Baba Eia English

Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s.
Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State
EIA Report
ENVIRONMENTAL IMPACT ASSESSMENT

________________________________________________________________
For
PROPOSED ENHANCEMENT OF SPONGE IRON PLANT FROM 100 TPD TO 175 TPD
(Installation of 1 x 75 TPD Rotary Kiln)
Proposed By
M/s. BABA AKHILA SAI JYOTHI INDUSTRIES PVT. LIMITED

Chikka Bagnal Village, Koppal Taluk & District, Karnataka State.
Prepared By
______________________________________________________________________________________
M/s. GLOBAL ENVIRO LABS

Tilaknagar X Roads, Bagh Amberpet,Hyderabad 500 013. Ph.: 040 65582886; Telefax:040 27407969 E.Mail: globalelabs@rediffmail.com
1 M/s. Global Enviro Labs, Hyderabad
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State
EIA Report
1 - INTRODUCTION
Rapid industrialization leads to around development and improvement in quality of people in the area. Andhra Pradesh is very congenial state for industrial growth due to availability of manpower, raw materials and other infrastuctural facilities. Steel being the basic commodity for all industrial activities, quantum of its consumption is considered as an index of industrial prosperity. Since the independence there has been a substantial growth in the steel sector in India. The Ministry of Steel constituted various sub-groups to assist the Working Group on Iron & Steel Industry for the Ninth Five Year Plan and then upto 2006-07. According to Ministry of Steel Reports, the total production of finished steel has been 20.75 million tones in 1995-96 as compared to 14.30 million tonnes in 1991-92 indicating an increase of 44.8%. The Committee also projected demand of finished steel at 21.225 million tonnes in 1996-97, 32.68 million tones in 2001-02 and estimated 48.8 million tons in 2007-2008. Thereby a substantial demand for steel in industrial, housing and construction sector. In order to meet the increasing steel demand, new steel plants shall be established. In has been observed that a combination of small, medium and large capacity steel plants can contribute in big way in achieving the national interest of self reliance. Sponge iron is the major raw material for manufacturing of steel. By considering the growing demand for Sponge Iron in the global steel market M/s. BABA AKHILA SAI JYOTHI INDUSTRIES PVT. LIMITED has taken Consent for Establishment from Karnataka Pollution Control Board & Environmental Clearance from State Environmental Impact Assessment Authority, Karnataka to install 1 x 100 TPD sponge Iron kiln in Sy. No: 79.83 & 84 in Chikkabaganal Village & Sy. No: 87/3 & 89 in Kunikeri Village, Koppal Tq. and District of Karnataka State. The present plant consists of 1 x 100 TPD Sponge Iron Kiln and having valid consent for manufacture of 100 TPD of Sponge Iron. Over the years, keeping in view of the excellent quality and service, the product enjoy very high reputation in domestic and international markets, the management of BASJIPL is proposed to enhance their plants capacity from 100 TPD to 175 TPD (by setting up of 1 x 75 TPD Kiln) in their existing plant area. For this all the statutory clearances have to be obtained. The project is under implementation stage. 2 M/s. Global Enviro Labs, Hyderabad
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State 1.1 PROJECT COST
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The present proposal pertains to installation of 1 x 75 TPD Rotary Kiln with a project cost of Rs. 7.84 crores. BASJIPL has already invested an amount of Rs. 16.5 crores for its existing unit of 1 x 100 TPD Sponge Iron Plant. BASJIPL will utilize some of the existing infrastructure, which is already developed for the expansion plant. There are number of Sponge Iron industries in the State. However, here it is the will of top management to take environment challenge seriously. Specific areas in which efforts are oriented by the company are: a) Improvement of process efficiency and product quality b) Effective utilization of waste materials. c) Emphasis on process cost reduction. d) Monitoring and controlling pollution. e) Technology upgradation f) Process control by Instrumentation and Computers. 1.2 PURPOSE OF THE REPORT Sponge Iron industries in addition to contributing significantly towards economic growth, also in their wake cause environmental imbalance by creating pollution. Therefore the plant activities must co-exist satisfactorily with its surrounding environment so as to reduce the environmental impact of these activities. This requires sound environmental management plan to be implemented by the plant proponents, which makes environmental protection as essential requirement equal in status with production/profit requirements. M/s. BABA AKHILA SAI JYOTHI INDUSTRIES PVT. LIMITED is conscious of its responsibility towards the society in minimizing the pollution load due to this proposed activity and according to letter issued on dated 2nd March 2010 for Environmental Clearance from State Environmental Impact Assessment Authority (SEIAA), SEAC, Karnataka; the project proponents intends to prepare a Environmental Impact Assessment Report along with Environmental Management Plan for submission for grant of Environmental Clearance for their proposed Expansion programme. 3 M/s. Global Enviro Labs, Hyderabad
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State 1.3 SITE SELECTION CRITERIA
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Selection of project site requires study of various aspects like land, water, fuel, environmental aspects etc. The study area of the proposed expansion in Sponge Iron Plant site is free from ecologically sensitive areas. The following factors have been considered. a. Availability of suitable and adequate facilities. b. Availability of water. c. Proximity of highway. d. Availability of raw materials. e. Availability of manpower. f. Availability of infrastructural facilities g. Suitability of land from geological and topographical aspects h. Environmental aspects etc. Based on the above guidelines the existing plant site in Sy. No: 79.83 & 84 in Chikkabaganal Village & Sy. No: 87/3 & 89 in Kunikeri Village, Koppal Tq. and District of Karnataka State has been chosen for the proposed expansion of sponge iron plant. 1.4 DETAILS OF THE PROJECT SITE The site is located to 7.0 km away from State Highway, which connects Hospet to Hubli The nearest railway facility is available at Ginigera, which is at about 8 Kms. from the project site. The required power will be obtained easily from Karnataka State Power Grid. Chikkabaganal is the nearest village is the near by habitation to the proposed project site located at a distance of 1.0 km. The topography of the site is without many undulations. The average annual rainfall in the area is 675 mm. The maximum temperature is 44oC & the minimum temperature is 16oC. The major crops in the study area are sun flower, groundnut, cotton, paddy etc., 4 M/s. Global Enviro Labs, Hyderabad
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State No habitations exist in the proposed project site. rehabilitation of people is not involved. No forestland is involved in the proposed site.
