86 29 16 8 1.13 1.86 0.99

Minimum 73 20 7 4 0.89 1.46 0.70

Maximum 97 38 20 12 1.01 1.69 0.79

98th percentile 96 37 20 11 0.91 1.58 0.68

50


Location Name : Nuthankal(AAQ 6) Sampling Duration 24 hrs period

Date PM10

µg/m3

PM2.5

µg/m3

NOX

µg/m3

SO2

µg/m3

CO

µg/m3

I II III

Standards 100.0 60.0 80.0 80.0

February-2019

04.02.2019 77 24 20 7 0.86 1.68 0.65

07.02.2019 97 37 16 11 0.79 1.56 0.60

11.02.2019 84 24 18 10 0.93 1.73 0.72

14.02.2019 80 20 16 6 0.78 1.52 0.61

18.02.2019 90 30 13 11 0.94 1.72 0.75

21.02.2019 94 38 15 9 0.87 1.68 0.68

25.02.2019 99 33 13 8 0.75 1.59 0.60

28.02.2019 89 26 11 5 0.81 1.67 0.62

March-2019

04.03.2019 96 38 18 12 0.82 1.70 0.63

07.03.2019 93 29 19 11 0.80 1.62 0.60

11.03.2019 82 37 16 10 0.91 1.78 0.72

14.03.2019 72 23 13 8 0.85 1.66 0.68

18.03.2019 98 33 12 11 0.96 1.78 0.77

21.03.2019 89 29 20 7 0.81 1.66 0.72

25.03.2019 84 22 14 8 0.80 1.65 0.64

28.03.2019 86 21 16 11 0.93 1.79 0.76

April-2019

01.04.2019 78 24 18 6 0.99 1.70 0.78

04.04.2019 84 28 20 10 0.86 1.65 0.62

08.04.2019 90 34 15 7 0.92 1.69 0.72

11.04.2019 91 37 20 10 0.89 1.66 0.70

15.04.2019 79 27 11 4 1.04 1.75 0.80

18.04.2019 89 33 12 7 1.15 1.90 0.86

22.04.2019 78 36 14 10 1.06 1.86 0.82

25.04.2019 81 27 16 9 1.02 1.79 0.79

Mean 87 30 16 9 1.15 1.90 0.86

Minimum 72 20 11 4 0.75 1.52 0.60

Maximum 99 38 20 12 0.91 1.70 0.70

98th percentile 98 38 20 12 0.79 1.60 0.60

51


Location Name : Sikindlapur(AAQ 7) Sampling Duration 24 hrs period

Date PM10

µg/m3

PM2.5

µg/m3

NOX

µg/m3

SO2

µg/m3

CO

µg/m3

I II III

Standards 100.0 60.0 80.0 80.0

February-2019

04.02.2019 66 36 20 7 0.86 1.66 0.72

07.02.2019 98 37 19 9 0.83 1.58 0.69

11.02.2019 88 32 22 4 0.92 1.76 0.79

14.02.2019 78 35 18 8 0.79 1.54 0.68

18.02.2019 75 31 16 8 0.90 1.72 0.75

21.02.2019 90 38 19 5 0.87 1.58 0.70

25.02.2019 97 30 12 8 0.83 1.60 0.66

28.02.2019 94 34 20 8 0.90 1.75 0.74

March-2019

04.03.2019 77 22 15 6 0.92 1.68 0.76

07.03.2019 98 29 17 11 0.98 1.79 0.80

11.03.2019 82 24 12 8 0.86 1.58 0.72

14.03.2019 68 20 18 10 0.92 1.72 0.74

18.03.2019 85 32 9 9 0.81 1.58 0.70

21.03.2019 80 28 20 9 0.86 1.50 0.65

25.03.2019 87 30 18 7 0.78 1.49 0.60

28.03.2019 91 33 13 10 0.81 1.56 0.72

April-2019

01.04.2019 86 24 17 10 0.98 1.65 0.79

04.04.2019 77 21 14 4 0.86 1.53 0.68

08.04.2019 97 36 19 7 1.04 1.79 0.89

11.04.2019 91 31 22 12 0.95 1.68 0.76

15.04.2019 78 27 21 11 0.89 1.60 0.65

18.04.2019 67 34 16 9 0.96 1.68 0.78

22.04.2019 90 33 22 10 1.10 1.85 0.92

25.04.2019 84 28 16 7 1.00 1.72 0.81

Mean 84 30 17 8 1.10 1.85 0.92

Minimum 66 20 9 4 0.78 1.49 0.60

Maximum 98 38 22 12 0.90 1.65 0.73

98th percentile 98 38 22 11 0.80 1.53 0.65

52


Location Name : Koochavaram(AAQ 8) Sampling Duration 24 hrs period

Date PM10

µg/m3

PM2.5

µg/m3

NOX

µg/m3

SO2

µg/m3

CO

µg/m3

I II III

Standards 100.0 60.0 80.0 80.0

February-2019

04.02.2019 92 38 18 7 0.82 1.42 0.68

07. 02.2019 94 36 16 11 0.81 1.58 0.72

11. 02.2019 85 31 13 10 0.90 1.52 0.78

14. 02.2019 62 23 15 6 0.92 1.40 0.76

18. 02.2019 87 26 15 12 0.80 1.42 0.72

21. 02.2019 98 38 18 10 0.86 1.50 0.70

25. 02.2019 86 28 20 10 0.78 1.62 0.68

28. 02.2019 80 36 24 13 0.81 1.43 0.74

March-2019

04.03.2019 90 39 10 8 0.86 1.64 0.74

07.03.2019 91 29 14 10 0.94 1.70 0.80

11.03.2019 96 34 18 13 0.98 1.62 0.79

14.03.2019 73 25 13 8 0.92 1.69 0.70

18.03.2019 95 30 15 11 0.90 1.72 0.68

21.03.2019 78 23 13 7 0.99 1.80 0.80

25.03.2019 90 25 18 9 0.96 1.64 0.79

28.03.2019 95 22 17 12 0.93 1.68 0.78

April-2019

01.04.2019 89 20 15 6 0.96 1.78 0.82

04.04.2019 97 34 21 11 0.98 1.86 0.84

08.04.2019 90 31 14 7 0.89 1.79 0.78

11.04.2019 98 28 21 10 0.94 1.82 0.80

15.04.2019 85 30 13 4 0.92 1.72 0.79

18.04.2019 99 35 24 7 0.97 1.86 0.86

22.04.2019 88 26 24 12 0.98 1.90 0.82

25.04.2019 91 34 22 14 0.94 1.85 0.89

Mean 89 30 17 10 0.99 1.90 0.89

Minimum 62 20 10 4 0.78 1.40 0.68

Maximum 99 39 24 14 0.91 1.66 0.77

98th percentile 99 39 24 14 0.84 1.42 0.69

Table 4.12-6: Results of Ambient Air Quality Monitoring (Maximum)

Name of the

Station PM10

µg/m3

PM2.5

µg/m3

NOX

µg/m3

SO2

µg/m3

CO

Project Area 92 40 25 12 1.61

Banda Mailaram 98 36 23 15 1.66

Baswapur 98 38 22 17 1.74

Rawalkole 99 37 19 13 1.59

Medchal 97 38 20 12 1.69

Nuthankal 99 38 20 12 1.70

Sikindlapur 98 38 22 12 1.65

53

Koochavaram 99 39 24 14 1.66

The results indicate that the results are within the standards specified in the NAAQS.

4.13 Ambient Noise Quality

The physical description of sound concerns its loudness as a function of frequency. Noise

in general is sound, which is composed of many frequency components of various types of

loudness distributed over the audible frequency range. The most common and universally

accepted scale is the A weighted scale, which is measured as dB (A). This is more suitable

for audible range of 20 to 20,000 Hz. The scale has been designed to weigh various

components of noise according to the response of human ear. The environmental impact of

noise can have several effects varying from Noise Induced Hearing Loss (NIHL) to

annoyance depending on loudness of noise.

4.13.1.1 Instrument Used for Sampling and Monitoring

The main objective of noise monitoring in the study area is to establish the baseline noise

levels, which was used to assess the impact of the total noise generated by the proposed

project activities. Noise level monitoring was carried out continuously for 24 - hours with

one-hour interval at each location using Sound level meter (HTC made in Taiwan Model

No. SL-1350) capable of measuring the Sound Pressure Level (SPL) in dB (A). Hourly Leq

values were computed by the noise integrating sound level meter and statistical analysis

was done for measured noise levels at 8 locations in the study area. The Leq day, and Leq

night calculated for various locations in the area are presented below which are compared

with the standards prescribed by CPCB for various zones.

4.13.1.2 Monitoring Locations

Noise at different generating sources has been identified based on the residential, industrial

and commercial activities in the area. The noise monitoring has been conducted for

determination of noise levels at eight locations in the study area. The noise levels at each

location were recorded for 24-hr.

Table 4.13-7: Sampling Locations

Station

Code

Name of the

Station


w.r.t.

site (km)

Direction Environmental

Setting

N1 Project Area 170 41' 54.34" 780 29 '4.82" - - Mixed Area N2 Banda

Mailaram

170 41' 53.43" 780 30 '21.00" 1.3 S-SW Cross wind

N3 Baswapur 170 42' 20.36" 780 32 '31.57" 6.4 E Cross wind N4 Rawalkole 170 39'

29.53"

78 0 30' 26.20" 4.22 SE Down wind

N5 Medchal 170 37'

15.77"

78 0 28' 54.6" 1.8 SW-W Downwind

N6 Nuthankal 170 41'

21.95"

780 26' 56.56" 5.7 S-SW Cross wind

N7 Sikindlapur 170 44' 6.62" 780 25' 31.62" 5.8 NE-E Cross wind

N8 Koochavaram 17 0 43

'47.69"

780 28' 12.52" 9.3 S Cross wind

54

Figure 4.13-3: Noise Monitoring Locations

Table 4.13-8: Monitoring Results

Project Name : Mahalakshmi Profiles Pvt. Ltd. Date: 04.04.2019

Time

Project Site N-1

Banda

Mailaram

N-2

Baswapur

N-3

Ravalkole

N-4

Medchal

N-5

Nuthankal

N-6

Skindlapur

N-7

Koochavara

m

N-8

6 AM 67.6 54.5 51.2 46.8 52.2 50.1 48.3 48.1

7 AM 69.7 57.5 52.6 49.3 54.1 49.3 51.9 48.9

8 AM 56.3 56.1 53.4 52.2 56.2 51.6 52.3 49.4

9 AM 57.8 58.2 56.7 54.3 57.6 53.1 53.3 50.4

10 AM 58.4 59.1 57.5 53.3 56.3 52.8 56.3 52.1

11 AM 59.2 60.5 59.1 55.3 57.8 53.7 57.2 52.8

12 Noon 58.1 58.6 59.4 54.3 58.4 54.2 58.3 53.2

13 PM 57.7 57.5 58.2 46.3 59.2 54.9 57.3 53.9

14 PM 58.9 59.8 59.8 54.2 58.1 55.1 56.8 54.1

15 PM 56.4 58.7 58.7 55.2 57.7 55.5 58.6 54.9

16 PM 58.4 57.7 57.6 56.6 58.9 56.2 57.8 55.5

17 PM 56.3 57.7 57.9 55.3 56.4 56.7 56.9 56.3

18 PM 57.8 58.9 58.4 53.5 58.4 54.1 57.8 56.7

55

Project Name : Mahalakshmi Profiles Pvt. Ltd. Date: 04.04.2019

Time

Project Site N-1

Banda

Mailaram

N-2

Baswapur

N-3

Ravalkole

N-4

Medchal

N-5

Nuthankal

N-6

Skindlapur

N-7

Koochavara

m

N-8

19 PM 58.4 57.5 59.2 52.1 55.1 55.2 56.6 55.2

20 PM 69.8 55.9 56.4 49.2 54.3 49.5 54.6 52.3

21 PM 68.8 53.1 54.6 47.9 52.9 48.2 53.6 50.1

22 PM 68.0 54.5 54.1 45.3 51.4 46.7 53.6 48.3

23 PM 66.2 53.4 52.4 44.3 48.6 45.4 51.3 47.2

24 MN 65.1 52.5 51.1 43.6 46.2 45.1 49.2 43.1

1 AM 63.2 53.6 52.7 42.6 45.1 44.3 48.1 42.5

2 AM 62.1 52.9 52.1 44.6 44.8 44.1 46.8 42.3

3 AM 63.8 51.1 52.6 42.3 43.2 42.2 44.3 41.0

4 AM 64.7 52.1 53.4 43.3 45.6 43.5 43.3 44.5

5 AM 66.4 53 53.1 44.3 46.4 46.4 44.8 45.2 Maximu

m 69.8 60.5 59.8 56.6 59.2 56.7 58.6 56.7

Minimum 56.3 51.1 51.1 42.3 43.2 42.2 43.3 41.0

Leq Day

dB(A)

66.3 58.1 57.7 53.4 57.1 54.0 56.3 53.6

Leq

Night

dB(A)

55.9 53.0 53.0 44.6 48.3 45.4 49.8 45.9

Leq Day

&Night

62.5 57.0 56.6 51.7 55.7 52.6 55.0 52.2

As per the standard of CPCB the noise level should be 75 dB (A) at day time and 70 dB

(A) at night time in industrial area. All the results found within the permissible limit.

However noise level in rural & residential is slightly above the standard limit.

4.14 Water Environment

Assessment of baseline data on Water environment includes

a) Identification of surface water sources

b) Identification of ground water sources

c) Collection of water samples

d) Analyzing water samples collected for physico-chemical and biological parameters

Ground water is another major water source in the study area and the water table lies at

about 50-80 m below 550 msl.

4.14.1.1 Monitoring Locations

Assessment of water quality and Soil Quality in the study area includes the quality

assessment of parameters as per the Indian standard IS 10500 (drinking water standard).

Eight Ground Water and Eight Surface Water samples have been collected from various

locations of the study area. The location of water and Soil sampling stations is shown in

Table-4.8 and the results are shown in Table 4.9, 4.10 and 4.11.

56

Figure 4.14-4: Surface and Ground water Monitoring Locations

Table 4.14-9: Water and Soil Sampling Locations

Station

Code for

Soil

Station

Code for

Ground

Water(GW)

and Surface

(SW)

Name of the

Station


w.r.t.

site (km)

Direction Environme

ntal Setting

S1 GW1/SW1 Project

Area

170 41' 54.34" 780 29 '4.82" - - Mixed

Area

S2 GW2/SW2 Banda

Mailaram

170 41' 53.43" 780 30 '21.00" 1.3 S-SW Cross wind

S3 GW3/SW3 Baswapur 170 42' 20.36" 780 32 '31.57" 6.4 E Cross wind

S4 GW4/SW4 Rawalkole 170 39' 29.53" 78 0 30' 26.20" 4.22 SE Down wind

S5 GW5/SW5 Medchal 170 37' 15.77" 78 0 28' 54.6" 1.8 SW-W Down wind

S6 GW6/SW6 Nuthankal 170 41' 21.95" 780 26' 56.56" 5.7 S-SW Cross wind

S7 GW7/SW7 Sikindlapur 170 44' 6.62" 780 25' 31.62" 5.8 NE-E Cross wind

S8 GW8/SW8 Koochavara

m

17 0 43 '47.69" 780 28' 12.52" 9.3 S Cross wind

Ground Water sample collected showed compliance of all parameters with the drinking

water standard of IS 10500 and surface water as IS 2296 Standards.

The study area is covered with alluvial read soil and in some parts with small patches of

clay with low thickness. Eight soil samples were collected within 10 km radial distance of

the study area and one sample from plant area were analyzed to study the soil quality.

4.15 Soil Environment

Medak district exhibits a variety of soils. Black cotton soil ranging in thickness from 0.3 to

0.75 m occurs in basaltic regions of Narayankhed, Nayalkel and Andole mandals. Red soil

57

ranges in thickness from 0.75 to 2.00 m. It possesses high water retention capacity.

Alluvium comprises 20 Sq.Km. area. Major part of the district is arable un-irrigated land

with patch of irrigated land around Medak. Areas of forest cover are seen in the central part

of the district with grass and scrubland in the western part. A few scrubland areas also exist

in the northeastern part around Siddipet.

Summary of Soil Quality in Plant Area

pH of the all soil sample was 7.21

Texture of soil sample is found to be clay with sand 36%, silt 16% and Clay

48%.

Phosphorus values in the soil sample collected was found to be 28 kg/ha.

Nitrate of the soil sample collected was found to be 186 kg/ ha.

Summary of Soil Quality in Study Area

pH of the all soil samples was found to be 7.16-7.86.

Texture of soil samples is found to be Clay and sandy Clay with sand % in

the range between 16-36%, silt between 16-48 % and Clay 34-54%.

Phosphorus values in the soil samples collected were in the range of 28-64

kg/ha

Nitrate of the soil samples collected were in the range of 186-282 kg/ha.

58

Figure 4.15-5: Soil Monitoring Locations

59

Table 4.15-10: Ground Water Sampling Results


S.No Parameter Requirement

(Desirable

Limits)

Permissible Limits

in the Absence of

Alternate Source

Units

Method of Analysis Instrument Used Project site

GW1

Banda

Mailaram

GW-2

Baswapur

GW-3

Ravalkole

GW-4

1 Ph 6.5 – 8.5 NR - IS:3025(Part 11) pH meter 6.68 7.84 7.18 7.14

2 Color (Hazen units) 5 25 Hazen IS:3025(Part 4) 02 02 01 02

3 Taste Agreeable - - IS:3025(Part 8) Agreeable Agreeable Agreeable Agreeable

4 Odor Unobjectionable

- - IS:3025(Part 5) Unobjec-tionable

Unobjec-tionable

Unobjec-tionable

Unobjec-tionable

5 Conductivity µS/cm IS:3025(Part 4) 3614 1036 1366 922

6 Turbidity (NTU) 5 10 NTU IS:3025(Part 10) Turbidity meter 1.80 1.60 1.40 1.80

7 Total Dissolve solids 500 2000 mg/l IS:3025(Part 16) Gravimetric method 2448 664 886 588

8 Total Hardness asCaCO3 300 600 mg/l IS:3025(Part 21) Titrimetric method 1628 416 472 400

9 Total Alkalinity 200 600 mg/l IS:3025(Part 23) Titrimetric method 240 300 480 360

10 Calcium as Ca 75 200 mg/l IS:3025(Part 40) Titrimetric method 477 125 109 152

11 Magnesium as Mg 30 100 mg/l IS:3025(Part 46) Titrimetric method 104 25 48 26

12 Residual Chlorine 0.2 min - mg/l IS:3025(Part 26) Titrimetric method Nil Nil Nil Nil

13 Boron 1 5 mg/l IS:3025(Part 57) AAS 0.04 <0.02 0.03 <0.02

14 Chloride as Cl 250 1000 mg/l IS:3025(Part 32) Titrimetric method 1079 116 86 35

15 Sulphate as SO4 200 400 mg/l IS:3025(Part 24) Spectrophotometer 69 66 68 42

16 Fluorides as F- 1.0 1.5 mg/l IS:3025(Part 60) Spectrophotometer 1.80 0.90 1.00 0.60

17 Nitrates as NO3 45 100 mg/l IS:3025(Part 34) Spectrophotometer 11 06 08 04

18 Sodium as Na $ $ mg/l IS:3025(Part 45) Flame photometer 76 43 93 26

19 Potassium as K $ $ mg/l IS:3025(Part 45) Flame photometer 06 03 04 02

20 Phenolic Compounds 0.001 0.002 mg/l IS:3025(Part 43) Spectrophotometer 0.006 <0.001 0.003 <0.001

21 Cyanides 0.02 NR mg/l IS:3025(Part 27) Spectrophotometer <0.02 <0.02 <0.02 <0.02

22 Anionic Detergents 0.2 1.0 mg/l APHA 5540-C MBAS Kit 0.3 <0.01 <0.01 <0.01

23 Mineral Oil 0.01 0.03 mg/l IS:3025(Part 39) Gravimetric method 0.004 <0.001 <0.001 <0.001

24 Cadmium as Cd 0.01 NR mg/l IS:3025(Part 41) AAS 0.002 <0.001 <0.001 <0.001

25 Arsenic as As 0.01 NR mg/l IS:3025(Part 37) AAS <0.001 <0.001 <0.001 <0.001

26 Copper as Cu 0.02 1.5 mg/l IS:3025(Part 42) AAS <0.01 <0.01 <0.01 <0.01

27 Lead as Pb 0.02 NR mg/l IS:3025(Part 47) AAS <0.04 <0.04 <0.04 <0.04

28 Manganese as Mn 0.1 0.3 mg/l IS:3025(Part 59) AAS <0.001 <0.001 <0.001 <0.001

29 Iron as Fe 0.3 1.0 mg/l IS:3025(Part 53) AAS 0.16 0.14 0.12 0.12

30 Chromium as Cr6+ 0.02 NR mg/l IS:3025(Part 53) AAS <0.001 <0.001 <0.001 <0.001

31 Zinc as Zn 5 15 mg/l IS:3025(Part 49) AAS 03 02 02 01

32 Aluminum as Al 0.03 0.2 mg/l IS:3025(Part 55) AAS <0.005 <0.005 <0.005 <0.005

33 Mercury as Hg 0.001 NR mg/l IS:3025(Part 48) Mercury ion analyzer <0.001 <0.001 <0.001 <0.001

34 Pesticides Absent 0.001 mg/l APHA 8081 B Gas chromatography Absent Absent Absent Absent

35 E-coli(Nos/100 ml) Absent IS 13428: 2005 Microbial count Nil Nil Nil Nil

36 Coliform Organisms MPN/100 ml IS 14543: 2004 Microbial count Absent Absent Absent Absent

60


S.No. Parameter Requirement

(Desirable Limits)

