summary on environmental impact assessment report · rolling mill units. coal is lifted to the coal...

Executive Summary

1

SUMMARY ON

ENVIRONMENTAL IMPACT ASSESSMENT

REPORT

OF

Expansion of Steel Plant

at

PLOT No.29, APIIC Gollapuram Industrial Park (Phase#3), Gollapuram Village,

Hindupur Mandal, Ananthapur District.

Submitted to

ANDHRA PRADESH POLLUTION CONTROL BOARD VIJAYAWADA

SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT

Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)

1.0 PROJECT DESCRIPTION

HINDUPUR STEEL & ALLOYS PVT. LTD. (HSAPL) is operating an existing Induction Furnace

of 30,000 TPA out of total 1,00,000 TPA capacity, 1,00,000 TPA of Rolling Mill & 6000 m3/hr

capacity of producer Gas plant at Plot No. 29, APIIC Gollapuram Industrial park (Phase - 3),

Gollapuram Village, Hindupur Mandal, Anantapur District, Andhra Pradesh. 4.05 Ha. (10

Acres) of total land has been taken on lease from APIIC and proposed expansion will be

taken up in the existing plant premises.

Now as a part of proposed expansion it is proposed to increase the capacity of the MS

Billets / MS Ingots Production from 1,00,000 to 1,45,000 TPA, TMT Bars / Structural steel

Production from 1,00,000 TPA to 3,00,000 TPA & Producer Gas plant (Gasifier) capacity

from 6000 m3/hr to 18,000 m3/hr in the existing plant premises located at Plot No.29, APIIC

Industrial Park Gollapuaram (Phase-3), Gollapuaram Village, Hindupur Mandal, Ananthapur

District, Andhra Pradesh State.

As per the Ministry of Environment, Forests & Climate Change, New Delhi notification,

dated 14th September, 2006 and its subsequent amendments, all Secondary metallurgical

processing industries are classified under Category ‘B’. However due to presence of Inter-

state boundary at a distance of 0.5 Kms., the plant, this project becomes Category ‘A’

project. The Ministry of Environment, Forests & Climate Change, New Delhi has accorded

Terms of Reference (TOR) for the proposed expansion project vide letter no. J-11011 / 250

/ 2011- IA II (I), dated 17th August 2017. The EIA Report has been prepared by

incorporating the TOR stipulated by the Hon’ble EAC.

Pioneer Enviro Laboratories & Consultants Private Limited, Hyderabad, which is

accredited by NABET, Quality Council of India, vide certificate No. NABET/ EIA/ 1619/ RA

026, for preparing EIA report for Metallurgical Unit, have prepared Draft Environmental

Impact Assessment (EIA) report for the proposed expansion project by incorporating the

TOR approved by Ministry of Environment, Forests & Climate Change, New Delhi. The

report contains detailed description of the following:



Characterization of status of environment with in an area of 10 km radius from the

plant for major environmental components including air, water, noise, soil, flora,

fauna and socio-economic environment.

Assessment of air emissions, liquid waste and solid waste from the proposed project

along with the noise level assessment.

Environmental Management Plan comprising of emission control measures proposed

to be adopted in the proposed project, solid waste management, Greenbelt

development.

Post Project Environmental Monitoring & Budget for Environmental Protection

Measures.

ENVIRONMENTAL SETTING WITHIN 10 Km. RADIUS OF THE PLANT SITE

The following is the environmental setting within the 10 Km. radius of the project site:

1. The plant is situated in APIIC Industrial Park

2. Proposed expansion will be taken up in the Existing plant premises only. No

additional land is proposed.

3. The plant area does not fall under the industrial areas / cluster, which are listed in

MoEF&CC Office Memorandum dated 13th January 2010 & its subsequent

amendments.

4. Nearest village is Gollapuram and is at a distance of 1.5 Kms. from the plant site.

5. There are no National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors

of Wild Animals within 10 Km. radius of the plant.

6. No forest land is involved in the plant site.

7. There are no Reserve/Protected Forests within 10 Km. raidus of the plant site.

8. Penneru River (3.2 Kms.), Nearest Pond (1.2 Kms.) & Few ponds exists with in 10

Km. radius of the plant site.

9. There are many industries are situated within APIIC Industrial Park & APIIC

Industrial Park Tumkunta.