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Hence displacement and
The following industries are situated with in 10 km radius of the proposed site M/s. Druvadesh Meta Steel & Power Pvt. Ltd. M/s. Harekrishna Metals M/s. KMMI Steals Pvt. Ltd. M/s. Hospet Ispat Ltd. M/s. Trivista Steals & Power Pvt. Ltd. M/s. Vanya Steals Pvt. Ltd. M/s. Bhadra Steals Pvt. Ltd. There are no Ecological and Sensitive areas like Religious and Historic places, Archeological Monuments, Scenic Areas, Hill Resorts, Biosphere reserves, National Parks and Sanctuaries, Seismic Zones and Defense installations within circular area of 10 km radius from plant site. Topo map and plant layout are shown in figure 1.0, & 2.0 respectively
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Table 1: SALIENT FEATURES OF THE PLANT AREA Details of the Study Area Taluk & District & State Village Topograpgy of the Area Latitude Longitude Soil Type Land Availability Koppal Taluk & District of Karnataka State Chikkabaganal Village & Kunikeri Village Plain & Barren 15o1714 N 76o1400 E Red Soils 13.37 Acres General Climatic Conditions Maximum Temperature Minimum Temperature Annual Rainfall Relative Humidity Wind Pattern during the study period 44oC 16oC Average 675 mm 65 75% West to NNE Accessibility Nearest Highway 7.0 km away from State Highway, which connects Hospet to Hubli Nearest Railway station Nearest Airport Nearest City Nearest Village Ginigera Railway Station 8 km Bangalore 250 km Koppal 20 km Chikkabaganal 1.0 km Historical / Important Places Archaeologically Important Site Historically Important Site Sensitive Places Sanctuaries / National Parks Forest Area Nil within the study area Nil within the study area Nil within the study area Nil within the study area Nil within the study area 8 M/s. Global Enviro Labs, Hyderabad
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2. SCOPE AND METHODOLOGY

2.1 SCOPE The scope of the study includes preparation of Environmental Impact Assessment study with detailed characterization of various environmental components such as air, noise, water, land, biological and socio economic within an area of 10 km radius around the proposed project site located at Chikkabaganal & Kunikeri Villages, Koppal Taluk & District of Karnataka State as per the latest guidelines of MOEF, during the Winter season i.e. for the months of December 2009 to February 2010. The main objectives of characterization are To assess the existing baseline status of air, water, noise, land, biological and socio economic environments within the project site (core zone) and around 10 km radius of the study area (buffer zone). To identify and quantify significant impacts due to the proposed activity on various environmental components through prediction of impacts. To evaluate the beneficial and adverse impacts of the proposed activity. To prepare an Environmental Management Plan (EMP) detailing control technologies and measures to be adopted for mitigation of adverse impacts if any, as a consequence of the proposed activity. To prepare a Post Project Monitoring Programme for checking and regulating the environmental quality of the project and help in sustainable development of the area. 2.2 METHODOLOGY OF REIA Any developmental activity is expected to cause impacts on surrounding environment during the construction and operation phases. The impacts may be adverse or beneficial. In order to assess the impacts due to the proposed activity, an Environmental Impact Assessment study has been conducted within an area of 10 km radius around the project site. 9 M/s. Global Enviro Labs, Hyderabad
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The various steps involved in Environmental Impact Assessment study are divided into the following phases: Identification of significant environmental parameters and assessing the existing status within the impact zone with respect of air, water, noise, soil, biological and socioeconomic components of environment. Prediction of impact on air quality taking into consideration the proposed emissions to project the overall scenario. Prediction of impact on Water, Land, Biological and Socio Economic Environment Evaluation of total impacts after superimposing the predicted scenario over the baseline scenario to prepare an Environmental Management Plan. The methodology adopted for studying the various individual components of environment are described below. 2.2.1 Micro Meteorology An auto weather monitoring station to record meteorological parameters was installed at proposed project site. Wind speed, Wind direction, maximum, and minimum temperatures, relative humidity, cloud cover was recorded on hourly basis continuously covering the entire Winter season i.e. for the months of December 2009 to February 2010. Wind speed & wind direction data recorded during the study period were used for computation of relative percentage frequencies of different wind directions. The meteorological data thus collected has been used for interpretation of the existing Ambient Air Quality status, and the same data has been used for prediction of impacts of future scenario due to the activities of the proposed scheme. 2.2.2 Ambient Air Quality The scenario of the existing ambient air quality in the study region has been assessed through a network of 8 ambient air quality stations during the study period within an area of 10 km radius around the project area. The monitoring network was so designed such that 10 M/s. Global Enviro Labs, Hyderabad
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representative samples are obtained form the upwind direction, down wind and cross wind directions of the project site. These monitoring sites have been established keeping in view the available climatological norms of predominant wind direction and wind speed of this particular region. The following points were also taken into consideration in designing the network of sampling stations: a) Topography/ Terrain of the study area b) Populated areas within the study area c) Residential and sensitive areas within the study area. d) Magnitude of the surrounding industries e) Representation of regional background levels f) Representation of cross sectional distribution in downward direction.