Permissible Limits

in the Absence of Alternate Source

Units METHOD OF

ANALYSIS

Instrument Used Medchal

GW-5

Nuthankal

GW-6

Skindlapur

GW-7

Koochavar

am

GW-8

1 pH 6.5 – 8.5 NR - IS:3025(Part 11) pH meter 6.84 7.36 7.36 7.72

2 Color (Hazen units) 5 25 Hazen IS:3025(Part 4) 02 02 02 02

3 Taste Agreeable - - IS:3025(Part 8) Agreeable Agreeable Agreeable Agreeable

4 Odor Unobjectionable

- - IS:3025(Part 5) Unobjec-tionable

Unobjec-tionable

Unobjec-tionable

Unobjec-tionable

5 Conductivity $ $ uS/cm IS:3025(Part 4) 2786 968 748 1026

6 Turbidity (NTU) 5 10 NTU IS:3025(Part 10) Turbidity meter 1.80 1.60 1.80 1.60

7 Total Dissolve solids 500 2000 mg/l IS:3025(Part 16) Gravimetric method 1784 602 478 652

8 Total Hardness as CaCO3 300 600 mg/l IS:3025(Part 21) Titrimetric method 1208 416 264 240

9 Total Alkalinity 200 600 mg/l IS:3025(Part 23) Titrimetric method 380 280 240 220

10 Calcium as Ca 75 200 mg/l IS:3025(Part 40) Titrimetric method 400 166 64 70

11 Magnesium as Mg 30 100 mg/l IS:3025(Part 46) Titrimetric method 135 31 25 14

12 Residual Chlorine 0.2 min - mg/l IS:3025(Part 26) Titrimetric method Nil Nil Nil Nil

13 Boron 1 5 mg/l IS:3025(Part 57) AAS <0.02 <0.02 <0.02 <0.02

14 Chloride as Cl 250 1000 mg/l IS:3025(Part 32) Titrimetric method 504 93 36 185

15 Sulphate as SO4 200 400 mg/l IS:3025(Part 24) Spectrophotometer 278 64 72 24

16 Fluorides as F- 1.0 1.5 mg/l IS:3025(Part 60) Spectrophotometer 1.80 0.80 0.60 0.80

17 Nitrates as NO3 45 100 mg/l IS:3025(Part 34) Spectrophotometer 09 04 06 05

18 Sodium as Na $ $ mg/l IS:3025(Part 45) Flame photometer 84 29 47 123

19 Potassium as K $ $ mg/l IS:3025(Part 45) Flame photometer 03 02 02 02

20 Phenolic Compounds 0.001 0.002 mg/l IS:3025(Part 43) Spectrophotometer <0.001 <0.001 <0.001 <0.001

21 Cyanides 0.02 NR mg/l IS:3025(Part 27) Spectrophotometer <0.02 <0.02 <0.02 <0.02

22 Anionic Detergents 0.2 1.0 mg/l APHA 5540-C MBAS Kit <0.01 <0.01 <0.01 <0.01

23 Mineral Oil 0.01 0.03 mg/l IS:3025(Part 39) Gravimetric method <0.001 <0.001 <0.001 <0.001

24 Cadmium as Cd 0.01 NR mg/l IS:3025(Part 41) AAS <0.001 <0.001 <0.001 <0.001

25 Arsenic as As 0.01 NR mg/l IS:3025(Part 37) AAS <0.001 <0.001 <0.001 <0.001

26 Copper as Cu 0.02 1.5 mg/l IS:3025(Part 42) AAS <0.01 <0.01 <0.01 <0.01

27 Lead as Pb 0.02 NR mg/l IS:3025(Part 47) AAS <0.04 <0.04 <0.04 <0.04

28 Manganese as Mn 0.1 0.3 mg/l IS:3025(Part 59) AAS <0.001 <0.001 <0.001 <0.001

29 Iron as Fe 0.3 1.0 mg/l IS:3025(Part 53) AAS 0.16 0.10 0.03 0.03

30 Chromium as Cr6+ 0.02 NR mg/l IS:3025(Part 53) AAS <0.001 <0.001 <0.001 <0.001

31 Zinc as Zn 5 15 mg/l IS:3025(Part 49) AAS 04 02 01 03

32 Aluminum as Al 0.03 0.2 mg/l IS:3025(Part 55) AAS <0.005 <0.005 <0.005 <0.005

33 Mercury as Hg 0.001 NR mg/l IS:3025(Part 48) Mercury ion analyzer <0.001 <0.001 <0.001 <0.001

34 Pesticides Absent 0.001 mg/l APHA 8081 B Gas chromatography Absent Absent Absent Absent

35 E-coli(Nos/100 ml) Absent NR IS 13428: 2005 Microbial count Nil Nil Nil Nil

36 Coli form Organisms Absent NR MPN/ 100 ml

IS 14543: 2004 Microbial count Absent Absent Absent Absent

61

Table 4.15-11: Surface Water Sampling Results

Project Name: Mahalakshmi Profiles Pvt. Ltd. Season : Winter - 2019

S.No Parameter Units IS:2296

Class C Limits

METHOD OF

ANALYSIS

Instrument Used Project site

SW1

Banda

Mailaram

SW-2

Baswapur

SW-3

Ravalkole

SW-4

1 Ph - 6.5 – 8.5 IS:3025(Part 11) pH meter 7.96 7.46 7.68 7.26

2 Color Hazen units 300 IS:3025(Part 4) 04 06 04 02

3 Conductivity S/cm $ IS:3025(Part 4) 326 216 462 408

4 Dissolved Oxygen mg/l 4 min IS:3025(Part 38) Titrimetric method 3.80 3.60 3.10 3.10

5 BOD ( 3 days at 27oC) mg/l 3 IS:3025(Part 44) BOD Incubator,

Titrimetric method

02 02 01 02

6 Total Dissolved Solids mg/l 1500 IS:3025(Part 16) Gravimetric method 208 134 292 256

7 Total Hardness mg/l $ IS:3025(Part 21) Titrimetric method 104 88 168 160

8 Chloride as Cl mg/l 600 IS:3025(Part 32 ) Titrimetric method 21 146 43 21

9 Fluorides as F- mg/l 1.5 IS:3025(Part 60) Spectrophotometer 0.3 0.2 0.30 0.30

10 Sulphate as SO4 mg/l 400 IS:3025(Part 24 ) Spectrophotometer 27 22 26 64

11 Alkalinity mg/l $ IS:3025(Part 23) Titrimetric method 140 60 140 100

12 Nitrates as NO3 mg/l $ IS:3025(Part 34 ) Spectrophotometer 03 03 02 04

13 Cyanide as CN mg/l 0.05 IS:3025(Part 27) Spectrophotometer <0.02 <0.02 <0.02 <0.02

14 Calcium as Ca mg/l $ IS:3025(Part 40) Titrimetric method 26 19 42 51

15 Magnesium as Mg mg/l $ IS:3025(Part 46) Titrimetric method 09 10 15 07

16 Sodium as Na mg/l $ IS:3025(Part 45) Flame photometer 25 06 27 18

17 Potassium as K mg/l $ IS:3025(Part 45) Flame photometer 01 02 01 02

18 Iron as Fe mg/l 50 IS:3025(Part 53) AAS 0.24 0.26 0.24 0.0.12

19 Chromium as Cr mg/l 0.05 IS:3025(Part 41) AAS < 0.001 < 0.001 < 0.001 < 0.001

20 Cadmium as Cd mg/l 0.01 IS:3025(Part 47) AAS < 0.001 < 0.001 < 0.001 < 0.001

21 Lead as Pb mg/l 0.1 IS:3025(Part 47) AAS < 0.04 < 0.04 < 0.04 < 0.04

22 Copper as Cu mg/l 1.5 IS:3025(Part 42) AAS < 0.01 < 0.01 < 0.01 < 0.01

23 Arsenic as as AS mg/l 0.2 IS:3025(Part 37) AAS < 0.001 < 0.001 < 0.001 < 0.001

24 Selenium as Se mg/l 0.05 IS:3025(Part 56) AAS < 0.01 < 0.01 < 0.01 < 0.01

25 Phenolics as C6H5Oh mg/l 0.005 IS:3025(Part 43) Spectrophotometer < 0.001 < 0.001 < 0.001 < 0.001

26 Zinc as Zn mg/l 15 IS:3025(Part 49) AAS 02 01 02 02

27 Mercury as Hg mg/l $ IS:3025(Part 48) Mercury ion

analyzer

<0.001 <0.001 <0.001 <0.001

28 Aluminum as Al mg/l $ IS:3025(Part 55) AAS <0.005 <0.005 <0.005 <0.005

29 Anionic detergents as mbas mg/l 1 APHA 5540-C MBAS Kit <0.1 <0.1 <0.1 <0.1

30 Oil and grease mg/l 0.1 IS:3025(Part 39) Gravimetric < 1.0 < 1.0 < 1.0 < 1.0

31 Sodium Absorption Ratio - - APHA 3000 ICP AAS 1.30 0.39 0.86 0.22

32 Insecticides mg/l Absent Gas

chromatography

Absent Absent Absent Absent

33 Coli form Organisms MPN/

100 ml

Should not exceed

5000

IS 14543: 2004 Microbial count

method

308 248 228 212

62


S.No Parameter Units IS:2296

Class C Limits

METHOD OF

ANALYSIS

Instrument Used Medchal

SW-5

Nuthankal

SW-6

Skindlapur

SW-7

Koochavaram

SW-8

1 Ph - 6.5 – 8.5 IS:3025(Part 11) pH meter 7.98 7.18 7.86 6.68

2 Color Hazen units 300 IS:3025(Part 4) 02 02 03 02

3 Conductivity S/cm $ IS:3025(Part 4) 362 264 288 228

4 Dissolved Oxygen mg/l 4 min IS:3025(Part 38) Titrimetric method 3.20 3.20 3.70 3.00

5 BOD ( 3 days at 27oC) mg/l 3 IS:3025(Part 44) BOD Incubator,

Titrimetric method

02 02 02 02

6 Total Dissolved Solids mg/l 1500 IS:3025(Part 16) Gravimetric method 228 168 178 146

7 Total Hardness mg/l $ IS:3025(Part 21) Titrimetric method 128 80 96 88

8 Chloride as Cl mg/l 600 IS:3025(Part 32 ) Titrimetric method 29 35 14 21

9 Fluorides as F- mg/l 1.5 IS:3025(Part 60) Spectrophotometer 0.3 0.30 0.20 0.20

10 Sulphate as SO4 mg/l 400 IS:3025(Part 24 ) Spectrophotometer 15 16 28 18

11 Alkalinity mg/l $ IS:3025(Part 23) Titrimetric method 120 60 80 80

12 Nitrates as NO3 mg/l $ IS:3025(Part 34 ) Spectrophotometer 03 03 03 03

13 Cyanides as CN mg/l 0.05 IS:3025(Part 27) Spectrophotometer <0.02 <0.02 <0.02 <0.02

14 Calcium as Ca mg/l $ IS:3025(Part 40) Titrimetric method 35 22 29 22

15 Magnesium as Mg mg/l $ IS:3025(Part 46) Titrimetric method 10 06 06 07

16 Sodium as Na mg/l $ IS:3025(Part 45) Flame photometer 22 22 20 10

17 Potassium as K mg/l $ IS:3025(Part 45) Flame photometer 01 01 01 01

18 Iron as Fe mg/l 50 IS:3025(Part 53) AAS 0.24 0.10 0.20 0.22

19 Chromium as Cr mg/l 0.05 IS:3025(Part 41) AAS < 0.001 < 0.001 < 0.001 < 0.001

20 Cadmium as Cd mg/l 0.01 IS:3025(Part 47) AAS < 0.001 < 0.001 < 0.001 < 0.001

21 Lead as Pb mg/l 0.1 IS:3025(Part 47) AAS < 0.04 < 0.04 < 0.04 < 0.04

22 Copper as Cu mg/l 1.5 IS:3025(Part 42) AAS < 0.01 < 0.01 < 0.01 < 0.01

23 Arsenic as as AS mg/l 0.2 IS:3025(Part 37) AAS < 0.001 < 0.001 < 0.001 < 0.001

24 Selenium as Se mg/l 0.05 IS:3025(Part 56) AAS < 0.01 < 0.01 < 0.01 < 0.01

25 Phenolics as C6H5Oh mg/l 0.005 IS:3025(Part 43) Spectrophotometer < 0.001 < 0.001 < 0.001 < 0.001

26 Zinc as Zn mg/l 15 IS:3025(Part 49) AAS 02 01 01 03

27 Mercury as Hg mg/l $ IS:3025(Part 48) Mercury ion analyzer <0.001 <0.001 <0.001 <0.001

28 Aluminum as Al mg/l $ IS:3025(Part 55) AAS <0.005 <0.005 <0.005 <0.005

29 Anionic detergents as mbas mg/l 1 APHA 5540-C MBAS Kit <0.1 <0.1 <0.1 <0.1

30 Oil and grease mg/l 0.1 IS:3025(Part 39) Gravimetric < 1.0 < 1.0 < 1.0 < 1.0

31 Sodium Absorption Ratio - - APHA 3000 ICP AAS 0.86 1.36 0.96 0.61

32 Insecticides mg/l Absent Gas chromatography Absent Absent 148 Absent

33 Coli form Organisms MPN/100 ml >5000 IS 14543: 2004 Microbial count method 214 224 212 248

63

Table 4.15-12: Soil Analysis


S.

No.

Parameter Instrument Analysis Method of Analysis Project site

S-1

Banda

Mailaram

S-2

Baswapur

S-3

Ravalkole

S-4

1 Texture - Texture Analysis Chart Sandy

Clay

Sandy Clay Clay Silty

Clay

Sand (%) - 36 32 26 18

Silt (%) - 16 18 22 48

Clay (%) - 48 50 54 34

2 pH Ph meter - 7.21 7.45 7.41 7.63

3 EC (us/cm) Conductivity Meter - 216 252 198 212

4 Bulk Density (g/cc) Colorimeter - 1.06 1.12 1.24 1.40

5 Available Nitrogen

(kg/ha)

Colorimeter - 186 212 246 282

6 Available P as PO4

(kg/ha)

Titrimetric method Sodium bicarbonate

method

28 34 48 64

7 Available K (kg/ha) Flame photometer method - 104 108 134 128

8 Exchangeable Ca

(meq/100gr)

Flame photometer method - 3.00 2.90 3.60 3.20

9 Exchangeable Mg

(meq/100gr)


10 Exchangeable Na

(meq/100gr)


11 Organic Carbon (%) Titrimetric method Walkley-Black method 0.24 0.30 0.40 0.40

12 Manganese (meq/100gr) Flame photometer method - 0.05 0.03 0.06 0.03

13 Zinc (meq/100gr) AAS - 2.90 3.40 4.10 4.40

14 Boron (meq/100gr) AAS - 0.04 0.03 0.04 0.02

64


S. No. Parameter Instrument

Analysis

Method of Analysis Medchal

S-5

Nuthankal

S-6

Skindlapur

S-7

Koochavara

m

S-8

1 Texture - Texture Analysis

Chart

Silty Clay Clay Sandy Clay Silty

Clay

Sand (%) - 16 18 32 16

Silt (%) - 34 28 24 38

Clay (%) - 50 54 44 46

2 pH Ph meter 7.72 7.19 7.86 7.16

3 EC (us/cm) Conductivity Meter 257 218 242 198

4 Bulk Density (g/cc) colorimeter 1.32 1.40 1.09 1.50

5 Available Nitrogen (kg/ha) colorimeter 256 268 192 274

6 Available P as PO4 (kg/ha) Titrimetric method Sodium bicarbonate

method

58 54 32 52

7 Available K (kg/ha) Flame photometer

method

- 156 132 124 136

8 Exchangeable Ca

(meq/100gr)

Flame photometer

method

- 3.60 3.20 3.40 3.20

9 Exchangeable Mg

(meq/100gr)

Flame photometer

method

- 1.30 1.40 1.38 0.90

10 Exchangeable Na

(meq/100gr)

Flame photometer

method

- 3.90 4.20 3.00 3.60

11 Organic Carbon (%) Titrimetric method Walkley-Black

method

0.30 0.30 0.30 0.60

12 Manganese (meq/100gr) Flame photometer

method

0.03 0.02 0.04 0.01

13 Zinc (meq/100gr) AAS 4.60 4.40 4.10 4.00

14 Boron (meq/100gr) AAS 0.03 0.02 0.03 0.04

65

4.16 Flora and Fauna

4.16.1 Forest

The period of monsoon is very short lived in this area, which has a significant bearing apart from

other biotic pressures, on the floristic composition of the forests. These are open forests in which

thorny and usually hard wood species predominate.

It is been found that the field area is inhabited by various types of plants belonging to families

like Leguminosae (104), Poaceae (83), Cyperaceae (49), Asteraceae (37), Euphorbiaceae (31),

Acanthaceae (22), Rubiaceae (20), Lamiaceae (18), Convolvulaceae (17) and Amaranthaceae

(15).

4.16.1.1 Flora

The study area does not habitat any thick vegetal cover. There is usually a thin grass growth

which December appear during the short rainy season in most of the study area, but more or less

the soil is barren and devoid of any grass growth.

Table 4.16.1-13: List of Flora

Name Family Common Name

Acacia Auriculiformis Mimoseae Cutch Tree

Carissa Spinarum Apocynaceae Karaunda

Cassia Pumila Caesal pinaceae Yellow Cassia

Cassia Renigera Caesal pinaceae Pink Cassia

Dendrocalamus Strictus Poaceae Solid Bamboo

Emblica Officinalis Euphorbiaceae Gooseberry

Ficus Gibbosa Moraceae Tella Barinika

Ficus Hispida Moraceae Kala Umbar

Heterophragma Roxburghii Bignoniaceae Barukoligottu

Mangifera Indica Anacardiaceae Mango Tree

Pinus Roxburghii Pinaceae Chilgoza

Prosopis Cineraria Mimos Eae Khejri

Psidium Guayava Myrtaceae Guava Tree

4.16.1.2 Fauna

Some of the animals which you would find here are Tigers, Panthers, Jackals, Indian Giant

Squirrel, Mouse Deer, Spotted Deer, Sambhar Deer, Black Bucks, Wild Boar, Tree Shrew,

Mugger Crocodiles, Wolves, Wild dogs, Foxes, and Sloth Bear. No endangered fauna species are

found in the area.