1.1 Plant Configuration and Production Capacity

The following are details of the existing,proposed products & production capacities



Units Permitted capacities as per the EC issued on

22nd June, 2015

Present proposed Expansion capacities

Production capacities After Present Proposed

Expansion

MS Billets / MS Ingots (through Induction furnace)

1,00,000 TPA (1x8 MT & 2x12 MT)

45,000 TPA (1x15 MT)

1,45,000 TPA (1x8 MT, 2x12 MT

& 1x15 MT)

TMT Bars / Rolled Products / Structural Steel (through Re-heating Furnace / Hot Charging)

1,00,000 TPA Upgradation of existing unit capacity from 1,00,000 TPA to

1,50,000 TPA +

Establishment of Additional 1,50,000 TPA unit

= Total 2,00,000 TPA

3,00,000 TPA

Producer Gas 6,000 m3/hr 12,000 m3/hr 18,000 m3/hr

1.2 Raw Materials

The following will be the raw material requirement for the proposed expansion project:

Raw Material Quantity (TPA) Sources Mode of Transport

For Steel Melting Shop (MS Billets) – 45,000 TPA

Sponge Iron 42,000 Bellary, Karnataka By road (through covered trucks)

Scrap & Mill scales 8,200 Hindupur By road (through covered trucks)

Ferro alloys 2,000 Gollapuram, Hindupur By road (through covered trucks)

For Rolling Mill (TMT bars & Structural Steel) – 2,00,000 TPA

Steel billets 2,10,000 Proposed SMS & Purchased from nearby plants in Industrial Park & out side Industrial Park.

By road (through covered trucks)

Furnace Oil 32 KLD Hindupur Town (or) near by Depot.

By road

For Producer Gas plant *

Coal Indian 36,000 Open Market By road (through covered trucks)

Imported 23,100 Indonesia / South Africa / Australia

Through sea route / rail route / by road

* Producer gas is not required if Rolled products manufactured through Direct rolling / Hot charging

1.3 MANUFACTURING PROCESS

1.3.1 STEEL MELTING SHOP

In Steel Melting 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. As part of



expansion project it is proposed to install 15 T capacity of Induction Furnace of to produce

MS Billets / MS Ingots in the SMS plant.

1.3.2 ROLLING MILL

1.3.2.1 Upgradation Of Existing Rolling Mill:

Regarding increase of production of existing Rolling Mill from 1,00,000 TPA to 1,50,000

TPA following upgradations will be taken up:

1. Inter Mill stand will get separated.

2. One (1) more DC Motor will be installed.

3. Speed of the mill will be increased from 10 m/sec to 15 m/sec

1.3.2.2 Additional Proposed Rolling Mill

In the proposed expansion project, Rolled products are manufactured either using

reheating furnace OR through Hot Charging / Direct hot Rolling technology.

Furnace oil / Producer gas will be used as fuel if manufactured through Re-heating furnace.

The cooled Ingots / Billets generated from Induction Furnace /CCM will be re-heated in

furnace and then sent to Rolling Mill.

If manufactured thorugh Hot Charging / Direct Hot Rolling method no fuel is required. The

hot billets generated from Induction Furnace /CCM will be directly sent to Rolling mill. A

bar and round mill will be installed in the plant to produce additional 1,50,000 TPA of

Rolled Products (TMT Bars / Rolled Products / Structural Steel etc.).

1.3.3 PRODUCER GAS PLANT (GASIFIER)

Producer gas plant is proposed to be established for supply fuel to Pelletization Plant &

Rolling Mill units. Coal is lifted to the coal storage bin by lifting system; the coal is added in

the carbonation stage of two-stage coal gasifier by a programmable control feeding

system. Air is blown in the bottom of furnace by air blower, at the same time, low pressure

steam goes through the blending bin and blends with air, becomes the gasification agent,

which will carry on the gasification reaction with 1200 Celsius degree semi coke in the

gasification stage.



1.4 WATER REQUIREMENT

The water requirement for expansion project will be 152 KLD. This includes water for

cooling purpose in Induction Furnace & Rolling Mill, Process water Producer Gas plant,

Dust suppression and for domestic.

APIIC will supply water from Penna Ahobilam balancing reservoir & Neelakantapuram

Srirami Reddy drinking water supply scheme. Water Clearance is already obtained for

water allocation of 10 MLD from the Penna Ahobilam balancing reservoir. The following is

the break-up of the water requirement for proposed project.

WATER REQUIREMENT FOR EXISTIING & FOR EXPANSION PROJECTS

S. No. Unit Quantity in KLD

Existing Permissions

Proposed Expansion

Total after Expansion

1 Cooling water make-up for SMS 46 20 66

2 Cooling water make-up for Rolling mill 66 130 196

3 Domestic requirement 9 2 11

4 For Greenbelt 10 --- 10

TOTAL 131 152 283

1.4 WASTE WATER GENERATION

There will be no effluent generation in the process & cooling in the IF, Rolling Mill & from

Producer gas plant as closed circuit cooling system will be adopted. Sanitary waste water of

1.6 KLD will be treated in septic tank followed by sub-surface dispersion trench.

1.5 WASTEWATER CHARACTERISTICS

The following are the Characteristics of Sanitary waste water

PARAMETER

CONCENTRATION

Sanitary waste water

pH 7.0 – 8.5

BOD (mg/l) 200 – 250

COD (mg/l) 300 – 400

TDS (mg/l) 800 – 900

Oil & Grease (mg/l) --

SS (mg/l) --



2.0 DESCRIPTION OF ENVIRONMENT

Base line data has been collected on ambient air quality, water quality, noise levels, flora

and fauna and socio economic details of people within 10 km radius of the plant.