The existing Ambient Air Quality status (AAQ) has been monitored for SPM, RSPM, SO2, NOx and PAH. SPM & RSPM at each station has been monitored on 24 hourly basis and all the gaseous sampling has been done on 8 hourly basis. PAH has monitored once in a study period.
Pre-calibrated respirable dust samplers have been used for monitoring of the existing AAQ status. Methodologies adopted for sampling and analysis were, as per the approved methods of Central Pollution Control Board (CPCB). Maximum, minimum, average and percentile values have been computed from the raw data collected at all individual sampling stations to represent the ambient air quality status of the study area.
2.2.3 Noise Environment Noise monitoring has been carried out at eight locations to identify the impact due to the existing sources on the surroundings in the study area. Noise levels were recorded at an interval of 30 minutes during the day and night times to compute the day equivalent, night equivalent and day-night equivalent level
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State 2.2.4 Water Environment
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Eight groundwater samples and one surface water samples from various locations around the project site within 10 km radius were collected for assessment of the existing physicochemical and bacteriological quality. Methodologies adopted for sampling and analysis were according to the IS methods. Field parameters such as pH, Temperature were monitored on site. The parameters thus analysed were compared with IS 10500. The activities surrounding the source during sampling were taken into consideration in interpretation of the water quality of that particular source. 2.2.5 Land Environment Ground truth studies were conducted to identify the land use in and around 10 km radius of the site. Representative soil samples were collected from- eight sampling locations within an area of 10 km radius around the proposed project site for analysis of the physico chemical characteristics to assess the cropping pattern, microbial growth etc. standard procedures were followed for sampling and analysis. The samples collected were also analysed to check the suitability for growth of native plant species in and around the project site. 2.2.6 Biological Environment Information on flora and fauna has been collected in the study area during the study period within 10 km radius. Secondary data have been collected from various government departments such as forest, agriculture, fisheries and animal husbandry to establish the biological environmental conditions. 2.2.7 Socio- Economic Environment Details on economic status of various villages within an area of 10 km around the project site have collected. Information on existing amenities have been collected to determine the developmental activities. Such developmental activities would result in upliftment of the economic status in the area. 12 M/s. Global Enviro Labs, Hyderabad
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All the above environmental parameters have been used for identification, evaluation and prediction of significant impacts. 2.3 PREDICTION OF IMPACTS, ENVIRONMENTAL MANAGEMENT PLAN & DISASTER MANAGEMENT PLAN Various technical aspects of the proposed expansion have been studied to identify the significant impacts, which would arise from the proposed activity. The identified impacts have been quantified through prediction of impacts to estimate the post project scenario. Identified impacts due to proposed enhancement programme have been studied in detail to predict the impacts on various environmental components. Predicted scenario has been superimposed over the baseline (pre-project) status of environmental quality to derive the ultimate (post-project) scenario of environmental conditions. Environmental Management Plan (EMP) for this proposed programme details the control measures, which will be suitable for proposed expansion to maintain environmental quality within the stipulated limits specified by State Pollution Control Board/CPCB/MoEF.
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TABLE-2: ENVIRONMENTAL ATTRIBUTES AND FREQUENCY OF MONITORING
Attribute Ambient Air Quality Ambient Air Quality Ambient Air Quality Meteorology
Parameters SPM, RSPM SO2, NOx, PAH
Surface: Wind Speed, direction, Temperature, relative humidity and rainfall Physical, Chemical and Bacteriological parameters Existing Flora and Fauna
Water Quality Biology
Noise Levels Soil Characteristics Land Use
Noise levels in dB(A)
Socio-economic Aspects
Parameters related to agricultural and afforestation potential Trend of land use change for By using Remote Sensing Different categories techniques and data from various Government agencies. Socio-economic characteristics, (Census Handbook, 2001) labour force characteristics, population statistics and existing amenities in the study area.