66

Table 4.16.1-14: List of Fauna

Scientific Name Common Name

Ananthana ellioti Tree shrew

Ratufa indica Indian Giant Squirrel

Mus dunni Mouse

Sus scrofa cristatus Indian Wild Boar

Axis axis Spotted Deer/ Chital

Cervus unicolor Samber

Pavo cristatus Peacock

Panthera pardus fusca Leopard

Ursus thibetanus Bears

Canis aureus Golden Jackal

Vulpus vulpus Fox

Columba livia wild pigeons

Corvus splendens Kaola

Anas crecca Teal

Gallinago gallinago snipe

Antilope cervicapra Blackbuck

Crocodylus palustris Mugger Crocodiles

4.17 Socio Economic Environment

Socio-economic environment includes description of demography, available basic amenities like

housing, health care services, transportation, education and cultural activities. Information on the

above said factor has been collected to define the socio-economic profile of the study area (10

km radius), which is also a part of Environmental Impact Assessment study for the proposed

project.

A detailed socio-economic survey was conducted covering all tehsils in the 10 km radius from

the center. The information on socio-economic aspects has been compiled from various

secondary sources including various government and semi-government offices.

Basic Socio-economic conditions are as follows:

There are 55 villages and many hamlets in the study area.

As per the 2011 census data, the population in the study area is 58,498.

Density of population is 164.12 persons per Sq km.

Literacy status of the area is found to be moderate with a total of 62 % of the

population. Male and Female literacy is about 72 % and 52% respectively.

67

Occupational status in the study area is in agriculture. 50 % of total population of

the study area falls under main workers category.

Agricultural activities are mainly in monsoon season. Major crops in the area are

Jowar, Maize, groundnut, Ragi, Onion, Vegetables etc

Medical facilities are inadequate, only few villages have the primary health care

centers. For any major health care, the populace of the area has to go to

Shadnagar, which is a major town located at a distance of about 13.0 Km from

the proposed site.

Educational facilities are adequate. Higher educational center is Shadnagar at a

distance of 13.0 km.

This region is well connected by road.

Many villages are adequately provided with protected water supply

68

5 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION

MEASURES

5.1 Introduction

Impact prediction is a very important phenomenon in evaluating the environmentally potential

adverse impacts for any proposed industrial project. The impact prediction is always carried out

under worst possible conditions so as to mitigate or to eliminate the environmental hazards.

These predictions thus calculated are superimposed over the baseline data to calculate the net

impact on the environment after the proposed project comes into production.

5.2 Air Environment

It is possible that increase in the background concentration of even a minor constituent of the

atmosphere may lead to significant changes in the atmospheric properties. So these changes are

essential in understanding potential climatic changes due to air pollutants. For example under

strongly stable condition, disturbances are highly damped and mixing of pollutants is strongly

suppressed. It is under such conditions that the worst air pollution episodes have occurred.

Prediction of impacts is the most important component in the environmental impact assessment

studies. Several scientific techniques and methodologies are available to predict impacts of

developmental activities on physico, ecological and socioeconomic environments. Such

predictions are superimposed over the baseline (pre project) status of environmental quality to

derive the ultimate (post project) scenario of environmental conditions. The prediction of

impacts helps to identify the environmental management plan required to be executed during and

after commissioning the proposed project to minimize the adverse impacts on environmental

quality.

The mathematical models are the best tools to quantitatively describe cause-effect relationships

between sources of pollution and different components of environment. In case, mathematical

models are not available or it is not possible to identify / validate through models for particular

situation, prediction could be arrived at through available scientific knowledge and judgments.

5.3 Impact on Topography and Climate

5.4 Impact on Topography

The major envisaged topographical changes would be limited to the immediate vicinity of the

plant. The change in topography will be only due to manmade structures like industrial complex

and administrative building. Similarly, it will invite positive benefits in the form of land leveling

and green belt development in the plant vicinity.

69

5.5 Impacts on Climate

As the temperature of effluent gases will not be high, generally this will not cause any thermal

imbalance as extensive greenbelt will be developed within the plant premises. However, there

will be natural dispersion of heat due to unstable conditions during day and as such there would

be no significant micro / macro climatological changes of any consequence.

5.6 Air Quality Impact Prediction

Different types of mathematical models are available for short term prediction of Ground Level

Concentrations (GLC's) of air pollutants. These models deal with different types of atmospheric

dispersion computations, air pollution sources, topographic features and comprehend to different

types of atmospheric conditions. The available mathematical models require the input of stack

characteristics such as diameter, height, source strength, meteorological data and computer

resources to handle the available inputs. Keeping the mentioned facts in view, one has to identify

a proper and suitable model applicable to the characteristics of source and prevailing topographic

conditions to enable GLC to be known at any location under a variety of factoral changes. The

area around the plant is generally flat.

The stacks will be situated very near to each other. Therefore, these stacks are identified as

elevated continuous point sources. The modeling is based on hourly meteorological data

collected at the plant site. Twenty hour average incremental GLCs have been predicted for the

proposed plant for multi stack dispersion modeling using double Gaussian diffusion equation.

Prediction of impacts on air environment has been carried out employing mathematical model

based on a steady state Gaussian plume dispersion model designed for multiple point sources for

short term. In the present case, Industrial Source Complex [ISCST-3] dispersion model based on

steady state Gaussian plume dispersion, designed for multiple point sources for short term and

developed by United States Environmental Protection Agency [USEPA] has been used for

simulations from point sources.

AERMOD is a regulatory steady-state plume modeling system with three separate components:

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

AERMET (AERMOD Meteorological Preprocessor). The AERMOD model includes a wide

range of options for modeling air quality impacts of pollution sources, making it a popular choice

among the modeling community for a variety of applications. AERMOD contains basically the

same options as the ISCST3 model.

70

5.7 Model Input Data

For the modeling purpose, all pollutants as described above are considered. The details of stack

emissions envisaged from the project are given in Table 5-1.

Table 5-1: Details of Emissions

Proposed

Parameters 2*12 TPH 320 KVA

Emissions

PM2.5 µg/m3 0.01 0.0086

PM10 µg/m3 0.021 0.0144

SO2 µg/m3 0.1 0.0062

NO2 µg/m3 0.3 0.132

CO µg/m3 0.0009 0.0000561

Stack Particulars

Exit Temp (K) 376 383

Exit vel- m/s 15 15

Dia (m) 1.5 0.2

Stack height (m) 30 9

Major pollutant of the source would be PM10, PM2.5, SO2 and NOx. For the transportation to and

from the plant, Fugitive Dust Model (FDM) has been used, which is a computerized air quality

model specifically designed for computing concentration and deposition impacts from fugitive

dust sources. The sources may be point, line or area sources. The model has not been designed to

compute the impacts of buoyant point sources, thus it contains no plume rise algorithm. The

model is generally based on the well-known Gaussian Plume formulation for computing

concentrations, but the model had been specifically adapted to incorporate an improved gradient

transfer deposition algorithm. Emissions for each source are apportioned by the user into a series

of particle size classes. A gravitational settling velocity and a deposition velocity are calculated

by FDM for each class. Concentration and deposition are computed at all user selectable receptor

location.

24 hours average incremental GLCs are summarized in Table 5.2 .The dispersion modeling is

carried out for the existing and expansion of the plant.

Meteorological Data

The hourly meteorological data recorded at site is converted to the mean hourly meteorological

data as specified by CPCB and the same has been used in the model. The meteorological data of

summer season is used for modelling.

71

5.8 Ground Level Concentration

In the present case, model simulations have been carried out for the study period. The Ground

level concentrations are computed for 24-hr average. Maximum Incremental Ground level

concentrations of PM10 is 0.8 μg/m3, PM2.5 is 0.1 μg/m3, SO2 is 0.6 μg/m3, NOx is 8.00 μg/m3

and CO is ).005 μg/m3 were falling within a distance of 200 m from the point source. The

obtained GLC’s are well within the stipulated CPCB standards. Figure 5.1 to 5.9 shows the

isopleths of different pollutants

The maximum GLCs for PM10, PM2.5, SO2 NOx and CO after the Installation of the proposed

project are well within the prescribed limit of 60g/m3 ,100 g/m3 , 80 g/m3 and 80 g/m3 and

4000g/m3 respectively for residential and rural zone. Based on the predicted concentrations it can

be inferred that area is unlikely to be significantly affected due to the proposed project.

Table 5-1: Isopleths of Maximum Total Concentration

Pollutant Maximum AAQ

Concentrations

Recorded During the

Study (g/m3)

Incremental

Concentration due to

proposed expansion

(g/m3)

Resultant

Concentration

(g/m3)

PM10 38.2 0.8 39.0

PM2.5 18.49 0.1 18.5

SO2 17.17 0.6 17.77

NOx 21.38 8.0 29.38

CO BDL 0.005 0.005

5-1: Isopleths of PM 2.5 Incremental Values

72

5-2: Isopleths of PM 2.5 Ambient Value

5-3: Isopleths of PM 10 Incremental Values

73

5-4: Isopleths of PM 10 Ambient Value

5-5: Isopleths of SO2 Incremental Values

74

5-6: Isopleths of SO2 Ambient Value

5-7: Isopleths of NOx Incremental Values

75

5-8: Isopleths of NOx Ambient Value

5-9: Isopleths of CO Incremental Value

76

5-10: Isopleths of CO Ambient Value

77

6 ANALYSIS OF ALTERNATIVES (SITE AND TECHNOLOGY)

6.1 General

This chapter summarizes the alternatives that were explored during development of the Project.

The range of alternatives considered included those that would reasonably accomplish the basic

Project objectives while avoiding or lessening any potentially significant, negative impacts of the

proposed Project. These include considerations of the project location, overall size, and choice of

machinery, access road locations, and use of alternative generating technologies.

It is very important to select technology and site for project setup because the /technology and

site selection factors play very decisive role for the industry future.

The Proposed project is an expansion of existing M.S. Ingots and Billets manufacturing unit

situated on Survey. No. 287, 288 & 289 in Kallakal village, Manoharabad Mandal, Medak

District in Telangana state. Thus, alternative of site is not applicable on this project as the

expansion is coming up on existing plant area. No additional land is required for expansion. The

unit is proposing additional induction furnaces for the proposed expansion capacity.

6.2 Analysis of Alternative Site

As mentioned above the proposed expansion is coming up in existing plot area and no additional

land is required for expansion thus, analysis of alternative site is not required for this particular

project. The existing plant is located in notified industrial area, Manoharabad Mandal. Thus, all

the basic amenities are within the reach of the unit.

6.3 Analysis of Alternate Technology

The unit is proposing to install one additional induction furnace of 12T capacity and wet

scrubber and bag filters as pollution control equipment. The proposed induction furnace is a core

less induction furnace which is one of the best available technologies.

6.4 Induction Furnace

The advantages of induction furnace are given below:

Optimized Consistency

78

Induction heating eliminates the inconsistencies and quality issues associated with open

flame, torch heating and other methods.

The heating pattern is repeatable and consistent

With modern solid state systems, precise temperature control provides uniform results; power

can be instantly turned on or shut off

With closed loop temperature control, advanced induction heating systems have the

capability to measure the temperature of each individual part

Specific ramp up, hold and ramp down rates can be established & data can be recorded for

each part that is run

Maximized Productivity

Heat is developed directly and instantly (>2000º F. in < 1 second) inside the part

No warm up or cool down cycle is required

Extended Fixture Life

Induction heating rapidly delivers site-specific heat to very small areas of part, without

heating any surrounding parts. This extends the life of the fixtures and mechanical setup

Environment Friendly

Induction is a clean, non-polluting process which will help to protect the environment. It

doesn’t require any fossil fuel

An induction system improves working conditions for employees by eliminating smoke,

waste heat, noxious emissions and loud noise

Heating is safe and efficient with no open flame to endanger the operator or obscure the

process

Non-conductive materials are not affected and can be located in close proximity to the

heating zone without damage

Reduced Energy Consumption

This uniquely energy-efficient process converts up to 90% of the energy expended energy

into useful heat; batch furnaces are generally only 45% energy-efficient.

And since induction requires no warm-up or cool-down cycle, stand-by heat losses are

reduced to a bare minimum.

The repeatability and consistency of the induction process make it highly compatible with

energy-efficient automated systems.

79

6.5 Reheating Furnace

No reheating furnace is being used in the system as the Ingot received from the CCM is directly

taken for rolling mill. The system is saving the energy without using the reheating furnace.

Figure 6-1: Venturi Scrubber

80

Figure 6-2: Layout of Pollution Control Equipment for Induction furnace and Rolling mill

7 ENVIRONMENTAL MONITORING PROGRAM

7.0 General

Monitoring is one of the most important components of a management system. The regular

monitoring of environmental parameters is of immense importance to assess the status of

environment during project operations. With the knowledge of baseline conditions, the monitoring

program will serve as an indicator for any deterioration in environmental conditions due to

operation of the project, to enable taking up suitable mitigation steps in time to safeguard the

environment. Monitoring is as important as that of control of pollution since the efficiency of

control measures can only be determined by monitoring.

7.1 Objectives of Monitoring

The objectives of the monitoring plan are as follows:

Verify effectiveness of planning decisions

To check and assess the efficacy of pollution control equipment

Measure effectiveness of operational procedures

Confirm statutory and corporate compliance

Identify unexpected changes

7.2 Environmental Monitoring

Environmental monitoring during operational phase will be carried out through outsource laboratory

(NABL/MOEF/TSPCB approved). Environmental monitoring schedules are prepared covering

various phases of project advancement, such as regular operational phase.

81

7.1 Monitoring Schedule during Operational Phase

During operational stage, following activities will be undertaken:

Ambient air quality

Ground water quality

Water and wastewater quality

Soil quality

Noise quality

The following routine monitoring program as detailed will be implemented at site. Besides to

this monitoring, the compliances to all environmental clearance conditions and regular permits

from TSPCB/MoEF&CC will be monitored and reported periodically.

Table 7-1: Environmental Monitoring during Operational Phase

S.

No

Potential

impact

Action to be

followed

Parameters for

monitoring

Frequency of

monitoring Location

1 Air emissions

Ambient air quality

within the premises of

the proposed unit and

nearby habitations to

be monitored

PM10, PM 2.5,

SO2, NOx and

CO

As per CPCB/

TSPCB

requirement or

on weekly basis

whichever is

earlier

At least two

locations

inside

premises, three

locations

outside.

Exhaust from vehicles

to be minimized by use

of fuel efficient

vehicles and well

maintained vehicles

having PUC certificate.

Vehicle logs to be

maintained -

-

Measuring onsite data

of Meteorology

Wind speed,

direction,

temperature,

relative humidity

and rainfall

Continuous

monitoring

using on-line

weather station

during

operation phase

Onsite at one

location

Vehicle trips to be

minimized to the

extent possible

Vehicle logs Daily records Main gate

2 Noise

Noise generated from

various plant

operations, vehicles to

be optimized and

monitored

Spot Noise Level

recording

Leq (night)

Leq (day)

Periodic

during

operation phase

Noise

measurement

at four

locations

Generation of Maintain records Periodic during

82

S.

No

Potential

impact

Action to be

followed

Parameters for

monitoring

Frequency of

monitoring Location

vehicular noise of vehicles operation phase

3 Waste water

discharge

No untreated discharge

to be made to surface

water, ground water or

soil.

No discharge

hoses in vicinity

of watercourses

Periodic during

operation phase

Take care in disposal

of wastewater

generated such that soil

and groundwater

resources are protected

Discharge norms

for effluents will

be maintained

Periodic during

operation phase

Compliance of treated

waste water usage/

discharge to standards

pH, TSS, TDS,

BOD, COD &

temperature

Periodic during

operation phase

One location

(treated waste

water)

4 Drainage and

effluent

management

Ensure drainage

system and specific

design measures are

working effectively.

Design to incorporate

existing drainage

pattern and avoid

disturbing the same

Visual inspection

of drainage and

records thereof

Periodic during

operation phase -

5 Water quality

and water levels

Monitoring used water

quality & ground water

quality and levels

Comprehensive

monitoring as per

IS:10500

Groundwater

level bgl

Periodic during

operation phase

Three

locations

surrounding

industry site

6 Energy usage

Energy usage for air

conditioning and other

activities to be

minimized.

Conduct annual

energy audit for the

buildings

Energy audit

report

Annual audits

and periodic

checks during

operational

phase

-

7

Emergency

preparedness,

such as fire

fighting

Fire protection and

safety measures to take

care of fire and

explosion hazards, to

be assessed and steps

taken for their

prevention

Mock drill

records, on site

emergency plan

evacuation plan

Periodic during

operation phase -

8 Maintenance of

flora and fauna

Vegetation, greenbelt/

green cover

development

No plants, species Periodic during

operation phase -

9 Waste

Management

Implement waste

management plan that

identified and

characterizes every

waste arising

associated with

Records of solid

waste generation,

treatment and

disposal

Periodic during

operation phase -

83

S.

No

Potential

impact

Action to be

followed

Parameters for

monitoring

Frequency of

monitoring Location

proposed activities and

which identifies the

procedures for

collection, handling &

disposal of each waste

arising

10 Soil quality Maintenance of good

soil quality

Physico-

chemical

parameters and

metals

Periodical

Monitoring

Plantation

areas

11 Health

Employees and

migrant labour health

checkups

All relevant

parameters

including HIV

Regular

checkups

7.3 Generation of Baseline Data

The detailed study carried out for ascertaining the baseline scenario within the project area for

different environmental components as follows:

Micro Meteorology: Weather monitoring station was used to monitor wind speed, wind

direction, temperature and relative humidity on hourly basis.

Ambient Air Quality: For assessing ambient air quality, monitoring was done within the

project site.

Water Analysis: Water sample from site was collected and analyzed as per drinking water

standards for different parameters to ascertain water quality.

Soil Analysis: Sample was collected and analyzed from the project area to estimate the soil

quality and its nature.

Noise: An integrated sound level meter was used to monitor noise levels on basis within the

project area.

Biological: The detailed flora and fauna study has been conducted to ascertain the different

species available within the study area.

Demography: Status of demography and socio-economic features within 10 km radius of

project site has been collected from the secondary sources.

7.4 Proposed Schedule of Environmental Monitoring

84

Monitoring is one of the most important components of a management system. Continuous

monitoring needs to be carried out for regulatory requirements, environmental effects and

performance of EMP implementation. Environmental monitoring program is a vital process of

any management plan of the development project. This helps in assessing the potential problems

that resulting from the proposed project, changes in environmental conditions and effectiveness

of implemented mitigation measures.

Table 7-2: Time Schedule for Post Project Environment Monitoring

S.

No

Area of

Monitoring

Sampling

Locations

Parameters to be

Analyzed

Frequency

of sampling

Air pollution monitoring

1 Stack Emission Each utility stack As per consent of

TPCB/CPCB Once in six month

2 Ambient Air Quality As per consent of

TPCB/CPCB Once in six month

3 Work zone

Environment All plant PM, SO2, NOx, CO. Once in six month

Water Pollution Monitoring

4 Ground and surface

water

Two sampling

locations

pH, TSS, COD, BOD,

TDS, Chloride, Sulphate

etc.

Once in Six month

Soil Pollution Monitoring

5 Soil Four sampling

locations of

Impact Area

As per consent of RPCB Once in Six month

Noise Pollution Monitoring

6 Noise

Noise generating

units

Sound Pressure Levels

(Leq) Once in Six month

Five sampling

locations

within Plant

Sound Pressure Levels

(Leq) Once in Six month

7.5 Proposed Investment for the Environment Control Measure

Total capital cost/annum for environmental pollution control measures for proposed expansion

would be Rs 75.00 Lac.