2.1 Ambient air quality

Ambient air quality was monitored for PM2.5, PM10, SO2, NOx & CO at 8 stations including

project site during 1st October 2017 to 31st December 2017. The following are the

concentrations of various parameters at the monitoring stations:

Parameter Concentration

PM2.5 : 17.2 to 44.6 g/m3

PM10 * : 30.6 to 78.2 g/m3

SO2 : 7.3 to 19.4 g/m3

NOX : 8.0 to 25.1 g/m3

CO : 678 to 1225 g/m3

2.2 Water Quality

2.2.1 Surface Water Quality

2 no. of samples have been collected from Penneru River which is flowing at a distance of

3.2 kms from the plant to assess surface water quality. The analysis of samples shows that

all the parameters are in accordance with BIS-2296 specifications.

2.2.2 Ground Water Quality

8 No. of ground water samples from open wells / bore wells were collected from the

nearby villages to assess ground water quality impacts and analyzed for various Physico-

Chemical parameters. The analysis of samples shows that all the parameters are in

accordance with BIS: 10500 specifications.

2.3 Noise Levels

Noise levels were measured at 8 locations during day time & Night time. The noise levels at

the monitoring stations are ranging from 43.86 dBA to 67.40 dBA.



3.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

3.1 Prediction of impacts on air quality

The likely emissions from the proposed project are PM10, SO2, NOx & CO. The predictions

of Ground level concentrations have been carried out using Industrial Source Complex (ISC-

3) model. Meteorological data such as wind direction, wind speed, max. and min.

temperatures collected at the site have been used as input data to run the model.

The following are the predicted max. incremental rise in PM10, SO2, NOx & CO

concentrations (24 hourly) at a distance of 800 m from the origin stack in the down wind

direction over the baseline concentrations and due the vehicular emission are given below.

Net Resultant maximum concentrations due to the Proposed Expansion Project

Item PM10

(g/m3)

SO2

(g/m3)

NOX

(g/m3)

CO

(g/m3)

Maximum baseline conc. in the study area 78.2 19.4 25.1 1225

Maximum predicted incremental rise in

concentration due to the Proposed Expansion

1.1 4.9 4.2 --

Maximum predicted incremental rise in

concentration due to Vehicular emissions

0.5 -- 3.1 1.7

Net resultant concentrations during operation of the

plant 79.8 24.3 32.4 1226.7

National Ambient Air Quality Standards 100 80 80 2000

The predicted results show that the net resultant concentration (max. baseline conc. +

max. incremental rise in conc.) of PM10, SO2, and NOx will be well within the National

Ambient Air Quality Standards after commissioning of proposed expansion project. Hence

there will not be any adverse impact on air environment due to the proposed expansion

project.

3.2 Prediction of impacts on noise quality

The major sources of noise generation in the proposed project will be Furnaces &

machinery. The ambient noise levels will be within the standards prescribed by MoEF vide

notification dated 14-02-2000 under the Noise Pollution (Regulation & Control), Rules 2000

i.e. the noise levels will be less than 75 dBA during day time and less than 70 dBA during



night time. 3.3 acres of extensive greenbelt has already been developed to further

attenuate the noise levels. Hence there will not be any adverse impact due to noise on

population in surrounding areas due to the proposed expansion project.

3.3 Prediction of impacts on Water Environment

There will be no effluent generation in the SMS (IF), Rolling Mill & Producer gas plant as

closed circuit cooling system will be followed. Sanitary waste water will be treated in septic

tank followed by sub-surface dispersion trench. Hence there will not be any adverse impact

on environment due to the proposed expansion project.

3.4 Prediction of Impacts on Land Environment

Zero effluent discharge will be adopted. All the required air pollution control systems will

be provided to comply with CPCB / SPCB norms. All solid wastes will be disposed / utilized

as per CPCB / SPCB norms. 3.3 Acres of greenbelt has already been developed in the plant

premises as per guidelines. Hence there will not be any adverse impact on land

environment due to the proposed expansion project.

3.5 Socio - Economic Environment

There will be lot of opportunities in employment to local people during construction as

well as in operation phase. Priority will be given to locals for Semi-Skilled and Unskilled

jobs. There will be further upliftment in Socio Economic status of the people in the area.

Hence there will be further development of the area due to the proposed expansion

project.