Frequency of Monitoring 24 hourly samples twice a week for twelve weeks at eight locations 8 hourly samples average to 24 hrs for twelve weeks at eight locations. PAH samples has been collected once at each station during the study Surface: Continuous monitoring station for entire study period on hourly basis and also data collection from secondary sources. Once during the study period at eight locations Through field visit during the study period and substantiated through secondary sources. Hourly observations for 24 hours per location Once during the study period at eight locations
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3. PROJECT DESCRIPTION
In the text to follow, the project, products, raw materials and the process technology of manufacturing process, facilities as well as the generation of pollutants are discussed in detail. 3.1 PRODUCTION CAPACITIES BASJIPL is presently producing about 100 TPD of Sponge Iron with 1 x 100 TPD capacity of Rotary Kiln. BASJIPL is in the process of erection 1 x 75 TPD Rotary Kiln for increasing its total production capacity of 175 TPD of Sponge Iron Plant. Present Production Capacity Sponge Iron: 100 TPD
After implementation of Proposed Expansion the Production Capacity: Sponge Iron: 3.2 RAW MATERIALS BASJIPL is presently consuming the following raw material for producing 100 TPD of Sponge Iron with one Kiln of 1 x 100 TPD capacity. The consumption of the raw material will increase with commission of 1 x 75 TPD Rotary Kiln for proposed expansion of production of 175 TPD. The fallowing table provides the details of raw material consumption in the BASJIPL plant. S. No. 1 2 3 Raw Material Iron Ore Coal Limestone Total Existing Production (100 TPD) 200 100 04 304 15 M/s. Global Enviro Labs, Hyderabad After Proposed Expansion (175 TPD) 350 175 07 532 Source Bellary, Hospet Imported & Indigenous coal Rayalcheruvu 175 TPD
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State 3.2.1 SPECIFICTIONS OF RAW MATERIALS
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The major raw materials required for production of sponge iron are iron ore, coal and limestone. The Fe content of iron ore should preferably be 65% and above with a gangue content under 5%. In respect of coal, the fixed carbon should be 45% or higher, with ash not more than 25%. Limestone, which is used as a desulphuriser, should have a CaO content of above 45%. The approximate annual requirement of the above raw materials in the size fraction as indicated against each are as follows: The chemical composition of raw materials shall confirm to the following: IRON ORE: Fe (T) : 63.50 % min SiO2 + A12O3 : 5.00 % max S : 0.01 % max P : 0.06 % max COAL: FC : 45 % min VM : 28 32% Ash : 25 % max Moisture : 10 % max LIMESTONE: CaO + Mg O : 45 % min SiO2 + Al2 O3 : 5 % max 3.3 TECHNICAL SPECIFICATIONS OF THE PLANT Sponge Iron Plant (Existing 1 x 100 TPD Rotary Kiln) Diameter of Kiln (ID) Length of Kiln Slope Diameter of cooler Length of cooler Slope Cooler Speed Production 3m 42 m 2.5% 2.3 m 22 m 2.5% 0.3-0.9 rpm 100 TPD
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State Sponge Iron Plant (Proposed 1 x 75 TPD Rotary Kiln) Diameter of Kiln (ID) Length of Kiln Slope Diameter of cooler Length of cooler Slope Cooler Speed Production 2.7 m 40 m 2.5% 2.0 m 20 m 2.5% 0.3-0.9 rpm 75 TPD
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3.4 MANUFACTURING PROCESS Major plant facilities The major plant facilities for the sponge iron plant envisaged are as follows: Day bins Rotary kiln and cooler Off gas system including waste heat power generation Product processing product storage. Day bins There shall be a day bin building to cater to raw material requirement of the kiln. The day bin building will comprise of Nine bins, two for iron ore, two for feed coal, one for dolomite and four bins for injection coal. These bins will generally have storage of about one days requirement of screened iron ore feed (5-20 mm), feed coal (4-8,8-18mm), limestone/dolomite(1-4mm) and injection coal (0-4 mm. 4-8mm ). Weigh feeders will be provided to draw the required quantity of various materials in proportion from the bins and the same will be conveyed to the kiln feed end discharge end. Rotary kiln and cooler The rotary kilns with 3.0m & 2.7m of dia. and 42m & 40m of length will be provided for reduction of iron ore into sponge iron using non-coking coal as reductant. The kiln will be lined with abrasion resistant refractory castables throughout its length with damps at feed end and discharge end. The rotary kiln will be supported on four piers. A slope of about 2.5% shall be maintained. Then main drive of the kiln will be by A.C motors with VVF Drive control. The speed of 17 M/s. Global Enviro Labs, Hyderabad
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the kiln can be varied depending upon the operating conditions. The speed of the kiln can be varied depending upon the operating conditions. The speed of the kiln will be in the range of 0.3-0.9 rpm. The auxiliary drive of the kiln will be by AC motors. The other main components of the kiln will be as given below: Feed end and discharge end transition housing of welded steel construction with refractory lining including feed chute. Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating at feed end and discharge end. On board equipment like fans, manifolds, ports, slip ring, instrumentation etc. Cooling fans at feed end and discharge end. Feed end double pendulum valve &dust valves. The kiln feed from the charging end will consist of sized iron ore (5-18mm), non-coking coal (4-18mm) and limestone/dolomite (1-4mm). Air will be supplied to the kiln through shell mounted air fans. A part of the required coal (0-4mm, 4-8mm,) shall be thrown from kiln discharge end. The injection coal will be withdrawn from the respective bins in suitable proportion and pneumatically injected into the kiln. Necessary rotary feeder, compressor, piping and valves will be provided. In the kiln, the iron ore will be heated to the reduction temperature of 1000-10500C. The iron oxide of the ore will be reduced to metallic iron by carbon dioxide generated in the kiln from coal. The heat required for the reduction process will also be supplied by the combustion of coal. Thermocouple will be installed along the length of the kiln shell for measurement of thermal profile of the kiln. The temperature will be controlled by regulating the amount of combustion air admitted into the kiln through no. of ports with the help of fans mounted on the kiln will have variable speed drive. Auxiliary drive is provided for slow rotation. The reduced material from the kiln will be cooled indirectly in a rotary cooler by an external water spray. The kiln will be provided with one rotary cooler. The rotary cooler will be of 2.3 m dia. And 22 m length and will be supported on two piers with a slope of about 2.5%. The main drive and the auxiliary drive of the cooler will be by one no. of 18 M/s. Global Enviro Labs, Hyderabad