Budget for Implementation of Environmental Management Plan

S. No Component Capital cost for the

proposed expansion in

Lakhs

1 Pollution equipment for Induction Furnace 75

2 Greenbelt development 5

3 Environmental management cell 25

4 CER 112

85

Total 217 Lakhs

7.6 Staff Requirements for Post-Project Monitoring

An environment protection cell will be created at Mahalakshmi Profiles Pvt. Ltd. directly under

General Manager / Production Manager. This cell will consist of the following persons and have

the responsibility of air, water and land environmental monitoring:

Environmental Engineer: One

Chemist: One

Technician: One

86

8 ADDITIONAL STUDIES

8.1 Public Hearing

This Draft report is being submitted for conducting Public Hearing.

8.2 Risk

Managing these accidental risks in today’s environment is the concern of every industry

including steel, because either real or perceived incidents can quickly jeopardize the financial

viability of a business. Many facilities involve various manufacturing processes that have the

potential for accidents which may be catastrophic to the plant, work force, environment, or

public. Risk analysis involves the identification and assessment of risks; the neighboring

populations are exposed to as a result of hazards present in the plant operation. This requires a

thorough knowledge of failure probability, credible accident scenario, vulnerability of

populations etc. The risk analysis is often confined to maximum credible accident studies.

The main objectives of the Risk Assessment Studies are as given below:

To identify the source of hazards in the unit.

Assessment of risk on basis of different tools available.

To safeguard employees and people in vicinity.

To minimize damage to property and environment.

To inform the employees, the general public and the authority about the hazards / risk

assessed, safeguards provided, residual risk if any and the role to be played in them in

the event of emergency.

To inform authorities and mutual aid centers to come for help.

To affect rescue and treatment of casualties.

To secure the safe rehabilitation of affected areas and to restore normalcy.

8.3 Risk Assessment & an Approach to Emergency Preparedness Plan

Risk assessment study includes study of nature of hazards due to the proposed expansion of the

M.S. Ingots/Billets manufacturing unit including operations activities and machinery handling.

The study includes:

Preliminary identification of hazardous area.

Identification of cause of accident.

Analysis of maximum accidental scenarios.

87

Study of characteristics of risk levels.

Evaluation of damage criteria.

Hazard identification provides information on hazardous substances, their nature, quantities and

details of storage.

Preliminary hazard identification is used to identify typical and often relatively apparent risk

sources and damage events in a system.

8.4 Identification of Hazards

8.5 Major Hazards

Hazard is the associated term with material, which is a measure or the likely hood of the damage

to human working with, or studying the material in question.

All the probable potential hazardous is classified under different heads.

Fire Hazards: Since the Stone Age term 'fire' is associated with fear. It is very dangerous if

occurs in uncontrolled manner. When a liquid is used having flash point below the normal

ambient temperature, it could, in suitable circumstances, liberate a sufficient quantity of

vapour to give rise to flammable mixtures with air.

Toxic Gas Release Hazards: Toxic substances affect in three ways by ingestion, absorption

& inhalation

Explosion Hazards: Release of energy in a rapid and uncontrolled manner gives rise to

explosion

Corrosion Hazards: Corrosion is a chemical reaction-taking place at the surface of metal

M/s Mahalakshmi Profiles Pvt. Ltd. is M.S. Ingot/Billet manufacturing unit. Thus, it possess

fire, explosive hazards because it deal with molten metal of high temperature.

The lists of source of fire and explosive hazards are given below:

Induction furnace with CCM

Ladle furnace

Rolling mill.

88

In all the above furnaces the temperature is too high and continuous cooling is required but if the

cooling fails there are chances of explosion. The molten metal taken through ladle furnace to

CCM and spillage during the travel can cause burn and fire. In rolling mill the molten metal

travel through series of mills and there are chances of burn while handling the bars. Along with

this the induction furnace is electric fired thus, higher amount of power load is required which

may sometime causes risk of fire in electric wiring.

Following are the measures to prevent the hazards:

Cooling of induction furnace should be continuous and back up cooling system should

be installed in case one of the systems fails to cool.

Overhead water tank should be placed for continuous water supply.

D.G. set should be installed for power back up and prevent sudden shut of furnaces.

The worker should be provided with gloves and shoes to prevent any burn incidences.

The wiring in the industry should be fire insulated to prevent any fire incidences

Organization of an investigative team to study the accident and to record the same to

avoid repetition of such an accident in future.

Provide training to specific company personnel in first aid as well as preliminary

rescue operations.

Arrangement for medical aid centers being informed immediately in case of such an

event.

8.6 Accidents

Process Operations

The process operation may lead to serious injuries at the site.

Power failures.

Failure of utility services.

System failure

Defective communication system

Types of Accidents

In steel industries accidents may occur due to the mishandling of the materials.

In steel making process burns may occur due to the heat generation in furnace.

Improper handling of mechanical transportations within the work areas.

89

8.7 Risk Assessment

Risk will be assessed by:

To identify potential hazard areas.

To identify the chances of explosion.

Recommendations to minimize accidental possibilities.

Preparation of Disaster Management Plan (DMP)

Identifying the emergency plan.

8.8 Risk Prevention Methods

Safety And Health Measures (Safety Organization)

Safety organization is of prime importance in the steel industry, involving all persons in site

hazard assessments, behavior observation and feedback exercises can promote positive safety

attitude and focus work groups to prevent injuries and illnesses.

Accident statistics identifies danger areas and require additional protection as well as greater

stress on housekeeping. The value of different types of protective clothing will be evaluated

and the advantages can be communicated to the workers concerned.

Training

Training will include information about hazards, safe methods of work, avoidance of risks and

the use of PPE. Training and refresher courses for all levels of personnel are particularly

valuable. They will be familiarized personnel with safe working methods, unsafe acts to be

prescribed, safety rules and the chief legal provisions associated with accident prevention.

Training will be conducted by experts and will make use of effective audio-visual aids. Safety

meetings or contacts will be held regularly for all persons to reinforce safety training and

awareness.

Engineering and Administrative Measures

All dangerous parts of machinery and equipment, including lifts, conveyors, long

travel shafts and gearing on overhead cranes, will be securely guarded. Preventive

maintenance plan should be adopted.

Proper housekeeping should be followed.

90

Industrial Hygiene

Good ventilation system with proper air circulation and maintaining the cleanliness

and housekeeping.

To improve work environment, induced ventilation will be installed to supply cool air.

Pedestal fans/ blowers are provided to give the comfort of working. Heat protection

can be provided by installing heat shields between workers and radiant heat sources,

such as furnaces or hot metal, by installing water screens or air curtains in front of

furnaces or by installing heat-proof wire screens.

Acclimatization to the work environment.

Wherever possible, sources of noise will be isolated.

Personal Protective Equipment

All parts of the body are at risk in steel industries. Type of protective wear required will vary

according to the activities & location. Those working at furnaces need clothing that protects

against burns-overall of fire-resisting material, spats, boots, gloves, helmets with face

shields/goggles. Safety glasses and helmets are imperative in almost all occupations and gloves

are widely necessary.

Medical Supervision

Medical examinations are of great importance in selecting persons suitable for the iron

and steel making industries.

Medical supervision required for those exposed to heat stress; periodic chest

examinations will be provided for those exposed to dust, and audiometric

examinations for those exposed to noise; mobile equipment operators will also receive

periodic medical examinations to ensure their continued fitness for the job.

8.9 Disaster Management Plan Including Risk Assessment and Damage Control

Rapid development has proposed wide-ranging hazards threatening safety and health of people.

Accidents may adversely affect the environment and the people living in the vicinity. These

accidents can be minimized to a great extent by proper procedures, handling and training.

8.10 On-Site Emergency Plan

The emergency is caused by an accident that takes place in a hazardous installation and the

effects are confined to the factory premises involving the people working in the factory. On-site

91

emergency plan is dealing with eventualities and it is the responsibility of the occupier, to

prepare/ implement necessary measures to contain the severity of cause of disaster to the bare

minimum. Furnishing of relevant information to the district administration authority for the

preparation of the off-site emergency plan is statutory responsibilities of the occupier of every

industry and other units.

8.11 Objectives

Maximize the resource utilization and combined efforts towards emergency operations. It

broadly covers the following:

Safety of the personal located in the premises.

To minimize the effects of accidents on people, property and environment.

To take remedial measures within time.

To utilize the internal resources in the most effective way.

To minimize the damage.

To keep the required emergency equipment at designated places.

To keep the concerned personnel fully trained for the use of emergency equipment.

To mobilize effected persons.

8.12 Basic Contents of Disaster Management Plan (DMP)

An emergency is said to have arisen when operators in the plant are not able to cope up with a

potential hazardous situation i.e. loss of control of an incident causes the plant to go beyond its

normal operating conditions, thus creating danger. When such an emergency evolves, chain of

events affect the normal working within the factory area and / or which may cause injuries, loss

of life, substantial damage to property and environment both inside and outside the factory and a

DISASTER is said to have occurred.

The various steps involved in the process of Disaster Management can be summarized as:

Minimize Risk Occurrence (Prevention)

Rapid Control (Emergency Response)

Effectively Rehabilitate Damaged Areas (Restoration)

Basically, the Disaster Management Plan (DMP) contains the following aspects:

Location of the site.

Brief Description of Unit.

Details of major potential hazards.

92

Identification of specific type of disasters.

Action plan – specific responsibilities.

Declaration of emergency with emergency action plan.

Evacuation and assembly points.

Evaluation of implementation system.

8.13 Purpose & Scope

The principal aim of DMP of steel unit is prevention of identified major hazards. It is totally

committed to “Total Quality Assurance” from conception stage to enable its objective of

prevention. The control strategy adopted could be reducing potential by way of minimizing the

handling of such materials manually by individuals both in process and storage within the

purview of continuous operation.

The adopted control measure could be well structured and well-rehearsed. On site plan which

could intercept any such occurrence with speed and rectify by ensuring safety of worker,

equipment, public and ultimately the environment as a matter of priority. General details like

location, project layout, neighboring entities and the assistance they can render etc are as

follows.

The important elements considered in this plan are:

Statutory requirements.

Roles and Responsibilities.

Communications during emergency.

Emergency shutdown & control of situation.

Rescue & rehabilitation.

Emergency facilities.

Important information.

The primary purpose of the on-site emergency plan or DMP is to control and contain the incident

and to prevent it from spreading. It is not possible to cover every eventuality in the plan and the

successful handling of the emergency will depend on appropriate action and decisions being

taken on spot.

8.14 Preventive Measures & Plans

DMP specifies the actions to be taken in case of such incident, including its prevention,

corrective action so as to mitigate such occurrence by the proponent. Practice and procedure with

respect to the operational hazards, equipment failure, human safety, malfunctioning of safety

interlocks. Natural disasters relevant to unit and its different section of operation will be

93

formulated and a detailed disaster management action plan will be prepared and made available

to all concerned persons to take care of the following aspects.

To install emergency alarm for immediate information.

A suitable location inside the unit will be demarcated for assembly point.

Intercom will be provided to all departments for easy and immediate means of

communication.

At sensitive fire prone areas fire alarm and fire hydrant lines will be provided.

Workers will be trained regularly to use personal protective equipment.

Mock drill will be conducted at regular interval to evaluate the effectiveness of the

emergency preparedness plan.

First aid boxes will be made available at various sensitive points to meet the

requirement.

Personnel will be appointed and responsibilities will be assigned.

Color-coding will be followed as per the statutory requirements.

All heavy moving machines will be properly maintained and protected and valid

license will be obtained before their usage.

All applicable Indian laws, rules and regulations for which company subscribes shall

be strictly followed under a senior qualified environment and safety personal.

8.15 Emergency Management

The emergency control center will be located in an area of minimum risk. Suitable location from

where clear view of the unit is possible.

8.16 Infrastructure at Emergency Control Centre

Emergency control center contains the following:

An adequate number of external telephones.

An adequate number of internal telephones.

Areas where there are large inventories of hazardous materials.

Sources of safety and first aid equipment.

The fire-fighting system and additional sources of water.

Site entrance and roadways, including up-to-date information on road traffic.

Assembly points.

Vehicle parking.

Additional work and lay out plans detailing alternate routes and affected areas during

an emergency.

A list of key personnel, with addresses, telephone numbers, etc.

94

The emergency control center will be located in an area of minimum risk. Suitable location from

where clear view of the unit is possible.

8.17 Health and Safety Measures For The Workers

Belts etc: The fitness of the belts should be regularly checked.

Helmets: To avoid any head injury helmets to be provide.

Machinery: All machines should be operated as per operation manual.

Methods of work: Work instructions should be followed.

Electricity: Electric installation should be carried during the idle hours of working.

Medical Check-up: Regular medical Checkups shall be carried as per the annual plan.

8.18 Safety of Personnel

Adequate personal safety equipment as applicable to the work i.e, industrial safety shoes, hand

gloves, ear muffs, welder’s screen, aprons, gas masks, respirators, safety belts, goggles, etc. are

to be provided to the workers.

8.19 Emergency Action Plan for Fire

The fire proximity suits be made available at the site to fight with the fire & Adequate personal

safety equipment as possible to the work i.e. industrial safety shoes, hand gloves, ear muffs,

welder’s screen, aprons, gas masks, respirators, safety belts, goggles etc. are to be provided to

the workers.

8.20 Emergency Action Plan For Electric Shock Casualties

Rescue And First Aid

Provide first aid without delay.

Switch off the supply immediately.

Use of non-conducting material to separate the victim.

The rescuer should use the gloves or using a jacket to pull the victim.

8.21 First Information

The first person who observes/ identifies the emergencies will inform by shouting and by

telephone to the Shift- in-charge and fire station about the hazard. The shift-in-charge will

inform to the incident controller.

95

8.21.1.1 Declaration of Emergency

The Chief Incident Controller taking into account of the severity of the situation will declare

emergency.

Emergency Alarm: Emergency will be declared by Emergency alarm, which will be sounded by

fire station on receipt of orders from Shift in-charge/ Works Incident Controller.

Evacuation: In an emergency it is necessary to evacuate personnel from affected areas and as

precautionary measure to evacuate non-essential workers. In the first instance from areas likely

to be affected will be evacuated immediately. The evacuation will follow at Assembly points.

Mock Drills: It is imperative that the procedures laid in this plan are put to the test by

conduction Mock Drills. The mock drills will be carried out by the step as stated below.

First Step: Test the effectiveness of communication system.

Second Step: Test the speed of mobilization of the unit emergency teams.

Third Step: Test the effectiveness of search, rescue and treatment of casualties.

Fourth Step: Test emergency isolation and shut down and remedial measures taken on

the system.

Fifth Step: Conduct a full rehearsal of all the actions to be taken during an emergency.

The Disaster Management Plan will be periodically revised based on experience gained from

mock drills. There are two types of mock drills recommended in Disaster Management Plan –

Full Mock Drill (to be conducted at least once in 6 months) and Disaster Management Efficacy

Drill (to be conducted at least once in 3 months.)

Full Mock Drill: This will be conducted with Unit Head, Head of O & M as General Manager;

Heads of Operation, Maintenance, Medical, Personnel, Security, Auto Base and Materials as

Members and Head of Safety as Convener and it shall test the following:

Properly functioning of Emergency Control Centre.

To evaluate communication of the Disaster Plan to all segments of employees.

To ensure that all facilities as required under the plan are available.

To ensure that the necessities under material assistance scheme is properly documented

and the concerned employees are fully aware in this regard.

To ensure that the employees are fully aware to fight any emergency.

8.21.1.2 Objectives of Onsite Emergency Plan

96

A quick and effective response at that time can have tremendous significance on whether the

situation is controlled with little loss or it turns into a major emergency. Therefore, the purpose

of this Onsite Emergency Plan (OSEP) is to provide basic guidance to the personnel for

effectively combating in case of an emergency.

To maximise the resource utilisation & combined efforts towards emergency operations as

follows:

During an Emergency

To increase thinking accuracy and to reduce thinking time.

To localise the emergency and if possible eliminate it.

To minimise the effects of accident on people and property.

To take correct remedial measures in the quickest time possible to contain the incident

and control it with minimum damage.

To prevent spreading of the emergency situation to other sections.

To mobilize the internal resources and utilize them in the most effective way.

To arrange rescue and treatment of causalities.

8.21.1.3 Elements of Onsite Emergency Plan

The important elements considered in this plan are:

Emergency Organisation

Emergency Procedures

Emergency Facilities

Roles and Responsibilities

Emergency Communications

Emergency Shutdown

Emergency Action for Control of situation and Mitigation

Important Information

8.21.1.4 Methodology

The consideration in this emergency planning includes the following:

Identification and assessment of hazards and risks

Identifying, appointment of personnel & Assignment of Responsibilities

Identification and equipping Emergency Control Centre

Identifying Assembly, Rescue points, Medical Facilities

Formulation of plan and of emergency sources

Action on site Training, Mock Drill & Evaluation

An emergency organisation is constituted towards achieving objectives of this plan.

97

General Manager is designated as site controller and over all in charge of onsite

emergency management. Head- Production is designated as an alternate to general

manager. Head- Laboratory is second alternate.

Mechanical, Head - Laboratory, Security In-charge are designated as Emergency

Coordinators.

Shift In-charge of Production is designated as Incident Controller. This being a process

industry, round the clock, Shift In-charge would be available.

All the above are Key Persons in Onsite Emergency Management.

All Engineers / Supervisors, Chemists in the shift, Assistants in the Shift, Operators in the

shift, Technicians in the Shift, Trained First Aiders, Trained Fire Fighters, Security

Guards, Drivers of the Transport Vehicles are designated as Essential Employees.

Figure 8-1: Elements of Onsite Emergency Plan

98

Figure 8-2: Emergency Organisation in Shift

Onsite Controller

In the absence of Site Controller, assumes the role of Site Controller in addition to his

role as Incident Controller. On arrival of Site Controller, hands over the charge of Site

Controller by word and continues to act at Incident Controller.

Proceed to site quickly

Assess the magnitude of the incident

Arrange to inform the Occupier

Protects him and initiates the emergency procedure to secure the safety of workers and

minimize damage to installation and property.

Direct, rescue and firefighting operations until (if necessary) the fire brigade arrives

Ensure that adequate Personal Protective Equipment is available for Emergency Team

Arrange for search of causalities

Arrange evacuation of non-essential workers to assemble at designated assembly point.

Emergency Coordinator (Departmental Heads)

On hearing about an Emergency, reach ECC and assist Site Controller in all respects

Seek information and instruction whenever necessary

Ensure special equipment like compressed air, power supply

During normal times, take stock of emergency needs including special equipment, blinds,

sealing material, available.


Organize emergency illumination including cutting of power supply to affected areas

Emergency Coordinators (Personnel Manager)



External Mutual Aid Site Controller Emergency Coordinators

Incident Controller

Essential Employees

in Shifts

99

Send Information to Emergency Services like Fire / Ambulance

Organize Emergency Transport for shifting injured / affected

Organize Emergency and First Aid for injured / affected

Organize head-count for rescue / evacuation / and organize rehabilitation and other

humanitarian needs of those who are evacuated and send proper intimation to their kith

and kin.

Maintain sufficient stock of first aid material, stretchers and other emergency equipment

for rescue.

Organize liaison with neighboring industries regarding mutual aid

Keep informed Statutory Authorities and Management, on the instructions of Site

Controller.

Direct Security In-charge regarding control at gate and for law and order coordinate with

Police Authorities and appraise Site Controller on a continuous basis .

Coordinate with other Emergency Coordinators for effective control of situation

He is responsible for maintenance of Emergency Control Centre and Assembly Points

Emergency Coordinators (Security In-Charge)



Ensure availability of firefighting equipment in order

Train regular and new Security Guards regarding plant hazards and demonstrate

emergency actions and firefighting, rescue and evacuation.