4.0 ENVIRONMENTAL MONITORING PROGRAMME

Post project monitoring will be conducted as per the guidelines of CECB and MoEF&CC are

tabulated below:

MONITORING SCHEDULE FOR ENVIRONMENTAL PARAMETERS

S.No. Particulars Frequency of Monitoring

Duration of sampling

Parameters required to be monitored

1. Water & Waste water quality

A. Water quality in the area

Once in a month except for heavy metals which

Composite sampling (24 hourly)

As per IS: 10500



will be monitored on quarterly basis.

B. Sanitary waste water Twice in a month Grab sampling (24 hourly)

As per EPA Rules1996

2. Air Quality

A. Stack Monitoring Once in a month Once in a month

PM PM, SO2 & NOx

B. Ambient Air quality Twice a week 24 hours continuously

PM2.5, PM10, SO2 & NOx

C. Fugitive emissions Once in a Month 8 hours PM

3. Meteorological Data

Meteorological data to be monitored at the plant.

Daily Continuous monitoring

Temperature, Relative Humidity, rainfall, wind direction & wind speed.

4. Noise level monitoring

Ambient Noise levels Twice in a year Continuous for 24 hours with 1 hour

interval

Noise levels

5.0 ADDITIONAL STUDIES

No Rehabilitation and Resettlement is involved in the proposed expansion project. Hence

no R & R study has been carried out.

6.0 PROJECT BENEFITS

With the establishment of the proposed project employment potential will increase. Land

prices in the area will increase. The economic status of the people in the area will improve

due to the proposed project. Periodic medical checkups will be carried out. Top priority will

be given to locals in employment. The project will generate employment opportunities for

about 150 persons during construction stage and for about 50 persons once the plant is

commissioned.

7.0 ENVIRONMENT MANAGEMENT PLAN

7.1 Air Environment

The following air emission control systems proposed in the proposed expansion project:

S. No.

Stack attached to No. of Stacks

Height (in M) Control Equipment

Particulate emission at the

outlet

1. IF (1x15 MT) 1 no. 30 Fume extraction system < 50 mg/Nm3



followed by Bag filter

2. Rolling mill with Re-heating Furnace

1 no. 54 -- --

3. Coal Gasifier (coal handling area)

-- -- Cyclone separator < 50 mg/Nm3

The following air pollution control systems/ measures are proposed in the Plant:

All conveyors will be completely covered with G.I. sheets to control fugitive dust.

All bins will be totally packed and covered so that there will not be any chance for dust

leakage.

All the dust prone points material handling systems will be connected with de-dusting

system with bag filters.

All discharge points and feed points, wherever the possibility of dust generation is

there a de-dusting suction point will be provided to collect the dust.

7.2 Water Environment

In the existing plant zero effluent discharge is being maintained and similar pattern will

be maintained after expansion also.

There will not be any effluent generation from SMS (IF), Rolling Mill & Producer Gas

plant as closed circuit cooling system will be followed.

Sanitary wastewater will be treated in septic tank followed by sub-surface dispersion

trench.

7.3 Noise Environment

The major sources of noise generation in the proposed project will be Furnaces and other

machinery. Acoustic enclosure will be provided to existing D.G. Set. All the machinery will

be manufactured in accordance with MoEF&CC norms on Noise levels. The employees

working near the noise generating sources will be provided with earplugs. The extensive

greenbelt developed within the plant premises will help in attenuating the noise levels

further. Noise barriers in the form of trees are recommended to be grown around

administrative block and other utility units.

7.4 Land Environment



There will not be any effluent generation from SMS (IF), Rolling Mill & Producer Gas plant

as closed circuit cooling system will be followed. Sanitary waste water will be treated in

septic tank followed by sub-surface dispersion trench. All the required Air emission control

systems will be installed and operated to comply with CECB norms. Solid wastes will be

disposed off as per norms. Extensive greenbelt has already been developed in the plant

premises. Desirable beautification and landscaping practices will be followed. Hence there

will not be any impact due to the proposed expansion project.

Solid waste generation and disposal

S.No Type of Solid waste

from Expansion (in TPA)

Disposal Proposed

1 Slag from IF 4,500 Presently we are giving slag [from existing SMS] to slag crushing units. The same practice will be followed in proposed expansion also.

2 Mill Scales from reheating furnace

2000 Mill scales will be given to nearby Ferro alloys manufacturing units or casting units.

3 End Cutting from Rolling Mill

8000 Recycled back as raw material in own induction Furnaces

4 Ash / cinders generated from Gasifier (Rolling Mill)

17 Ash will be given to nearby Bricks manufacturing units.

5 Tar 0.25 Will be Given to TAR recyclers or Road making contractors.

7.5 Greenbelt Development

Greenbelt of 3.3 acres of greenbelt has already been developed in the proposed project.

Capital cost for environment protection for the total project is Rs.5.0 Crores.

7.6 Implementation of CREP Recommendations

All the CREP recommendations will be strictly followed.

*********

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