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separate AC motor. The speed of the drive will be about 0.3-0.9rpm. The cooler will be provided with one plain riding ring and thrust riding ring and will be provided with four sets of support rollers at two piers and one set of hydraulic thrust rollers with antifriction bearings. About 1 m end portion of the cooler acts as a screening section, which separates all the accretions larger than 50 mm from the reduced material. These lumps will be discharged separately via lump gate. Rest of the material will be discharged on to the conveyor via double pendulum valve. The other main components of the cooler will be the following. Feed end housing (part of reactor to cooler transition) of welded steel construction with refractory lining. Cooler discharge end housing of welded steel construction. Pneumatic cylinder acuted labyrinth air seal complete with auto lubricating system at feed end and discharge end. The cooler will be lined with refractory castable for about 4.0m length from the feed end. Bypass arrangement will be provided at the discharge end of the cooler for emergency discharge of materials. The cooled product will be conveyed to the product processing building by a system of belt conveyors. The cooling water will be collected in the trough below the cooler and sent to the cooling tower for cooling. The cooled water will be re-circulated. Closed circuit cooling system will be followed in the plant. The rotating parts of the kiln and cooler will be sealed suitably against the stationary parts at the connecting points to avoid leakage of dust-laden gases. Off gas system The kiln shall have its separate off gas circuit. Hot waste gases leave the rotary kiln at about 800 8500C through kiln feed end housing, dust settling chamber and come to an After Burning Chamber (ABC), where combustibles are burnt completely by supplying excess air. The gases at about 950 1,0000C will then be led to a after burning chamber and then the gas will then be cleaned in Electro- static precipitator (ESP) before letting them out into the atmosphere through ID fan and stack of 60 m height. M/s. Global Enviro Labs, Hyderabad 19
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State Product processing and storage
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There shall be one product-processing unit for handing the cooler discharge. The product containing sponge iron, char and spent lime, from the cooler discharge end will be discharged to a set of conveyors and sent to the product processing building. The kilncooler system shall have a separate surge bin of approx.400 T capacity. Product from surge bin can be withdrawn through vibrating feeder and to the product will first be screened in a double deck screen having 3mm and 20mm screens. +20mm material shall be dumped as rejects. The screened product i.e., +3-20 mm and -3 mm fraction shall separately be sent to the product storage separation. Sponge iron lump (3-20 mm) shall be sent to the product storage building for storing in two no. of bunkers where three days storage has been proposed. The sponge iron fines (-3 mm) will be stored in the fines bunker in the product processing building itself where one-day storage capacity will be provided. The sponge iron lump & iron fines will be further conveyed from the respective bunkers by truck to the steel making unit as per the requirement. The char/non- magnetics shall be stored in a separate bin from where it will be sent to the compnays own brick manufacturing unit.
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PROCESS FLOW DIAGRAM OF SPONGE IRON PLANT
IRON ORE
COAL
LIMESTONE
CRUSHING & STORAGE
FEED TO ROTARY KILN HEAT UP TO 1100 deg.C
COOLING WITH WATER IN COOLER
SCREENING
MAGNETIC SEPARATOR 0-4m
MAGNETIC SEPARATOR 4-18 m
DOLOCHAR CHAR SPONGE LUMPS
SPONGE FINES
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State 3.4 RESOURCES REQUIREMENT 3.4.1 RAW MATERIALS REQUIREMENT
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The raw materials those required for producing the Sponge Iron are Iron Ore, Coal and Dolomite etc., These raw materials are purchased from outside sources. Table 3: MATERIAL BALANCE Material Balance for the existing 100 TPD of Sponge Iron production: Input Iron Ore Coal Limestone Quantity in TPD 200 100 04 Quantity in TPD Sponge Iron 100 Char (disposed to brick manufacturing 35 units) Iron Ore fine generated during crushing 16.3 (some portion will be re-used in the process and some portion will be sold to cement industries) Dust collected from coal crushing and 3.0 screening Bag Filter (re-used in Rotary Kiln) Dust collecting from Rotary kiln (sold to 5.2 mini cement plants) Kiln Accretion (will be used in road 0.5 formations) Wet scrapper sludge (given to brick 1.0 manufacturers) Weight loss of the Iron Ore by Oxygen 54.0 removal Other losses of Iron Ore in the Process 12.0 itself Coal & limestone consumption in Process 77.0 itself Total 304 Output
Total
304
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Material Balance after implementation of the proposed Expansion of 175 TPD production of Sponge Iron:
Input Iron Ore Coal Limestone
Quantity in TPD 350 175 07
Total
532
Quantity in TPD Sponge Iron 175 Char (disposed to brick manufacturing 61.25 units) Iron Ore fine generated during crushing 28.52 (some portion will be re-used in the process and some portion will be sold to cement industries) Dust collected from coal crushing and 5.25 screening Bag Filter (re-used in Rotary Kiln) Dust collecting from Rotary kiln (sold to 8.86 mini cement plants) Kiln Accretion (will be used in road 0.87 formations) Wet scrapper sludge (given to brick 2.0 manufacturers) Weight loss of the Iron Ore by Oxygen 94.5 removal Other losses of Iron Ore in the Process 21.0 itself Coal & Dolomite consumption in Process 134.75 itself Total 532
Output
3.4.2 WATER REQUIREMENT The manufacturing process of sponge iron does not require the water at any stage. The water only used for cooling and domestic purpose only. The total water requirement is in the order of 70.0 m3/day for the existing plant operations is met by ground water table through bore well located in the plant premises. During the proposed expansion of sponge iron production the water requirement will be increased to 116 m3/day and the breakup details are indicated below.