Organize control measures at gate to prevent unauthorized persons entering the plant

during emergency and liaise with police officials in maintaining law and order.

Direct unconnected truck drivers and vehicles etc. to move away from plant to a safe

location

Security guards posted in night are to be fully informed of emergency telephones and

how to communicate emergencies if required.

Arrange Emergency Telephone numbers displayed in security and are to be updated as

and when there is a change.

8.21.1.5 Risk Assessment Matrix

Likelihood

Almost Certain

Probable

Possible

Possible (under unfortunate circumstances)

Rare

100

Severity

Fatality

Major Injury, resulting in disability

Injury Requires, Doctor's or Hospital attendance

Minor Injury, 1st Aid required

Minor Injury, 1st Aid not required

Risk Rating

Is calculated by multiplying the likelihood against the consequences, e.g. taking a likelihood of

4, which is classified as Probable, and multiplying this against a consequence of 2, which is

classified as a Minor Injury 1st aid required, would give you and overall risk rating of 8, which

would be risk rated as a low risk.

Table 8-1: Risk Assessment

High risk equals 16 to

25

High Risks activities should cease immediately until

further control measures to mitigate the risk are introduced.

Medium risk equals 9

to 15

Medium Risks should only be tolerated for the short-term

and then only whilst further control measures to mitigate

the risk are being planned and introduced, within a defined

time period.

Note: Medium risks can be an organizations greatest risk,

it's achilles heel, this due to the fact that they can be

tolerated in the short-term.

Low risk equals 1 to 8 Low Risks are largely acceptable, subject to reviews

periodically, or after significant change etc.

Table 8-2: General Risk Assessment

Flow of Communication during Emergency

Whoever

Notices,

Informs

incident

controller,

Site

controller

Site

controller

would cause

informed to

all

concerned in

the plant

If emergency

has a potential

of turning an

off-site

controller

would send

information to

all concerned

101

S.

NO.

Hazards

& details

Persons

at risk Control measures

Action plan in case of

emergency

Risk

Likeli

hood

Seve

rity

Risk

rating

L S Rr= l x

s

1

Induction

furnace-

fire

hazard

caused

by

fuels/igni

table

substanc

es.

Persons

working

in the

Furnace

area-

Burns

may be

possible

if

directly

coming

in

contact.

Emergency alarm

to be put on to

signal the

emergency.

Switch off the

system.

2 3 6

Firefighting

equipment

power/foam type

extinguishers on

vehicles and

mounted on walls

are kept readily

available

Water hose will be

operated to set out

the fire depending

on the situation.

Water hose is

provided.

Outside fire brigade

is to be called if the

fire cannot be

extinguished

immediately.

No smoking zone

declared.

Inform the

occupier/manager

and activate the

onsite emergency

plan.

Plant workers are

trained to fight

fire.

Immediate first aid

to the victim and

sent to hospital for

treatment.

2

In case of

furnace

crack,

molten

metal

may leak

causing

splash of

hot

metal.

Persons

working

in the

tapping

area.

Continuous

monitoring of

furnace shell is

done to maintain

and observe proper

temperature.

Immediately drain

out the furnace by

pouring or tapping

out. Molten splashed

metal is allowed to

cool down before

removing.

2 4 8

Movement of staff

and labor is not

permitted near the

Further process is

stopped till repairs

are conducted.

102


S.

NO.

Hazards

& details

Persons



emergency

Risk

Likeli

hood

Seve

rity

Risk

rating

L S Rr= l x

s

furnace.

Heat zone sign is

displayed near the

furnace.

In case of fire,

firefighting

equipment are used

to set out the fire.

Safety shoes,

safety goggles,

hand gloves, apron

and safety helmet

provided to

workers.

Plant workers are

trained to fight fire

3

Slag pot

leakage

due to

breakage.

Persons

working

in the

tapping

area.

Frequent checking

of slag pot to be

observed.

Further process

should be stopped

till slag cools down

and after cooling the

slag is removed

carefully.

3 4 12

4

Molten

hot metal

may fall

on

human

body.

Persons

working

in the

tapping

area.

Whole process is

done under

supervision of

qualified/ trained

persons

No entry zone

should be declared.

3 4 12

Only trained labors

are allowed with

proper heat proof

dress/gum, boots/

aprons

First aid should be

given to the victim

and send to hospital

for further treatment. Entry of other

workers /persons is

strictly prohibited.

5 Hoist

rope

Persons

standing

No movement of

strange people in

Crane movement is

carried out only after 1 5 5

103


S.

NO.

Hazards

& details

Persons



emergency

Risk

Likeli

hood

Seve

rity

Risk

rating

L S Rr= l x

s

breakage

in E.O.T.

crane

below

the

crane

bay and

in

nearby

areas.

crane bay is

permitted.

getting the signal of

line clearance.

Frequent checking

of rope and other

load bearing

material before

process is started.

Cranes are not

allowed to operate

without line clear

signal.

Weak rope is

immediately

replaced.

6

Electrical

Transfor

mer-

Electrical

shock

and fire

Persons

near the

transfor

mer

Shock proof

insulated PCC

Platform.

Cut off power

supply.

2 3 6

Treat the injured for

electrical shock.

If fire is caused,

immediately fight

fire with available

resources,

summoning outside

help if necessary.

7

Lab-

Chemical

s-in case

of bottle

breakage,

causes

burns

and

damage

to

Persons

working

in the

lab.

Proper care should

be taken while

handling the

chemicals.

Immediately treat

the persons as

guided in the MSDS.

3 2 6 First aid box

should be available

at the site with all

necessary and

required

medicines.

Hospitalize the

effected person if

deemed necessary.

104


S.

NO.

Hazards

& details

Persons



emergency

Risk

Likeli

hood

Seve

rity

Risk

rating

L S Rr= l x

s

respirator

y

systems

due to

inhalatio

n.

Firefighting

equipment like fire

extinguishers, sand

buckets should be

always available.

Instruction boards

to be displayed for

knowledge of

other workers to

care of the

situation in the

event of

occurrence.

8

Cooling

Tower-

Burns

from

returning

hot water

Persons

working

with the

cooling

tower.

All workers are

not permitted near

the tank and hot

water line. Railing

is provided all

around the tank.

Victims are first

aided by trained

person and then

referred to

Doctor/Hospital.

2 3 6

Always

precautionary

measures should

be taken and

adopted.

If any worker gets

hurt, then immediate

first aid should be

provided to him and

he should be referred

to the

Hospital/doctor for

further treatment.

9

Charging

of scrap

and other

material

in

furnace

Persons

working

in the

raw

material

handling

Workers are

provided with

gloves & proper

equipment to

handle and feed

the scrap.

Immediate first aid

should be given to

the victim by trained

person and refer to

the doctor/hospital

for further treatment.

3 3 9

105


S.

NO.

Hazards

& details

Persons



emergency

Risk

Likeli

hood

Seve

rity

Risk

rating

L S Rr= l x

s

and

moving

parts like

fly

wheel,

roller

stand and

other

accessori

es-

cut/burn

and fire

may be

possible.

yard and

in the

furnace

floor.

Workers charging

the materials in the

furnace are

equipped with fire

proof dress and

proper equipment

to handle the scrap

and material.

Fireproof system

made available and

firefighting

equipment like

extinguisher &

water with

sufficient number

of points easily

available.

Only trained &

qualified people

will operate the

furnace.

10

Furnace

transfor

mer-Fire

Hazard

Persons

working

in

Furnace

area and

in the

electrica

l

sections.

Furnace will be

operated with

prescribed load.

Power line should be

immediately put off.

2 3 6

Carefully changing

of tap on load.

Firefighting steps

should be taken to

stop fire.

Temperature of

furnace/

transformer should

be observed

continuously.

Further processing

must be stopped till

repairing is over. Furnace oil

level/quality

should be

106


S.

NO.

Hazards

& details

Persons



emergency

Risk

Likeli

hood

Seve

rity

Risk

rating

L S Rr= l x

s

mentioned.

Unauthorized

persons will be

restricted and no-

Entry Board will

be put up.

11

Water

tank-

drawing

of

personne

l

Persons

near the

water

tank

Water tank will be

fenced/ covered. Drowned person

should immediately

be given first aid.

2 2 4 The tank will not

be permitted for

general utility.

12

Control

Room

electrical

shock

Persons

working

in the

control

room

Earth leakage

circuit breaker

installed.

Main supply will be

immediately shut

off.

2 2 4

Responsibility;

Site Controller; head-production

Incident controller: Shift-in charge

Emergency Co-coordinators: Departmental Heads.

8.22 Heat Stress

Aim is to maintain body core temperature within +1°C of normal (37°C). This core body

temperature range can be exceeded under certain circumstances with selected populations,

environmental and physiologic monitoring, and other controls.

8.23 Source

High temperature and humidity; direct sun or heat; limited air movement; physical exertion; poor

physical condition; some medicines; inadequate tolerance for hot workplaces; and insufficient

water intake can all lead to heat stress

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Table 8-3: Heat Stress

Signs &

symptoms Cause Symptoms Treatment Prevention

Heat Rash

Hot humid

environment;

plugged sweat

glands.

Red bumpy rash

with severe

itching.

Change into dry

clothes and avoid

hot environments.

Rinse skin with

cool water.

Wash regularly to

keep skin clean

and dry.

Sunburn

Too much

exposure to

Sun.

Red, painful, or

blistering and

peeling skin.

If the skin blisters,

seek medical aid.

Use skin lotions

and work in the

shade.

Work in shade;

cover skin with

clothing; use sun

protection lotions

with the factor 15.

Heat

Cramps

Heavy

sweating

Painful cramps in

arms, legs or

stomach which

occur suddenly at

work or later at

home.

Move to a cool

area and drink cool

salted water.

While working in

the heat, workers

should put salt on

their food and

avoid taking salt

tablets.

Fainting

Not enough

blood flowing

to the head,

causing loss

of

consciousness.

Sudden fainting

after two hours of

work; cool moist

skin; weak pulse.

Fainting may be

due to the heart

attack get the

medical aid

immediately and

move to the cool

place; loosen

clothing and make

the person lay

down. Offer sips of

cool water.

Reduce activity

levels and/or heat

exposure. Drink

fluids regularly.

Drink fluids

regularly.

Heat

exhaustion

Inadequate

salt and water

intake causes

a person’s

body’s

cooling

system to start

to break

down.

Heavy sweating;

moist skin; body

temperature over

38 deg.

Centigrade; weak

pulse; normal or

low blood

pressure; person

is tired, weak

clumsy, upset or

confused; is very

thirsty.

Arrange medical

aid

Reduce activity

levels and/or heat

exposure.

Regularly. Drink

fluids regularly.

Heat Stroke

The body used

all its water

and salt, it

High body

temperature(over

41 deg.

Call Ambulance.

Meanwhile remove

the excess

Reduce activity

levels and/or heat

exposure.

108

Table 8-3: Heat Stress

Signs &

symptoms Cause Symptoms Treatment Prevention

will stop

sweating and

will cause

body

temperature to

rise.

Centigrade) clothing; start fan

and spray with

cool water; offer

sips of cool water

if the person is

conscious.

Regularly. Drink

fluids.

Table 8-4: Permissible Heat Exposure Threshold Limit Value

WORK LIGHT MODERATE HEAVY

Continuous work 30.0˚C (86˚F) 26.7˚C (80˚F) 25.0˚C (77˚F)

75 % work, 25% rest,

each hour 30.6˚C (87˚F) 28.0˚C (82˚F) 25.9˚C (78˚F)

50 % work,50% rest,

each hour 31.4˚C (89˚F) 29.4˚C (85˚F) 27.9˚C (82˚F)

25 % work,75% rest,

each hour 32.2˚C (90˚F) 31.1˚C (88˚F) 30.0˚C (86˚F)

8.24 Occupational Health & Safety

In general occupational health and safety is an interdisciplinary area concerned with

safety, health and welfare of people engaged in industries.

The main concerns of occupational health are:

Promotion and maintenance of the highest degree of physical, mental and social well-

being of workers in all occupations

Prevention amongst workers of departures from health caused by their working

conditions

Protection of workers in their employment from risks resulting from factors adverse to

health.

Placing of worker in an occupational environment suitable to his physiological and

psychological capabilities.

Working conditions and the nature of employment tend to have major repercussions on the

health of a workman. The concept of ‘Occupational health’ has evolved from work-related

ailments. Occupational health broadly means any injury, impairment or disease affecting a

worker or employee during his course of employment. Further, it not only deals with work-

related disorders but also encompasses all factors that affect community health within it.

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The occupational health and safety laws exist in all countries including India which makes the

employee of the worker responsible for any damages to its work force. The ignorance of law

cannot be an excuse under any circumstances. Hence, the owners and managers must have the

basic knowledge of the subject.

8.25 Legal Provisions

The Indian Constitution has shown notable concern to workmen in factories and industries as

envisaged in its preamble as Directive Principles of State Policy.

For securing the health and strength of workers, men and women

That the tender age of children is not abused

That citizens are not forced by economic necessity to enter avocations unsuited to their

age or strength

Just and humane conditions of work and maternity relief are provided and,

That the Government shall take steps, by suitable legislation or in any other way, to

secure the participation of workers in the management of undertakings, establishments or

other organizations engaged in any industry

The Factories Act, 1948, the Mines Act, 1952, the Dock Workers (Safety, Health & Welfare)

Act, 1986 are some of the laws, which contain provisions regulating the health of workers in an

establishment. Whereas the Employees State Insurance Act, 1948 and the Workmen’s

Compensation Act, 1923 are compensatory in nature. It may be sufficient to indicate at this stage

that metallurgical industries are classified as hazardous industry and legal provisions must be

adhered to avoid any harm to work force and local residents in the vicinity of the industry.

8.26 Role of Management

It is believed that “the safety begins at the top”. The ‘Safety Engineer’, ‘Foreman’ and

“Supervisor’ can never achieve good result if the top management does not take lead in the

promoting and maintaining a high standard of safety and health at work place. The cost towards

‘Health & Safety’ must be part of total production cost and should not be treated as extra.

The management concerned with safety has duties as below:

Have undeniable decision making authority

Lead in the establishment of rules and policies designed to promote safety and health,

accident prevention and hazard awareness

Be responsible for maintaining the safety policy, safety manual, the proper safety and

health training documentation and the necessary recordkeeping

Make all employees aware of the established safety and health rules of the safety policy

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Hold each employee responsible and accountable

Monitor all aspects of the safety policy and safety manual

Promote and ensure proper safety training, worksite audits, accident investigations, and

hazard control

Manage the safety team (committee)

Conduct or coordinate all site safety inspections

Manage safety violation and award program

Provide and/or coordinate safety training for all new employees

Be notified immediately regarding accidents and/or injuries

Eliminate all hazardous practices performed by employees

Assign and train a replacement in the event he/she is unavailable for duty

In any industry, particularly hazardous industry like metallurgical plants, the incidences do

happen with many safety provisions. This needs investigation and modifications in the safety

system. This requires accident statistics.

8.27 Accident Record

India has had legislation on occupational safety and health for past 50 years. However, the nation

lacks strong system to monitor and regulate incidences though it employs around 26 million

industrial workers besides millions who work in the informal sector with absolutely no

safeguards. The work safety improvements are possible when the related data is available for

analysis.

Accident

The occupational (industrial) accident can be defined as an undesirable event that results in a

certain length of disability and stoppages of work and time loss due to the effect of production

related dangerous factor. The accident may cause personal injury, material damage and loss of

production time.

Injury

The injury is an external damage to the human body resulting from accident. It can be

mechanical (bruise, cut, tissue rupture, breakage etc.), chemical (burn, acute intoxication and

poisoning), radiated (tissue regeneration, changes in the hematopoietic system) or combined

effect of more than one cause. The result of accident may be (serious, minor or no injury) may

cause temporary or permanent disablement.

Occupational Disease

The unhealthy condition caused to the person by exposure to unsafe working conditions

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Occupational Poisoning: It is occupational disease caused by long exposure of relatively

small amount of poisonous material.

Accidental Poisoning: Acute intoxication is caused by penetration of large amount of

noxious substance in a short exposure.

Accident Investigation Form: It is the principle document that provides information for

record and statistical analysis of the data. This form gives the detail of the accident, injuries

by cause and identification of cause. This may help in making policy to avoid its re-

occurrence. This form must be filled within 24 hours

Accidental Statistics

The statistical method is based on total number of accidents (serious and minor) compiled for a

certain period of time. The statistical method is helpful in showing the distribution of accidents

by occupation, length of service, age or sex, cause or type, nature of injury, equipment involved,

and by organizational and technical factors.

The various indices used to indicate safety performance are following:

Number & Type: The total number of incidences and its type record may help in planning

the mitigation of incidents by adopting appropriate means.

The Frequency Coefficient (F): It is defined as number of incidents per 1000 man hour

exposure. It is expressed as;

F = (1000 T) / P,

Where, T - number of injuries for a given period

P - Total man hours of exposure.

The Severity Coefficient (S): It is defined as the average time loss (length of disability) due

to incident per one incident for a given period. This is expressed as

S = D / T,

Where, D - Time loss in days due to all incidents that occurred for a given period

T - Number of incidents in a given period.

Accident Responsibility: In the event of an incident causing loss of production time,

damage to equipment, injury to worker (minor, major, fatal) or loss of life the records form

the basis of fixing the responsibility of the incidence. This could lead to different types of

liability depending upon the nature of incident.

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Disciplinary Liability: This implies the punishment in the form of disciplinary action by the

management which could be in the form of warning, reprimand, transfer, term demotion or

dismissal.

Administrative Liability: This implies penalties imposed by state authority for violating the

safety regulations causing the incident.

Financial Liability: This is compensation by the violator for losses and rehabilitation of the

victim decided by court of law.

Criminal Liability: This is a sanction by law for violating safety laws and industrial

regulations causing accident and other serious consequences.

8.28 General Safety at Work

The safety at work begins at the planning stage. While planning various manufacturing units to

provide safety measures like guards, emergency switches, interlocking and signaling (operating,

warning, and indicating). In addition the training, good housekeeping, color labeling, display

signs, notices etc. can help in improving safety at work and reduce the chance of accidents.

8.28.1.1 Safe Guards, Signals, Signs

The working areas must have safe guards at all moving and hazardous points to prevent casual

access. The moving cranes and equipment must have sound and light signals to keep people at

safe distance. The various activities in the area must be indicated by sign boards in suitably big

size to warn people. This must be in local language of the area with mostly known language like

English. Some typical sign are illustrated in figures 8.3.

In addition to possible hazards the workers and visitors may be advised to use protection wears

while working or entering in the area. The signs displaying such warnings are illustrated in figure

8.4

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Figure 8-3: Some Typical Warning Signs Figure 8-4: Signs for Putting Protection

Wears in Various Areas of The Plant

8.28.1.2 Safety Guards

The use of safety helmet and shoes are mandatory in the plant area while the use of glasses, face

shield, dust mask, ear muff are advisable in many parts of the plant depending on the hazard

nature. Some of the safety gears are shown in figure 7.5

Figure 8-5: Commonly Used Safety Gears

8.28.1.3 Electric Safety

Several accidents occur due to defective electrical systems. The machine frame, casings, motor

guards, control panel etc. get connected to main electrical supply due to poor insulation, heat,

moisture etc. Such incidents could be avoided by using good quality electrical fittings, providing

electrical earth to the equipment, rubber / wooded matting at control panel.

8.28.1.4 Hoisting, Loading & Handling

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The material is handled using cranes of different types. The ropes and chains are essential parts

of the system. The strength of ropes and wires require high safety factor (k) which is expresses as

k = P / S

Where, P – Breaking load, N

S – Maximum anticipated stress, N

The safety factor (k) is generally kept 5-6 in most cases. It is kept as 9 when people are to be

hoisted.

The stress in the rope depends on number of strand and the angle formed by pulling rope as

shown in figure 7.6. The rope type and its quality selection must be made accordingly. The rope

gets worn with time and use. These ropes must be inspected time to time before use.

The hook of the crane is a very critical component and must be tested periodically for any stress

defect.

Figure 8-6: Changes in Rope Stress Due to Pulling Rope Angle Caused by Sling Position

8.28.1.5 Safety Training & Drills

Safety training plays significant role in minimizing incident rate and fatality. A trained worker

not only is able to help himself but he can also save others under given situation. This safety

training is normally imparted to freshly employed persons but it is necessary to conduct refresher

courses for trained persons also. The periodic mock drill is necessary to check the fitness and

alertness.

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8.29 Occupational Health Monitoring & Record

The working conditions and the nature of employment are known to have major repercussions on

the health of a workman. The concept of ‘Occupational Health’ has evolved from work-related

ailments. Occupational health broadly means any injury, impairment or disease affecting a

worker or employee during his course of employment. Further, it not only deals with work-

related disorders but also encompasses all factors that affect community health within it.

Article 21 of the Indian Constitution guarantees the protection of life and personal liberty of a

person. Various Supreme Court judgments have, under this "right to life" upheld the ‘right to

employees’ health.

In view of this provision the employer is obliged to provide health care to its worker during

employment and retirement period.

Health Examination

The workers must be medically examined at the time of employment to observe the physical

fitness and to know any ailment which may need care while placing him in some hazardous area.

The medical examination must be done for every worker on annual basis to monitor the effect of

working atmosphere on his health.

Health Record And Analysis

The industry is supposed to keep health records of all its employees starting from employment

date till their retirement.

These medical records must be analyzed annually to know the trend of employee health. In case

some serious trend is noted then suitable action should be taken to address such health issues.

Some typical health record analysis are given here as illustration.

Chest X-Ray: The chest X-Ray is conducted to reveal the health problems associated with

dust. Silicosis (particularly the acute form) is characterized by shortness of breath, cough,

fever, and cyanosis (bluish skin). It may often be misdiagnosed as pulmonary edema (fluid in

the lungs), pneumonia, or tuberculosis.

Spirometry Test: Pulmonary function tests are a group of tests that measure how well the

lungs take in and release air and how well they move gases such as oxygen from the

atmosphere into the body's circulation. Spirometry (meaning the measuring of breath) is the

most common of the Pulmonary Function Tests (PFTs), measuring lung function, specifically

the measurement of the amount (volume) and/or speed (flow) of air that can be inhaled and

exhaled. Spirometry is an important tool used for generating pneumotachographs which are

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helpful in assessing conditions such as asthma, pulmonary fibrosis, cystic fibrosis,

and Chronic obstructive pulmonary disease (COPD).

Pulmonary function tests are done to:

Diagnose certain types of lung disease (especially asthma, bronchitis, and emphysema)

Find the cause of shortness of breath

Measure whether exposure to contaminants at work affects lung function

Electrocardiogram (ECG) Test: The electrocardiogram (ECG) is a diagnostic tool that

measures and records the electrical activity of the heart in exquisite detail. A typical ECG

record is illustrated in figure 7.10 Interpretation of these details allows diagnosis of a wide

range of heart conditions. These conditions can vary from minor to life threatening.

Audiometry Test: Audiometry is the testing of hearing ability, involving thresh-holds and

differing frequencies. Typically, audiometric tests determine a subject's hearing levels with

the help of an audiometer, but may also measure ability to discriminate between different

sound intensities, recognize pitch, or distinguished speech from background noise. Acoustic

reflex and otoacoustic emissions may also be measured. Results of audiometric tests are used

to diagnose hearing loss or diseases of the ear, and often make use of an Audiogram.

Noise-induced hearing loss (NIHL) is an increasingly prevalent disorder that results from

exposure to high-intensity sound, especially over a long period of time. The ear can be

exposed to short periods in excess of 120 dB without permanent harm — albeit with

discomfort and possibly pain, but long term exposure to sound levels over 80 dB can cause

permanent hearing loss.

There are two basic types of NIHL:

NIHL Caused by Acoustic Trauma: refers to permanent cochlear damage from a one-

time exposure to excessive sound pressure. This form of NIHL commonly results from

exposure to high-intensity sounds such as explosions, gunfire, a large drum hit loudly

and firecrackers.

Gradually Developing NIHL: refers to permanent cochlear damage from repeated

exposure to loud sounds over a period of time. Unlike NIHL from acoustic trauma, this

form of NIHL does not occur from a single exposure to a high-intensity sound pressure

level.

Vision Test: An eye examination is a battery of tests performed by an ophthalmologist and

optometrist assessing vision and ability to focus on and discern objects, as well as other tests

and examinations pertaining to the eyes. Health care professionals often recommend that all

http://en.wikipedia.org/wiki/Ophthalmologist

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people should have periodic and thorough eye examinations as part of routine primary care,

especially since many eye diseases are asymptomatic.

Eye examinations may detect potentially treatable blinding eye diseases, ocular manifestations of

systemic disease, or signs of tumors or other anomalies of the brain.

A refractive error (RE): or refraction error is an error in the focusing of light by

the eye and a frequent reason for reduced visual acuity.

Colour blindness: or colour vision deficiency is the inability or decreased ability to

see colour, or perceive color differences, under lighting conditions when color vision is

not normally impaired. "Color blind" is a term which indicate a fault in the development

of either or both sets of retinal cones that perceive color in light and transmit that

information to the optic nerve.

8.30 Disasters & its Types

A disaster is the impact of a natural or man-made hazard that negatively affects society or

environment

Natural Disasters

A natural disaster is the consequence of a natural hazard (e.g. earthquake, flood, tsunami,

hurricane etc.) which affects humans. The damage is caused by the lack of

appropriate emergency management leading to financial, environmental and human life loss.

Man – Made Disasters

The man-made disasters are caused by human action, negligence, error, or involving the failure

of a system, Human-made disasters are in turn categorized as technological disaster.

Technological disasters are the results of failure of technology involving material, design, system

or operational failures. The metallurgical plants like steel industry require very good hazard

management plan due to its hazardous nature and large scale of operation.

8.31 Hazards in Steel Industry & its Effects

Steel plants use and produce various chemicals in their day to day operation. Some of the

common chemicals used annually in a steel plant are illustrated below:

Sulphur,

Calcium Carbide

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118

Hydrochloric Acid

Diesel

Furnace oil

Sulphuric Acid

The hazardous substances storage capacity of some substances can be listed as:

Coke Oven Gas Holder

Blast Furnace Gas Holder

LD (BOF) Gas Holder

Liquid Oxygen

Liquid NH3

Sulphuric Acid

Hot Metal (mixer vessel)

Liquid Steel in Ladles

Acetylene pipe

These chemicals always pose a risk of accident leading to a disaster. These can be largely

prevented by a good safety management system. Common causes of chemical accidents are

therefore deficiency of safety systems, human error or natural calamity.

Nature of possible hazards could be:

Toxic release of Blast Furnace Gas, BOF Gas, Coke Oven Gas

Fire and explosion of tank firm areas.

Hot metal spillage and overflows during handling.

Leakage of liquid Oxygen

Fire & explosion

8.32 Common Hazards in Industry

The various types of common hazards and their effect are described briefly in following sections.

Explosion

The word explosion is used to cover all processes characterized by a sudden flow of material

(usually hot gases) outward from one point. There are two types of explosions depending on the

cause of this outflow:

Explosion due to physical cause (eg. pressure vessels)

Explosion due to chemical reaction resulting release of heat. This is again of two types:

Deflagration occurs when the burning velocity is relatively slow (1 m/s).

119

Detonation occurs when the flame speed is very high (2000-3000 m/s).

The explosions are characterized by the production of a shock wave causing damage to building

and eject sharp pieces like missiles over long distances causing injury to the people.

Dust Explosion & Release

The dust explosion occur when a flammable solid material (eg pulverized coal) are extensively

mixed with air. Such explosions follow initially small fire or explosion which causes settled

powder airborne and cause second explosion. This chain of explosion continues.

This generally causes effect locally and people in the plant vicinity are not affected unless large

quantity of dust particles becomes airborne.

Fire

Fire is the release of energy during the oxidation of a fuel (burning substance) with most of

energy being in the form of heat. The fire can be in different forms such as:

Jet Fire: is a narrow flame. This is formed when a leaking gas from pipe line gets ignited

from some source.

Pool Fire: results from the ignition of pooled oil spilled from pipe line.

Flash Fire: occurs when the escaping fuel gas reaches an ignition source and rapidly

burns back to the point of gas release.

Fire Ball: (BLEVE - Boiling Liquid Expanding Vapor Explosion) is a combination of fire

and explosion. This type of fire occurs with tankers carrying liquefied petroleum gas

(LPG). The tank failure or tippling can cause the release of LPG which rapidly expands at

room temperature forming a rising cloud. When this gas cloud is ignited a fire ball

appears. Depending on the quantity of gas involved the heat intensity may be sufficient to

cause death and severe skin burns at several hundred meters away from the tank.

Toxic Release

A toxic release is the uncontrolled emission of a toxic material in the atmosphere/ water / soil

which is harmful to living objects. The impact on human body depends on the concentration of

the toxic material, age and health of the person exposed.

8.33 Disaster Management

120

Any type of disaster management needs its analysis and assessment to make preparations. As

human being we learn from our past experience and make efforts to avoid it in future. Analysis

of accidents has revealed that they are the result of chain of event often starting with relatively

trivial incident which is ignored many a times. Now there is a trend to have a predictive approach

towards risk assessment for determining the safety parameters.

8.34 Risk Assessment

Many different methods and systems have been devised with varying degree of complexity to

assess risk in different fields.

The figure 7.7 shows an example of risk matrix suitable for ranking risk as an aid to the decision

making. In another circumstances if it is needed to know whether the industrial process is in safe

limits then a more complex quantified risk analysis system may be needed. The figure 7.9 shows

an ALARP (As Low as Reasonably Practicable)

Figure 8-7: The Risk Matrix

Triangle is practiced in UK. This triangle shows “not to be exceeded limit” as upper part of the

triangle and “negligible risk limit” in the lower part. The area in between the two limits is

considered for risk reduction with cost benefits for plant operation.

In industry nothing can be said as “zero risk” or “100 percent safe”. One has to understand the

possible risk and adopt preventive means and keep preparedness to manage the hazard.

121

Figure 8-8: THE ALARP TRIANGLE

8.35 Disaster Management Steps

The disaster of any nature leads to an emergency situation and demands an effective and efficient

management system to minimize the loss. This emergency management has four components (4

R’s) shown in figure 7.9:

Figure 8-9: Four Steps for Hazard Management

Mitigation

122

The mitigation concerns knowing the possible hazards and avoiding unnecessary risks. This

includes an assessment of possible risks to health and property.

One example of mitigation would be to avoid industry in the area that is exposed to hazards like

flood, subsidence, landslide etc. The structural mitigation in earthquake prone areas includes

appropriate building layout and structures which can sustain earthquakes, installation of

a device to instantly shut off the some harmful systems.

Preparedness

The preparedness focuses on planning and having the required material and equipment with

well-planned procedures for their use during emergency period. This includes following:

Communication and Warning devices

Shelter area

Emergency Power system

Life Saving Material Storage (Water, Medicine, Food, warm cloths etc)

Evacuation plans.

The preparation of a survival kit such as a "12-hour kit” is often advocated. These kits may

include food, medicine, flashlights, candles etc.

Response

The response phase of an emergency may commence with search and rescue but in all cases the

focus will quickly turn to fulfilling the basic humanitarian needs of the affected area. This

requires following:

Local Emergency Management Agency (LEMA) for conducting the operation

Evacuation Plan and Shelter Place to accommodate the affected people temporarily till

they are shifted to hospital or other places.

Transportation facility for injured ( Ambulances) and supplies (Heavy Vehicles)

Fire Fighters with equipment to deal with fire caused by disaster.

Security to manage the law and order situation

The quick and efficient coordination of many agencies involved in the process would need a

good planning and mock drills.

Recovery

The recovery phase starts after the immediate threat to human life has subsided. This may

involve cleaning up the area and reconstruction of the damaged equipment and building etc.

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123

This also involves reviewing the incident and analyzing for various aspects to know the

deficiency in mitigation, preparedness and response during hazard management.

8.36 Incident Control and Command

In the event of any incident a command structure is required to take necessary action. The

common weakness during such time is due to following reasons:

Lack of accountability, including unclear chains of command and supervision.

Poor communication due to both inefficient uses of available communications systems and

conflicting codes and terminology.

Lack of an orderly, systematic planning process.

No predefined methods to integrate inter-agency requirements into the management structure

and planning process effectively.

Freelancing by individuals with specialized skills during an incident without coordination

with other first responders

Lack of knowledge with common terminology during an incident.

Key Factors

The key to a good incident command structure (ICS) are:

Unity of Command: Each individual participating in the operation reports to only one

supervisor. This eliminates the potential for individuals to receive conflicting orders from a

variety of supervisors, thus increasing accountability, preventing freelancing, improving the

flow of information, helping with the coordination of operational efforts, and enhancing

operational safety. This concept is fundamental to the ICS chain of command structure.

Common Terminology: When different organizations are required to work together, the use

of common terminology is an essential element in team cohesion and communications, both

internally and with other organizations responding to the incident

8.37 Incident Action Plans (IAP)

Incident action plans ensure that everyone is working in concert toward the same goals set for

that operational period by providing all incident supervisory personnel with direction for actions

to be taken during the operational period identified in the plan. Incident Action Plans provide a

coherent means of communicating the overall incident objectives for both operational and

124

support activities. They include measurable strategic objectives to be achieved in a time frame

called an Operational Period.

Action Plans must have four elements:

What do we want to do?

Who is responsible for doing it?

How do we communicate with each other?

What is the procedure if someone is injured?

Resource Management During Incident

The resource management is a key management principle that implies that all assets and

personnel during an event need to be tracked and accounted for. It can also include processes for

reimbursement for resources, as appropriate. Resource management includes processes for:

Categorizing resources.

Ordering resources.

Dispatching resources.

Tracking resources.

Recovering resources.

Communication System

The use of a common communications plan is essential for ensuring that responders can

communicate with one another during an incident. Communication equipment, procedures, and

systems must operate across jurisdictions. Developing an integrated voice and data

communications system, including equipment, systems, and protocols, must occur prior to an

incident.

Effective ICS communications include three elements:

Modes: The "hardware" systems that transfer information.

Planning: Planning for the use of all available communications resources.

Networks: The procedures and processes for transferring information internally and

externally.

The plant must have an independent communication system like satellite phone, ham radio or

wacky-talkie system. In the event of earth quake and fire regular communication towers may not

be operational.

8.38 Incident Command Structures (ICS)

125

ICS is organized by levels holding supervising person's title as given below:

Incident Commander:

Single incident commander: Most incidents involve a single incident commander. In

these incidents, a single person commands the incident response and is the decision-

making final authority.

Unified command: A Unified Command is used on larger incidents usually when

multiple agencies are involved. A Unified Command typically includes a command

representative from major involved agencies and one from that group to act as the

spokesman, though not designated as an Incident Commander. A Unified Command acts

as a single entity.

Area command: During multiple-incident situations, an Area Command may be

established to provide for Incident Commanders at separate locations. Generally, an Area

Commander will be assigned - a single person - and the Area Command will operate as a

logistical and administrative support. Area Commands usually do not include an

Operations function.

Command Staff Member (Officer): Command Staff

Safety officer: The Safety Officer monitors safety conditions and develops measures

for assuring the safety of all assigned personnel.

Public information officer: The Public Information Officer (PIO or IO) serves as the

conduit for information to and from internal and external stakeholders, including the

media or other organizations seeking information directly from the incident or event.

While less often discussed, the Public Information Officer is also responsible for

ensuring that an incident's command staff is kept apprised as to what is being said or

reported about an incident. This allows public questions to be addressed, rumors to be

managed, and ensures that other such public relations issues are not overlooked.

Liaison Officer: A Liaison serves as the primary contact for supporting agencies

assisting at an incident

Section (Chief): General Staff

Branch (Director)

Division (Supervisor): A Division is a unit arranged by geography, along jurisdictional

lines if necessary, and not based on the makeup of the resources within the Division.

126

Group (Supervisor): A Group is a unit arranged for a purpose, along agency lines if

necessary, or based on the makeup of the resources within the Group.

Unit, Team, or Force (Leader): Such as "Communications Unit," "Medical Team," or a

"Reconnaissance Task Force." The Task Force is composed of different types of resources

(one ambulance, two fire trucks, and a police car, for instance).

Individual Resource: This is the smallest level within ICS and usually refers to a single

person or piece of equipment. It can refer to a piece of equipment and operator, and less

often to multiple people working together

127

9 PROJECT BENEFITS

9.0 General

The proposed expansion project M/S Mahalakshmi Profiles Pvt. Ltd. is proposing expansion of

its current M/S Billets, Skelp and Pipes manufacturing. The demand of the product has been

increasing swiftly which has resulted in the proposed expansion of the existing capacity. The

industry is expanding which predicts economic benefits on the regional basis

9.1 Tangible Benefits

The proposed expansion project offers many tangible benefits. It includes increase in production

capacity, increase in tax income to the government, employment generation etc.

The proponent will give employment to 600 people (Existing 250 No. & Proposed 350 No)

Localities will be preferred for the jobs as per their skill, experience and knowledge. Due to the

expansion nature of the project not many direct jobs will be created. However, there will be

increase in the income of the indirect employment as the returns will increase especially those

involved in the supply chains or direct selling, Government revenues, taxes, transportation will

also gain from the expansion project.

9.2 Intangible Benefits

The proposed expansion project will increase the intangible benefits. The expansion is of the

existing products which indicate the market potential of it. The creditability of the products is

excellent which is increasing the demand in the market. Increase in income will lead to more

saving as well as investment which will be satisfying for an individual.

9.3 Other Benefits

The expansion project will bring newer opportunities, increase in network work related influence

area, and increase in accomplishments

128

10 ENVIRONMENT COST BENEFITS ANALYSIS

Not applicable for this project

129

11 ENVIRONMENTAL MANAGEMENT PLAN

11.1 Environmental Management Cell

Apart from having an environmental management plan, it is also necessary to have a permanent

organizational set up charged with the task of ensuring effective implementation. In this effect,

M/s. Mahalakshmi Profiles Pvt. Ltd. will assign responsibilities to officers from various

disciplines to co-ordinate the activities concerned with management and implementation of

environment control measures. An organogram of Environment management is shown in figure-

11.1. Basically, this department undertakes the monitoring of environmental pollution level by

measuring stack emissions, ambient air quality, water and effluent quality, Noise level, etc.,

either departmentally or appointing external agency whenever required.

The industry will continue the regular

monitoring in future to ensure that pollution is

limited below prescribed limits and to take

corrective action by either providing new

equipment or improving the performance of

existing pollution control equipment. In case the

monitored results of environment pollution are

found to exceed the prescribed limits, remedial

actions are taken through the concerned plant

authorities. The actual operation and

maintenance of pollution control equipment of

each department is under respective department

heads. The Environmental, Occupational health

and Safety department is also looking after for

preparation of environment statement, carrying

out environment audit, preparation of Water

Cess Return and various consent applications

and renewal under water (Prevention and Control

of Pollution) Act, 1974 and Air (Prevention and

Control of Pollution) Act, 1981 as well as

application for authorization and its renewal

under Hazardous Waste (Management and

Handling) Amended Rules, 2003 under

Environment Protection Act, 1986.

Fig 11.1: Organogram for Environment

Management Cell

130

11.2 Environment Management Plan

Operation phase of any industry being longer in duration and because of its’ potential to create

continuous impacts, is much more important from the environmental impact point of view and a

comprehensive and effective EMP has to be prepared and implemented to safe-guard

environmental concerns during operation phase of any unit.