WATER REQUIREMENT (m3/day) SOURCE Existing (KL/day) SPONGE IRON PLANT Cooling (Makeup water) Gardening Domestic Total 50 10 10 70
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QUANTITY Process After proposed Expansion (KL/day) 90 12 14 116
The total water requirement of 116 m3/day after the proposed expansion programme will be met by groundwater table through bore well located within the factory premises. WASTEWATER GENERATION There is no generation of wastewater from this sponge iron manufacturing process. Cooling tower water is continuously re-circulated in the cooling water circuits, heat exchangers and discharged to the sump or holding tank through cooling towers where evaporation losses, drift losses and spillages are encountered. Only 5.0 KL/Day of Domestic effluent is generated from the existing process and this is sent to septic tank fallowed by soak pit. After implementation of the proposed expansion also cooling tower water will be continuously re-circulated in the cooling water circuits, heat exchangers and discharged to the sump or holding tank through cooling towers where evaporation losses, drift losses and spillages will be encountered. During the proposed expansion domestic effluent generation will be increased from 5.0 KL/day to 7.0 KL/day and this will also sent to septic tank fallowed by soak pit. Water Balance at BASJIPL is given below:
Table 3: WATER BALANCE Existing Production (KL/day) Input KL/day Output KL/day Cooling 50 Cooling 50 purpose tower (Makeup evaporation water) loss Domestic 10 Sanitary 05 Effluent Gardening 10 Gardening 10 Domestic 05 Losses and Others Total 70 Total 70 After Enhancement of Production (KL/day) Input KL/day Output KL/day Cooling 90 Cooling 90 purpose tower (Makeup evaporation water) loss Domestic 14 Sanitary 07 Effluent Gardening 12 Gardening 12 Domestic 07 Losses and Others Total 116 Total 116
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State 3.4.3 LAND REQUIREMENT
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BASJIPL owns about 13.37 acres of land near Chikkabaganal Village housing the Sponge Iron Plant. The proposed enhancement of production will be coming within the existing premises of BASJIPL. Land Breakup at BASJIPL After Implementing the Proposed Expansion AREA in Acres 2 1 2 0.2 1 0.2 1.3 4.5 1.17 13.37
Sponge Iron Plant Plant Facilities Raw materials & Product Yard Ash Handling Facility Storage (Fuel) Storage (Water) Approach Roads Greenbelt Vacant Land Total
3.4.4 OTHER UTILITIES REQUIREMENT Power: The present power requirement at BASJIPL is 500 KVA and it is obtaining from the Public Grid. For the proposed expansion of sponge iron plant, the power requirement is 380 KVA and it will be obtained from the Public Grid. Manpower: The present manpower at BASJIPL is 80 including contract labourers. The proposed expansion programme will requires the manpower for production and administration purposes and will be recruited locally without any difficulty. The expected total manpower is: 50 including contract labourers for the proposed expansion. Fire Protection Facilities: In order to combat occurrence of fire, necessary fire hydrant hoses shall be provided in the open areas. Adequate number of suitable types of fire extinguishers shall be provided in all the necessary locations Fuel oil system: Light diesel oil (LDO) has been considered as the fuel for the initial start up and for intermittent use during operation. 25 M/s. Global Enviro Labs, Hyderabad
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Laboratory : A laboratory is planed with facilities for the sample preparation and chemical analysis. Illumination: Appropriate level of illumination has been envisaged for the plant. Rain Water Harvesting: S. No Description No. of rain water Size / Capacity harvesting pits / surface collection ponds Rain water 3 ---harvesting pits Period Investment
June 2009
Rs. 30,000/-
3.4.5 CONTROL & INSTRUMENTATION: In order to have a full control on process, instrumentation will be provided at many places such as: PLC Based Control System: Various process parameters like Pressure, Temperature, Level, Flow etc. are sensed by the transmitters. The transmitters will send the proportional signal to the Programmable Logic Controller (PLC). These signals are wired to the Input Channels of the PLC. PLC is interfaced with computer through a special data cable. PC will access all the data in the PLC and display it in the user-friendly SCADA (Supervisory Control and Data Acquisition) software. The outputs from the PLC derived from the control loops are wired to the respective control valves. Typical PLC Based Control Automation System: All these control loops shall consist typically of a process variable transmitter (like RTD / Flow meter / Pressure transmitter / level transmitter etc.), I to P converter and a control valve. The process variable is passed on to a PLC from where it is viewed on a PC. The Set variable can be set through the PC. Variable transmitter, I to P converter and Control valve shall be situated in the field. The PLC and the personnel computer are located in the control room. 26 M/s. Global Enviro Labs, Hyderabad
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State 3.4.6 REGULATORY COMPLIANCE BASJIPL has obtained the statutory clearances for the following. a) Consent to operate Existing 1 x 100 TPD Sponge Iron Plant
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b) Authorization under Hazardous Waste (Management and Handling) amendment Rules, 2003 valid for five years for the following: Hazardous Waste Item Used oil Quantity generated per year 800 Lit/Annum Disposal Stored on covered HDPE Drums & Will be sold to KSPCB recognized agencies for reprocessing. Stored on covered HDPE Drums & Will be sold to KSPCB recognized agencies for reprocessing.