Detailed EMP is as under:

Table 11.1: Detailed EMP

PARTICULARS EMP

Air Pollution

Control

Raw material stockyard for Iron & steel billets/Ingots, Scrap, sponge

iron etc. Other raw materials are being stored under cover sheds.

Good housekeeping is essential for steel complex.

Height of all the stacks will be as per statutory requirement. All the

stacks will have stack monitoring facility (SMF) consisting of sampling

port-hole, platform and access ladder.

Transport vehicles will be properly maintained to reduce air emissions

(PUC).

Induction furnace will be operated by electricity; hence there will be no

pollution by combustion of the fuel.

The hoods with proper geometry will be designed.

Plantation of trees, herbs & shrubs will be developed to attenuate the

pollution. This not only providing aesthetic benefits to site, but such

vegetation is able to capture dust.

Measures will be taken to avoid fugitive dust emission.

Idle running of vehicles will be minimized during material loading /

unloading operations

Air Pollution

Minimization

During

Manufacturing

Process

Regular maintenance is being done for exhausters, chimney and

abatement equipment (Wet Scrubber).

To prevent the quench water becoming contaminated.

Quench towers are being cleaned out periodically.

Pipe joints are welded and pumps are gas tight.

In furnace the sequence in which vent and bleeder valves open is

important, opening the cleanest first.

The essential requirement of electric Induction furnace is for primary

fume control.

131


PARTICULARS EMP

The primary fume is extracted from the electric Induction furnace

through a duct by the exhaust fan(s) of the abatement plant.

Dust and fume is being minimized by discharging slag from the electric

Induction furnace into slag pots.

Solid Waste

Management

The generation of solid wastes from process operation is minimal, and

may include contaminated redundant equipment, refractory linings and

cleaning debris.

The generation and use of furnace oil is controlled to avoid

contamination of land.

Waste oil from interceptors, sweeping is being recovered.

No hazardous waste will be generated from the project.

Green Belt

Development

Plan

Extensive green belt development has been done.

About 10233.238 sq m i.e. 35 % of total plant area shall be developed

as green belt at plant boundary, road side, around offices & buildings

and Stretch of open land. Total investment in green belt development

shall be Rs. 5.0 Lac. Apart from greenbelt, lawns, gardens and approach

road-side plantation also carried out at all vacant spaces inside the plant

premises. The main objective of the green belt is to provide a barrier

between the source of pollution and the surrounding areas. The green

belt helps to capture the fugitive emissions and to attenuate the noise

generated apart from improving the aesthetics.

Occupational

Health Plan

Exposure problems to noise, dust, heat and gases are the major

occupational hazards. The employees working in dusty environment will

be diagnosed for respiratory functions at periodic intervals and during

specific complaints for lung function test, sputum test, X-ray test, etc.

Plant personnel working in dust prone areas will wear personnel

protective equipment like air filters over their nose. Job rotation schemes

will be practiced for over-exposed persons.

In case a person inhales CO, he will be removed to fresh air and kept

calm. Thereafter, supportive treatment will be given in the hospital.

It will be ensured that workers are not exposed above the threshold

limits prescribed above through suitable administrative controls. PPE

like earplugs and muffs will be provided and administrative pressure

applied to the workers to using them despite uncomforted.

Auditory examination by qualified doctors upon the first employment

and thereafter periodic examination will be conducted.

132


PARTICULARS EMP

Workers exposed to mechanical accident-prone areas will be given

personal protective equipment (PPE).

Safety data sheets of the hazardous chemicals will be displayed at

specific locations.

All safety and health codes prescribed by the Bureau of Indian Standards

will be implemented.

Fire hydrants will be located at all convenient and strategic points

along the major drains and checked for water availability on regular

basis. Fire extinguishing equipment, sand buckets, water sprinklers and

water hoses will be provided at all convenient point. Fire, heat and

smoke detection alarms will be installed.

Noise Pollution

Control

Noise generating sources and their platforms will be maintained properly

to minimize noise vibrations generated by them.

Personnel working near the noisy machines in different plant locations,

will be provided with well-designed ear muffs / plugs (effective noise

reduction 10-15 dB (A).

Green belt will be developed to act as a noise barrier.

Noise barriers/ shields in the form of walls, beams will be provided

around the units wherever found feasible

Training to personnel will be imparted to generate awareness about

effects of noise and importance of using PPEs.

Structure of

Environmental

Management

Department

Recommended functions of the Environment Management Department

are given below:

1. Develop and maintain Environmental Management System in

line with ISO 14001.

2. Regular monitoring of stack emissions and fugitive emissions

and report any abnormalities for immediate corrective measures.

3. Regular monitoring of ambient air quality around the plant and

work environment monitoring inside the plant.

4. Regular monitoring of re-circulating water quality, water quality

of the storage ponds, ground water quality and surface water

quality.

5. Regular noise monitoring of the work zone and surrounding area.

6. Green belt plantation, maintenance, development of other forms

of greenery like lawns, gardens, etc. in the plant boundary,

133


PARTICULARS EMP

premise.

7. Regular monitoring of solid wastes quantity and developing

avenues for utilization of solid wastes.

In addition to above the EMD will estimate the following performance

indicators:

1. Annual mass emissions to air (SO2, NOx, PM2.5, PM10)

2. Energy use and efficiency;

3. Annual raw materials use;

4. Water use and efficiency; and

5. Annualized waste generation, minimization and recycling.

All the above observations will be compiled and documented to serve

the following purposes.

1. Identification of any environmental problems that are occurring

in the area.

2. Initiating or providing solutions to those problems through

designated channels and verification of the implementation

status.

3. Controlling activities inside the plant, until the environmental

problem has been corrected.

4. Suitably respond to emergency situation.

Safeguard

Mechanisms for

Pollution

Control and

Sustainable

Development

The safeguard mechanism for pollution control and sustainable

development is double sided mechanism comprising on one hand and

Regulatory Authorities on the other hand.

To submit the yearly progress report and compliance report to the

regulatory authorities.

To allow unrestricted entry inside its premises to the staff of the

regulatory authorities at any time for inspection and checking provided

the staff carries with him.

The functions of regulatory authorities are covered under Water

(Prevention & Control of Pollution) Act, Air (Prevention & Control of

Pollution) Act and Environment Protection Act. The environmental

compliance and performance of this project will be monitored and

checked by the State Level Authorities/Central Level Authorities.

134

11.3 Central Pollution Control Board {CPCB} Guide Lines for Steel Industry

CPCB in its publication “Probe/97/2002 - 03”- ‘Environmental Management in Selected

Industrial Sectors Status / Needs’, which also includes steel sector has brought out

suggestions/recommendations and norms for steel units. The suggestions/ recommendations and

norms as applicable to proposed expansion and their compliance status are detailed below:

135

Table 11.2: Action Points as per CPCB Guidelines for Steel Industry

S.

NO Action Point Action Implemented

1 Conservation of water Already under compliance with zero

liquid effluent discharge.

2 Fugitive Emissions Reduction Remedial measures will be adopted.

3 Solid Waste/hazardous waste management All the solid waste generated would be

recycled back.

4

Monitoring of Effluent, Emission and

Ambient air quality

A detailed environmental monitoring

plan has been proposed which would be

implemented with additions after

approval by the TPCB.

5 Emission Control

Emission control is met by installation

of:

High efficiency Wet

scrubbing system;

High Stack as per norms;

6 To Improve overall housekeeping. Agreed

7 To implement rainwater harvesting Rain water harvesting will be adopted.

8

To implement the recommendations of

Life Cycle Assessment (LCA) study

Sponsored by MoEF by December 2003.

The issue shall be examined & shall be

done as per the Government Directives.

9

The industry will initiate the steps to adopt

the following clean technologies/measures

to improve the performance of industry

towards production, energy and

environment.

Agreed

10 Environmental Management Cell EM cell will be there to execute the

tasks related to EHS.

136

12 DISCLOSURE OF CONSULTANTS ENGAGED

Name of the Project M/S Mahalakshmi Profiles Pvt. Ltd., established on Survey. No. 287, 288

& 289 in Kallakal village, Manoharabad Mandal, Medak District in

Telangana state

Nature of the

consultancy

Name of the

Consultant/expert

Address & E-

mail

Approvals, if any from

(NABL/ DGMS/ IBM/

NRBPT/ MOEF/ CPCB/

others etc)*, give reference

EIA/EMP Organization Global Management And

Engineering Consultants

International

Saharan

Tower, 308,

Officers

Campus

Extension,

Sirsi Road,

Khatipura,

Jaipur-302012

E-mail:

info@gmecint

ernational.com

NABET Accredited EIA

Consultant Organization

An ISO 9001:2008

Certified company

Env.Coordinator Dr. Meena Bhaduri

FAE-LU

TM

Vikas Kumar Samaria

Omprakash Kumar

FAE- AP

TM

Omprakash Kumar

FAE-AQ

TM

Dr. Meena Bhaduri

Yogesh Poonia

FAE-WP

FAA

TMs

Omprakash Kumar

FAE-EB

FAA

TM

Dr. Alok Pandey

Sunil Lamba

Yogesh Poonia

FAE-NV

TM

Shishir Chandra Bhaduri

FAE-SE Dr. MeenaBhaduri

137

FAAs Raj Kumar Tailor

Brijesh Chaturvedi

Bhaskar Sinha

FAE-HG Dr. MeenaBhaduri

FAE-GEO Parmeshwar P Soni

FAE-RH

TM

Sunil Lamba

FAE-SC

TM

Dr. Sita Ram Bhakar

Dr. MeenaBhaduri

FAE-SHW

TM

Omprakash Kumar

Environmental Monitoring &

analysis

Nakshatra Enviro

Services

66/40, Heera

Path,

Mansarover,

Jaipur

NABL Accredited Laboratory

An ISO 9001:2008 Certified

Laboratory

Hydro - geological

study& Rain Water

Harvesting

Dr. MeenaBhaduri Saharan Tower,

308, Officers

Campus

Extension,

SirsiRoad,

Khatipura,

Jaipur-302012

--

138

139

140

Annexures 3.1

LAND CONVERSION LETTER BY RDO-1

141

142

143

144

145

146

147

148

149

Additional Information of Galvanizing

DATE :- 27/04/2019 SHEET :- 1 OF1

CONT. STRIP GALVANIZING LINE

LIST OF CONSUMABLES & CHEMICALS FOR 300 TONS PER DAY

S.No. DESCRIPTION SPECIFICATION INITIAL FILL

(QTY.) CONSUMPTION REMARKS

1 ELECTRIC POWER 415 V± 10 % 3 PHASE, AC 40 KWH / Ton 600 KVA

CONNECTED LOAD

2 WATER REQUIREMENT

INDUSTRIAL WATER TDS < 250 ppm.

30 KL 30 KL / DAY COOLING + PICKLING

3 AIR REQUIREMENT CLEAN LUBRICATED

AIR 50 CFM AT 7 BAR MISC. USE

4 LEAD HIGH GRADE 99.9 % 125 TON NEGLIGIBLE BOTTOM BUFFFER

5 ZINC HIGH GRADE 99.9 % 25 TON 10.5 Kg / Ton ZINC COATING

6 ALUMINIUM (Al ) HIGH GRADE 99.9 % 0.25% In Zinc MIXING WITH ZINC

7 WET FLUX

AMMONIUM CHLORIDE

ZINC CHLORIDE ( CHLORIDE BASE )

50 Kg 1.2 Kg / Ton SURFACEP

PREPRATION FOR ZINC COATING

8 DEGREASING AGENT

CAUSTIC BASE 150 Kg 2 Kg / Ton SURFACE CLEANING

9 CHROMIC ACID DICHROMATE FLAKES 2 - 2.5 % IN WATER 200 - 300 Gms /

Ton PASSIVATION

10 FUEL FURNACE OIL 12 Litre / Ton ZINC MELTING

FURNACE

11 FUEL ( OR ) H S DIESEL 12 Litre / Ton ZINC MELTING

FURNACE

12 FUEL ( OR) NATURAL GAS 11 Kg / Ton ZINC MELTING

FURNACE

150

13 DM WATER PH VALUE 6 - 7.5 & CONDUCTIVITY < 50

Microsiemens 10 KL 20 Litre / Ton

FOR QUENCHING + CHROMATING

14

HYDROCHLORIC ACID COMMERCIAL GRADE

STRENGTH 33% SPECIFIC GRAVITY

1.15 Gms/Cm³ 20 KL 25 Litre / Ton FOR PICKLING

15 NATURAL GAS STORAGE BULLET INDUSTRIAL LPG

CYLINDER - 2 NOS.

4 Kg / Ton PREHEATER PILOT

BURNER

EFFLUENTS GENERATION :-

1. SPENT HCL ACID OF APPROX. 6 - 8 % CONC. -

20 Litre / Ton

2.SPENT & BURNT FLUX (CHLORIDE BASE ) -

0.5 Kg / Ton

3. RINSING WATER WITH HCL ACID CONCENTRATION OF 1 - 2 % -

50 Litre / Ton

4. SPENT DEGREASING AGENT (SOAP CAUSTIC BASE) -

0.25 Kg / Ton

Additional Information of Galvanizing

DATE :- 27/04/2019 SHEET :- 1 OF1

HOT DIP PIPE GALVANIZING PLANT

LIST OF CONSUMABLES & CHEMICALS FOR 300 TONS PER DAY

S.No. DESCRIPTION SPECIFICATION INITIAL FILL

(QTY.) CONSUMPTION REMARKS

1 ELECTRIC POWER 415 V± 10 % 3 PHASE, AC 5 KWH / Ton 100 KVA

CONNECTED LOAD

2 WATER REQUIREMENT

INDUSTRIAL WATER TDS < 250 ppm.

15 KL 10 KL / DAY COOLING WATER

3 AIR REQUIREMENT CLEAN LUBRICATED

AIR

100 CFM AT 7 BAR

MISC. USE

151

4 LEAD HIGH GRADE 99.9 % 20 TON NEGLIGIBLE BOTTOM BUFFFER

5 ZINC HIGH GRADE 99.9 % 30 TON 25 - 30 Kg / Ton ZINC COATING

6 ALUMINIUM (Al ) HIGH GRADE 99.9 % 0.25% In Zinc

7 WET FLUX

AMMONIUM CHLORIDE

ZINC CHLORIDE ( CHLORIDE BASE )

100 Kg 800 Gms / Ton SURFACEP

PREPRATION FOR ZINC COATING

8 CHROMIC ACID DICHROMATE

FLAKES 2 - 2.5 % IN

WATER 200 - 300 Gms /

Ton PASSIVATION

9 FUEL FURNACE OIL 15 Litre / Ton ZINC MELTING

FURNACE

10 FUEL ( OR ) H S DIESEL 15 Litre / Ton ZINC MELTING

FURNACE

11 FUEL ( OR) NATURAL GAS 13 Kg / Ton ZINC MELTING

FURNACE

12 DM WATER PH VALUE 6 - 7.5 & CONDUCTIVITY < 50

Microsiemens 10 KL 20 Litre / Ton

FOR QUENCHING + CHROMATING

13

PICKLING AGENT HYDROCHLORIC ACID COMMERCIAL GRADE

STRENGTH 33% SPECIFIC GRAVITY

1.15 Gms/Cm³ 20 KL 25 Litre / Ton FOR PICKLING

EFFLUENTS GENERATION :-

1. SPENT HCL ACID OF APPROX. 6 - 8 % CONC. -

23 Litre / Ton

2.SPENT & BURNT FLUX (CHLORIDE BASE ) -

0.5 Kg / Ton

3. RINSING WATER WITH HCL ACID CONCENTRATION OF 1 - 2 % -

50 Litre / Ton

5. SPENT CHROMIC ACID WITH 2% CONCENTRATION -

50 Gm / Ton

a

EXECUTIVE SUMMARY

1.0 Introduction

M/S Mahalakshmi Profiles Pvt. Ltd., established on Survey. No. 287, 288 & 289 in Kallakal

village, Manoharabad Mandal, Medak District in Telangana state, is already manufacturing

Steel Billets. Presently it has two induction furnaces (one stand by) with 12 tons capacity, with

total production of 29,700 tons per Annum. It also has a Strip mill and Tube mill of 165tonnes

per day capacity each. The existing plant is having valid Consent for Operation from TS

Pollution control Board.

Now the company have proposed to expand the existing plant by installing 12TPH x 6 more

(total 8 No. 12TPH) Induction Furnaces along with CCM for making 621 TPD (2,04,930 TPA)

of MS Billets and New roughing stand/Modernization activities for making 534 TPD

(1,76,220 TPA) of MS Skelp and installation of 3 new ERW Tube mills for production of 835

TPD (2,75,550 TPA) of MS Pipes and installation of scaffolding workshop for production of

50 TPD (16,500 TPA) of Scaffolding. It will also Install continuous coil Galvanizing unit for

manufacturing of 300 TPD (99,000 TPA) of Galvanized Strips /Coils and installation of Hot

Dip Galvanizing unit for manufacturing of 300 TPD (99000 TPA) of Hot Dip Galvanizing of

MS ERW Tubes.

Project Proponent

M/S Mahalakshmi Profiles Pvt. Ltd. is a Private Limited Company. The Directors of the

company are as under:

Directors: The company is promoted by: Mr. Ramniranjan Agarwal and Mr. Vinod Kumar

Agarwal.

Address: Mahalakshmi Profiles Pvt. Ltd. Private Limited has its registered office at 1-9-8,

I.D.A, Azamabad, Hyderabad, Telangana.

1.1 Location

M/S Mahalakshmi Profiles Pvt. Ltd.is situated at village Kallakal village, Manoharabad



The land area of the plant is 19 Acres and 17 Guntas (78,610.256 sq m) out of which 13.675

acres is being used for the Industrial processes and 5.75(33.0% )Acres has been allocated for

green belt.

b

2.0 Product and Capacities

The project proposes to expand the production capacity by upgrading existing capacity as

given below:

S. No. Product Capacity

Existing Expansion After Expansion

1 MS Billets though Induction Furnace

90 TPD 621 TPD 711TPD

2 MS Skelp through Strip mill

165 TPD 534 TPD 699 TPD

3 Pipes through Tube Mill 165 TPD 835 TPD 1000 TPD

4 Scaffolding -- 50 TPD 50 TPD

5 Galvanized Strips/Coils -- 300 TPD 300 TPD

6 Hot Dip galvanizing of MS ERW Tubes

-- 300 TPD 300 TPD

The unit obtained CFO for Furnace on 16-08-2017 (valid up to 31-01- 2022) from State

Pollution Control Board to manufacture 90 T/Day of MS Ingots ,60TPD MS Pipes and 70TPD

hot Rolling strips . The unit obtained the respective Consent Orders accordingly and started its

operations.

Salient Features of the Project


Proponent( Director) Mr. Ramniranjan Agarwaland Mr. Vinod Kumar

Agarwal.

Nature of the Project Secondary Metallurgical Process based industry

Latitude and Longitude S.

NO.

LATITUDE LONGITUDE S.

NO.