Used grease
500 kg/Annum
BASJIPL is regularly filling all the necessary annual returns under Hazardous Waste (Management and Handling) Amendment Rules, 2003. BASJIPL is regularly submitting the Cess returns and the Environmental Audit (Form V) 3.4.7 CREP GUIDELINES GAZETTE OF INDIA EXTRAORDINARY PART-II-SECTION 3-SUB-SECTION I PUBLISHED BY AUTHORITY NO.] NEW DELHI, WEDNESDAY OCTOBER 11, 2006 MINISTRY OF ENVIRONMENT & FORESTS NOTIFICATION G.S.R. (E) - In exercise of the powers conferred by Sections 6 and 25 of the Environment (Protection) Act, 1986 (29 of 1986), the Central Government hereby makes the following Rules further to amend the Environment (Protection) Rules, 1986, namely: 1. These rules may be called the Environment (Protection) Second Amendment Rules, 2006. 2. They shall come into force on the date of their publication in the Official Gazette or otherwise as mentioned. 2. In the Environment (Protection) Rules, 1986 in schedule I:27 M/s. Global Enviro Labs, Hyderabad
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After Serial No.98 and entries relating thereto, the following serial No. and entries shall be inserted, namely :SCHEDULE I Sl. No. 99. Industry SPONGE IRON PLANTS Parameters 1.0 Emission Standards 1.1 Stack Emission Standards for Kiln Standards 100 mg/Nm3 (Coal based)* : 50 mg/Nm3 (Gas based)* *12% CO2 correction : Shall be atleast 99.9% and be computed as below: CE=%CO2/[%CO2+%CO]x 100
Combustion Efficiency (CE) of after Burner Chamber (ABC)
The Kiln off-gas stack height should be calculated for proper dispersion of SO2 (with the formula of H = 14Q0.3. Where Q=emission of SO2 in kg/h) as per emission regulations Part III of CPCB. Sulphur percentage shall be the percentage of sulphur in coal. The stack height in no case should be less than 45 m. Sampling Portholes and Platforms etc shall be provided as per CPCB regulation. Stack Emission Standards for dedusting units Particulate matter (PM) : 100 mg/Nm3 All de-dusting units should be connected to a stack having a minimum stack height of 30 m. Sampling porthole and platform etc. shall be provided as per CPCB emission regulation to facilitate stack monitoring. De-dusting units can also be connected to ABC Chamber and finally emitted through common stack with kiln off-gas emissions, provided separate arrangements are made for monitoring of emission. 1.3 Fugitive Emission Standards The fugitive emissions of suspended particulate matter (SPM) should not exceed 2000 m g/m3 at a distance of 10 m (approx.) form the sources, identified and mentioned below in table 1, where fugitive dust emissions are anticipated. However, the existing industry is allowed up to 3000 m g/m3 of fugitive emission level of suspended particulate matter (SPM) till one year from the date of issue of the notification. 28 M/s. Global Enviro Labs, Hyderabad
Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd, Chickbaanal Village, Koppal Taluk & District, Karnataka State Table 1 S. No. 1. 2. 3. 4. 5. Area Raw material handling area Crusher area Raw material feed area Cooler discharge area Product processing area
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6.
Other areas
Monitoring Location Wagon tippler, Screen area, Transfer Points, Stock Bin area Crushing plant, vibrating screen, transfer points Feeder area, Mixing area, transfer points Over size discharge area, Transfer Points Intermediate stock bin area. Screening plant, Magnetic Separation unit, Transfer Points, Over size discharge area, Product separation area, Bagging area. Areas as specified by State Pollution Control Board.
2.0 Effluent Discharge Standards 1. All efforts should be made to reuse and re-circulate the water and to maintain zero effluent discharge. 2. Storm water / garland drain should be provided in the plant. 3. In case of maintenance / cleaning of the system the settling tanks effluent of wet scrubbing system or re-circulation system if require to be discharged, should be treated suitably to conform to the following standards: pH Total Suspended Solids (TSS) Chemical Oxygen Demand (COD) Oil and Grease (O&G) : Between 5.5 9.0 : 100 mg/l : 250 mg/l : 10 mg/l
Note (i) For facilitating the compliance of the standards and pollution prevention at source the guidelines / code of practice issued by the Central Pollution Control Board should be followed.