LATITUDE LONGITUDE

1 17°42'3.22"N 78°29'1.19"E 14 17°41'56.60"N 78°28'47.00"E

2 17°41'57.66"N 78°29'0.91"E 15 17°41'56.50"N 78°28'47.00"E

3 17°41'57.60"N 78°28'55.80"E 16 17°41'55.90"N 78°28'42.00"E

4 17°41'52.50"N 78°28'55.60"E 17 17°41'56.20"N 78°28'41.90"E

5 17°41'52.50"N 78°28'55.40"E 18 17°41'56.80"N 78°28'46.70"E

6 17°41'54.20"N 78°28'50.00"E 19 17°41'57.60"N 78°28'46.70"E

7 17°41'54.20"N 78°28'49.60"E 20 17°41'57.50"N 78°28'48.20"

8 17°41'54.10"N 78°28'49.10"E 21 17°42'0.80"N 78°28'48.50"E

9 17°41'55.30"N 78°28'48.80"E 22 17°42'0.70"N 78°28'50.60"E

10 17°41'55.40"N 78°28'49.40"E 23 17°42'2.00"N 78°28'50.90"E

11 17°41'56.60"N 78°28'49.40"E 24 17°42'2.30"N 78°28'56.20"E

c


12 17°41'56.70"N 78°28'49.60"E 25 17°42'2.20"N 78°28'56.20"E

13 17°41'56.90"N 78°28'49.70"E 26 17°42'2.79"N 78°29'0.25"E

Site Location Survey. No. 287, 288 & 289 in Kallakal village,

Manoharabad Mandal, Medak District in Telangana state

Total land area 78,610.255 sq. m

Total area of green belt developed 2,594.22 sq. m (33.0%)

Nearest High way The plant site approached by small road which connect

NH-7 and Industry

Nearest Rly Stn Dabilpur Rail Way Station is 2.8 Km from the site

Nearest Air Port Rajiv Gandhi International Airport, Shamshabad,

Hyderabad is 70 km from the site

Nearest fire station Narsapur 21 km (North –West)

Nearest village Kallakal Village North 1km

Nearest surface water bodies Pond near Gomaram 9.0 km (West-North West)

Water body near Meenjipeta 5.5 km(North East)

Water body near Tunki Makta 8.0 km (NE)

Medchal Lake 8.63 km (South)

Nearest Reserve Forest Ellampet Reserve Forest 2.0 km South –South West

Any ecologically sensitive areas None

Fresh Water Requirement Industrial: 16 KLD; Domestic: 3.6 KLD (Existing)

Industrial: 57KLD; Domestic: 16 KLD (Proposed)

Source of Water Telangana: Gram Panchayat and tanker supply

Man Power 500 Members to be employed directly and around 100

people may be employed indirectly

Power Demand 15500 KVA and is supplied by Telangana Electricity

supply board

DG Set Existing one DG set of 380 kVA

Project Cost The cost of the project is Rs 150 crores (15000 lakhs)

along with all the accessories

3.0 Requirement of the Proposed Project

3.1 Raw Materials

d

The existing unit is using the MS Scrap; Sponge Iron and Alloying metals for the MS Billets.

It is proposed to increase the production capacity of MS Ingots/Billets from 27,000 TPA to

213,300 TPA, thus the raw material requirement will also increase which is mentioned below.

Raw Materials Requirement for Existing Unit

Raw Materials Requirement for Expansion of the Unit

S.No. Raw Material Consumption Source of Raw

Materials

Method of Transport

Induction Furnaces with concast

1 Sponge Iron 551 TPD From Sponge iron

plants By Road (covered trucks)

2 Scrap 164 TPD Local By Road (covered trucks)

3 Ferro Alloys 6 TPD Local By Road (covered trucks)

Strip mill

1 Billets 587 TPD In plant generation Conveyors

2 High grade coal

thermal 32 TPD

Imported/Purchased

from Traders By Road (Covered trucks)

Tube Mill

S.N

o

Raw

Material

Source Transportation Quantity

TPD TPA

For Existing (90 TPD)

1 Sponge Iron Local/adjacent States By Road 63.54 19,062

2 Iron Scrape Local/Imported By Road 9.9 2,970

3 Pig Iron Local/adjacent States By Road 18.63 5,589

4 Ferro Alloys Local/adjacent States By Road 0.81 243

Strip mill

1 Billets In plant generation and

purchased from Market

Conveyors and

By Road

(Covered trucks)

165TPD

2 High grade

coal thermal

Imported/Purchased from

Traders

By Road


Tube Mill

1 MS Skelp In plant generation By Road


Material Balance for Existing

Billets 90 27,000

Slag 2 600

Cutting& Scaling 1.5 450

e


2 HR Coil 354 TPD

Purchased from

SAIL/TATA/JSW/

Other Manufacturers

By Road (Covered trucks)

Scaffolding

1 MS Tubes 47 TPD In plant generation By Road (Covered trucks)

2 Accessories/

Components 3 TPD

Purchased from local

Manufacturers By Road (Covered trucks)



2 HR Coils 150 TPD Purchased from

SAIL/TATA/JSW By Road (Covered trucks)



Hot Dip Galvanizing

1 MS ERW Tubes 300 TPD In plant generation By Road (Covered trucks)



3.2 Water requirement

Fresh Water

Requirement

Industrial: 15KLD; Domestic: 3 KLD (Existing)

Industrial: 75KLD; Domestic: 15KLD (Proposed)

Source of Water Gram Panchayat and tanker supply

4.0 Manufacturing Process

Billets

Sponge iron, scrap and metal alloys are charged to furnace. Small quantity of silico-manganese

and flux chemicals will be added to molten metal. The advantage of the induction furnace is a

clean, energy-efficient and well-controllable melting process compared to most other means of

metal melting.

Raw materials for the process are scrap, fluxes and Ferro alloys. Sponge iron can substitute

f

scrap up to 50%. The 16”x16” size Scrap bundles will be Lifted and Transported by Overhead

cranes and fed to Induction Furnace. Scrap/ sponge iron, fluxes, Ferro alloys are melted in an

Induction furnace, wherein electric current is passed through it. In the Induction Melting

Furnace the scrap melts at temperature of about 1650C. When the total charge is melted into

hot liquid metal then the metallurgy of steel in terms of carbon, phosphorus content, alloy

elements etc., is controlled at this stage. Based upon the Composition of the molten steel,

additives will be added to get the requisite composition and grade of Steel.

The molten material is poured into mould to produce ingots. The ladle is placed over the

Continuous Casting machine to cast the molten steel into required size of billets. The Cut

Billets are transported by a Billet handling crane and stored in the Storage yard as per the

Grade and Quality for dispatch.

Strip Mill

Reheating of semi-finished steel slabs of steel nearly to their melting point, then roll them

thinner and longer through 8 successive rolling mill stands driven by motors totaling 10,000

HP and finally coiling up the lengthened steel strip for transport to the next process.

Tube Mill

The coil as per desired width and thickness is received from the stock yard and loaded onto

decoiler. The end of the strips are sheared and butt-welded and fed into a storage cage. The

strip is passed through the forming section of the pipe mill and then into the Fin-pass section,

it gradually takes the shape of a round tube.

Continues Coil Galvanizing

Coating gauge is designed for online measurement of metal coatings on both sides of metal

sheet in Continuous Galvanizing Lines (CGL). The deviations from preset target values are

instantly detected allowing immediate corrections to the production process to maintain

uniform coating. As the steel exits the furnace, it enters into a vacuum chamber, or snout,

before entering the molten zinc bath to prevent and air from re-oxidizing the heated steel

product. ERW Pipe are completely immersed in a bath of molten zinc. The bath chemistry is

specified by ASTM B6, and requires at least 98% pure zinc, to form series of bonded zinc-iron

alloy layers.

4.1 Material Balance and Emissions

g

Material Balances for (Existing )M.S. Billets to the tune

of 27,000 Material Balances for (Expansion) M.S. Billets to the

tune of 213,300 TPA

5.0 Measures for Mitigating the Impacts

The purpose of mitigation measures is to avoid, reduce or minimize unwanted impacts on the

environment. To minimize & control the Flue Gas emission from the stack attached to Boiler

& DG Set, M/S Mahalakshmi Profiles Pvt. Ltd. shall be installing Separate Bag filters with

Induction Furnaces & canopy with DG set. 51.76 TPD of Slag from furnaces is given to

cement plant for reuse for land filling. Solids from APCD are disposed off at designated TSDF

site. Used Oil from DG set is being sold to the authorized Recyclers. STP is provided for

treatment of domestic effluent. Treated effluent is used for plantation in the premises. The

industry is regularly operating and maintaining its APCD and ensuring that the emissions are

adequately collected and concentration of air pollutants in its emissions conforms to the

emission standards laid down by the board.

6.0 Cost of the Project

The total project cost is Rs 150.0 Crores (after addition of proposed machinery).Proposed

Employment Generation from proposed project will be around 600 persons out of which 500

persons will be having direct employment and 100 persons will have indirect employment.

7.0 Site Selection

M M/S Mahalakshmi Profiles Pvt. Ltd. is situated at village Kallakal village, Manoharabad


h


The land area of the plant is 19 Acres and 17 Guntas (78,610.256 sq m) out of which 13.675

acres is being used for the Industrial processes and 5.75(33.0% )Acres has been allocated for

green belt.

No National Parks/ Wildlife Sanctuaries/ Biosphere Reserves exist within 5 km radius of

project site. Nearby water body is at Meenjipeta 5.5 km(North East) from the unit.

7.1 Land ownership and Related Details

The project land is owned by the proponent Mahalakshmi Profiles Pvt. Ltd.

It is an Orange category industry that comes under the Industrial area of

Manoharabad, The project falls under the Manoharabad Mandal.

Non agriculture waste Land has been converted for industrial purpose. Land

conversion documents has been enclosed at the end of the report

The existing industry is with a Shed and two 12 tons per hour (TPH) Induction

furnace and a Re- rolling mill. To increase the production The industry is now

proposing addition of 6more 12 TPH additional induction furnace in the same

premises.

8.0 Baseline of the Environment

8.1 Regional Meteorology

The study area has a severe summer season during the month of May with temperature

shooting up to 47oC. The Normal means minimum temperature is 13.7

0C and means maximum

is 39.90C. The onsite of the monsoon in the area is from June and tapers off during October.

The average annual rainfall of the area is 644 mm. The area in general has dry climate with

low humidity.

The predominant wind direction during this period was from SE to NW sector accounting to

about 45.83 % of the total time with calm winds of less than 1.0 kmph. During some of the

times the wind speed was recorded more than 11 kmph. The monitoring period is from March

to May 2019.

8.2 Ambient air quality

Ambient air quality of the study area has been assessed in and around the project. PM10

monitored in the Plant area showed 98th

percentile value of 91.0 g/m3 with PM 2.5 of 39.0

µg/m3. 98

th percentile values of Sulphur dioxide and Oxides of Nitrogen in the Plant area from

the monitored data were 11.0 g/m3 and 25.0 µg/m

3 respectively. CO concentration at all the

locations was found to be 1.47 µg/m3 .

8.3 Air Quality in Buffer Zone

The maximum monitored value of Air pollutants at site and in the buffer zone at selected

i

location is given below:

Name of the

Station PM10

µg/m3

PM2.5

µg/m3

NOX

µg/m3

SO2

µg/m3

CO

Project Area 92 40 25 12 1.61

Banda Mailaram 98 36 23 15 1.66

Baswapur 98 38 22 17 1.74

Rawalkole 99 37 19 13 1.59

Medchal 97 38 20 12 1.69

Nuthankal 99 38 20 12 1.70

Sikindlapur 98 38 22 12 1.65

Koochavaram 99 39 24 14 1.66 Source : Primary monitoring

8.4 Water Quality

Assessment of water quality in the study area includes the quality assessment of parameters as

per the Indian standard IS 10500 for Ground Water. Water characteristics are as follows:

Parameters Results mg/l

TDS 478 - 2448

Hardness 240 - 1628 mg/l

Chlorides 35 - 1079 mg/l

Sulphates 24 - 278 mg/l

Calcium 64 - 477 mg/l

Magnesium 14 - 135 mg/l

Iron 0.03 - 0.16 mg/l

Heavy metals Zn, Pb, Cu and Al BDL Source :Primary monitoring

The analyzed values are found within the permissible/desirable limits of IS: 10500.

8.5 Nature of Soil

Soil samples were analyzed in and around the project site.

The following are the highlights of soil quality in the study area.

Summary of Soil Quality In plant Area

pH of the all soil sample was 7.21.

Texture of soil sample is found to be clay with sand 36%, silt 16% and Clay 48%.

Phosphorus values in the soil sample collected was found to be 28 kg/ha.

Nitrate of the soil sample collected was found to be 186 kg/ ha.

Summary of Soil Quality in Study Area

pH of the all soil samples were found to be 7.16-7.86.

j

Texture of soil samples is found to be Clay and sandy Clay with sand % in the

range between 16-36%, silt between 16-48 % and Clay 34-54%.

Phosphorus values in the soil samples collected were in the range of 28-64 kg/ha

Nitrate of the soil samples collected were in the range of 186-282 kg/ha.

8.6 Ambient Noise

Noise monitoring was conducted in and around the project site. The values were below the

respective statutory norms as applicable. 1st Feb to 30

th April

8.7 Forests

The period of monsoon is very short lived in this area, which has a significant bearing apart

from other biotic pressures, on the floristic composition of the forests. These are open forests

in which thorny and usually hard wood species predominate. Rangipalli ,Manoharabad,

Minajipet ,Kanukunta ,Munurabad and Dabilpur Reserve forest falls within 10 km radius

around the site, with forest wealth such as Teak wood, Bamboo, Tamarind, Rosa grass, Beedi

leaves, Neem seeds, medicinal plants etc., Bamboo fetches maximum revenue along with

Beedi leaves ranging from 50 lakh to one crore per annum.

8.8 Flora

The study area does not habitat any thick vegetal cover. There is usually a thin grass growth

which may appear during the short rainy season in most of the study area, but more or less the

soil is barren and devoid of any grass growth.

8.9 Fauna

Some of the animals which you would find here are Indian Giant Squirrel, Rhesus Monkey,

Jackal, Red vented bulbul, Indian cuckoo, Common House Rats, Indian Fox, Indian Palm

Squirrel, Wild Boar, House Sparrow, Common Myna, Common kingfisher, Common Peafowl,

Common Pigeon, Goose Greylag, Grey Heron, House Crow, Indian Courser and Indian Pond

Heron. No endangered fauna species are found in the area.

8.10 Socio-economic Status

Basic Socio-economic conditions are as follows:

There are 60 villages and many hamlets in the study area.

As per the 2011 census data, the population in the study area is 60,000.

Density of population is 313 persons per sq. km.

Literacy status of the area is found to be moderate with a total of 61.42 % of the

population. Male and Female literacy is about 71.43 % and 51.37% respectively.

Occupational status in the study area is in agriculture. 50 % of total population of the

study area falls under main workers category.

k

Agricultural activities are mainly in monsoon season. Major crops in the area are

Jowar, Maize, groundnut, Ragi, Onion, Vegetables etc

Medical facilities are inadequate, only few villages have the primary health care

centers. For any major health care, the populace of the area has to go to Medchal

/Manoharabad, which are major towns located at a distance of about 8.0 Km from the

proposed site.

Educational facilities are adequate. Higher educational center is Medchal at a distance

of 8.0 km.

This region is well connected by road.

Many villages are adequately provided with protected water supply.

9.0 Identification of Hazards & Risks

Based on the type of operations, the possible Hazards and Emergencies are identified

and appropriate mitigation measures are proposed. Safety hazards relating to Induction

Furnace and Rolling Mill can be classified into 3 categories:

Thermal hazards

Electrical hazards

Physical hazards

S.No. Plant

Area

Possible Deviation from

normal operation

Likely Causes Consequences

1 Furnace Re-circulating and cooling

water coming in contact with

the molten iron or slag

Leakage of water

from the walls

Spurting of metal/

slag

Explosion under

extreme cases

Presence of Oil & Grease and

other Impurities in raw

materials

Fire

Sudden catches

fire & flames

2 High

Power

Transforme

r

Oil temperature being very

high.

Varying room

Temperatures

Sudden flashing

of fire or

bursting.

3 High

Tension

Electrical

Installation

Heavy sparking at the pot

heads and the joints.

Loose joints, cable

cut, burning of

fuses, short

circuits etc.

Sparks in the

beginning,

devastating fire

if neglected.

10.0 Likely Impact on Environment

10.1 Air Environment

l

During construction water will be sprinkled on the soil to avoid dust generation if any. The

debris and unused construction material shall be removed immediately for recycling, if any, or

for land fill.

Bag filters & Cyclone shall be provided to arrest SPM from flue gases to keep it within

permissible limits. All vehicles for service activities at the project site shall be checked for

vehicular emission. The agencies will be asked to keep them within prescribed limits. They

will also be asked to maintain them properly.

A chimney of suitable height is already provided for the D.G. set to control the G.L.C. of

S.P.M., SO2, & NOx levels. Extensive tree plantation shall be resorted to for further improving

the air environment in general and minimize noise levels.

10.2 Water Environment

Water shall be drawn from a tube-well installed in the factory area and distributed through an

Over Head Service Reservoir. This will all be a closed system. During construction existing

toilet facilities shall be used by the labour. Finally waste water from the toilets shall be taken

to septic tank. It will not be thrown outside either on land or in any water body. Roof top Rain

Water shall be harvested and used for ground water recharge to minimize effect of withdrawal

of water from the underground.

10.3 Land Environment

No additional land will be required for expansion. The requirements of sand and aggregates for

the construction works like foundation etc. will be supplied by venders. The land use is thus so

planned that there is minimum adverse impacts.

10.4 Solid/Hazardous Waste

The other solid/Hazardous wastes from the bag filters shall be stored in a dumping pit of

R.C.C. Construction and sent for proper disposal. Slag from the manufacturing process shall

be used for making roads or sent to cement plant for further use.

10.5 Green Belt

The main objective of the green belt is to provide a barrier between the source of pollution and

the surrounding areas. The green belt helps to capture the fugitive emission and to attenuate

the noise generated, apart from improving the aesthetics. Development of green belt and other

forms of greenery shall also prevent soil erosion and washing away of topsoil besides helping

in stabilizing the functional ecosystem and further, to make the climate more conducive and to

m

restore water balance. It is planned that the selected plants will be grown as per normal

horticultural (or forestry) practice and authorities responsible for plantation will also make sure

that adequate provision for watering and protection of the saplings exists at site.

11.0 Emergency Preparedness Plan

Emergency planning is primary for the protection of plant personnel and people in nearby

areas and the environment that could be affected by unplanned hazardous events. Use of

proper personnel protective equipment, fire protection systems and continuous training of

people working in the shop floor are the only measures which helps industries to avoid

accidents.

12.0 Issues And Response During Public Hearing

It is a Draft report submitted to SPCB for grant of public hearing dates.

13.0 Corporate Environment Responsibility

Proposed project will result in growth of the surrounding areas by increased direct and indirect

employment opportunities in the region including ancillary development and supporting

infrastructure. Special emphasis on Financial and Social benefits will be given to the local

people. Development of social amenities will be in the form of medical facilities, education to

underprivileged and creation of self-help groups. The company has earmarked Rs 112 lakhs

towards the Corporate Social Responsibility (CSR) Activities.

14.0 Occupational Health Measures

Conceptually when the healthy employees are placed on the jobs, they produce much better

than what unhealthy employees produce. Larger the number of unhealthy employees, the

greater is the loss to the steel plant in terms of low productivity, increasing healthcare cost,

sickness absenteeism, and loss of production.

Project management is keenly protecting health of the employees by preventing and

controlling occupational diseases and by eliminating occupational factors and conditions

hazardous to the health of the employees at work place by promoting regular medical checkups

and by building safe protecting environment at work sites.

15.0 Post Project Environmental Monitoring Program

A number of environmental aspects will be regularly monitored so as to ensure the

implementation and effectiveness of various mitigative measures adopted. The implementation

and monitoring of effectiveness of the environmental mitigation measures will be assigned to

the Environmental Control Department. An Environmental Management Unit, comprising of

n

senior management level officers will periodically assess and monitor the implementation of

mitigation measures and environmental monitoring Program, and tackle the bottlenecks of the

implementation of mitigation measures.

Budget for Implementation of Environmental Management Plan

S. No Component Capital cost for the

proposed expansion in

Lakhs

1 Pollution equipment for Induction Furnace 75

2 Greenbelt development 5

3 Environmental management cell 25

4 CER 112

Total 217 Lakhs

Documents

Telangana State Pollution Control Board Profile Pvt Ltd, Kallakal (V...Title: Figure 3- Author: Figure 3- Subject: 3-5 Created Date: 5/12/2019 6:53:21 PM