(ii) The standards will be applicable with effect from the date of notification to all new, green field units set up after the date of this notification and all expansion/ modernisation of existing units taken up after the date of the notification. However, the existing units shall install effective pollution control system within six months and shall conform to the standards, after six months of the date of notification. 29 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State
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3.4.8 Guidelines / Code of Practice for Pollution Prevention for Sponge Iron Plants October 2006 3.4.8.1 Air Pollution 3.4.7.8.1 Stack Emission from Kiln 1. Adequately designed ESP or any other adequate air pollution control
system/combination of system should be installed to achieve the prescribed stack emission standards. As installation and operation of Pollution Control Equipment for plants with less than 100 TPD capacity is not economically viable, therefore, it is recommended that plants with less than 100 TPD shall not be permitted in future. Program for phasing out old plants having capacity less than 100 TPD shall be worked out by the State Pollution Control Board. 2. All Pollution control equipment should be provided with separate electricity meter and totaliser for continuous recording of power consumption. The amperage of the ID fan should also be recorded continuously. Non-functioning of Pollution control equipment should be recorded in the same logbook along with reasons for not running the Pollution Control Equipment. 3. The safety cap/emergency stack of rotary kiln type plant, which is generally installed above the After Burner Chamber (ABC) of feed end column should not be used for discharging untreated emission, bypassing the air pollution control device. 4. In order to prevent bypassing of emissions through safety cap and non-operation of ESP or any other pollution control device, software controlled interlocking facility should be provided on the basis of real time data from the plant control system, to ensure stoppage of feed conveyor, so that, feed to the kiln would stop automatically, if safety cap of the rotary kiln is opened or ESP is not in operation. The system should be able to take care of multiple operating parameters and their inter relations to prevent any possibility of defeating the basic objective of the interlock. The system should be foolproof to prevent any kind of tempering. The software based interlocking system, proposed to be installed by industry should be get approved by the concerned State Pollution Control Board, for its adequacy, before installation by the industry. 30 M/s. Global Enviro Labs, Hyderabad
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5. Mechanical operated system for timely collection and removal of the flue dust generated in ESP or any other pollution control device shall be installed. 3.4.8.1.2 Stack Emission from de-dusting units All de-dusting units should be connected to a stack having a minimum stack height of 30 m. Sampling porthole and platform etc. shall be provided as per CPCB emission regulation to facilitate stack monitoring. De-dusting units can also be connected to ABC Chamber and finally emitted through common stack with kiln off-gas emissions. 3.4.8.1.3 Fugitive Emission The measurement may be done, preferably on 8-hour basis with high volume sampler. However, depending upon the prevalent conditions at the site, the period of measurement can be reduced. 3.4.8.2 Effluent Discharge I. All efforts should be made to reuse and re-circulate the water and to maintain zero effluent discharge. II. Storm water / garland drain should be provided in the plant. 3.4.8.3 Noise Control The industry should take measures to control the Noise Pollution so that the noise level standards already notified for Industrial area are complied. 3.4.7.4 Solid Waste Management 3.4.7.4.1 Char Char should be mixed with coal or coal washery rejects and used as fuel in Fluidized Bed Combustion Boilers (FBC) for generation of power. The plants having capacity 200 TPD and above should install Fluidized Bed Combustion Boilers (FBC) for generation of power. Also the smaller capacity individual Sponge Iron Plants (Capacity upto 100 TPD) and operating in cluster can collectively install common Fluidized Bed Combustion Boilers 31 M/s. Global Enviro Labs, Hyderabad
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(FBC) for power generation. The Sponge Iron Plant are free to explore other options / possibilities to use char for generation of power. Char can be sold to local entrepreneurs for making coal briquettes. It can also be mixed with coal fines, converted to briquettes and used in brick kilns. Under no circumstances char should be disposed off in agricultural fields/other areas. Logbook for daily record, of Char production and usage must be maintained by the industry and the record shall be made available to officials of CPCB/SPCB/PCC during inspection. 3.4.8.4.2 Kiln Accretions The kiln accretions are heavy solid lumps and can be used as sub- base material for road construction or landfill, after ascertaining the composition for its suitability and ensuring that it should not have any adverse environmental impact. 3.4.8.4.3 Gas Cleaning Plant (GCP)/Scrubber Sludge The sludge should be compacted and suitably disposed off after ascertaining the composition for its suitability and ensuring that it should not have any adverse environmental impact. 3.4.8.4.4 Flue Dust / Fly ash Flue dust is generated from air pollution control system i.e. ESP or any other air pollution control system installed with kiln. Secondary flue dust is also generated from Bag Filters or any other air pollution control equipment installed with Raw Material Handling, Coal Crusher, Cooler Discharge and Product house unit. The reuse/ recycling of the flue dust generated / collected may be explored and suitably implemented. Fly ash brick manufacturing plant should be install for fly ash utilization. Fly ash can be utilized in cement making by Cement industry also. 3.4.8.4.5 Bottom Ash Bottom ash may have objectionable metallic compounds, therefore should be stored in properly designed landfills as per CPCB guidelines to prevent leaching to the sub-soil and underground aquifer. 32 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 3.4.7.4.6 General
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(a) Solid waste management program should be prepared with thrust on reuse and recycling. Solid waste disposal site should be earmarked within the plant premises. The storage site of solid waste should be scientifically designed keeping in view that the storage of solid waste should not have any adverse impact on the air quality or water regime, in any way. (b) The various types of solid wastes generated should be stored separately as per CPCB guidelines so that it should not adversely affect the air quality, becoming air borne by wind or water regime during rainy season by flowing along with the storm water. 3.4.8.5 Raw Material handling and Preparation (a) Unloading of coal by trucks or wagons should be carried out with proper care avoiding dropping of the materials from height. It is advisable to moist the material by sprinkling water while unloading. (b) Crushing and screening operation should be carried out in enclosed area. Centralized de- dusting facility (collection hood and suction arrangements followed by de-dusting unit like bag filter or ESP or equally effective method or wet scrubber and finally discharge of emission through a stack) should be provided to control Fugitive Particulate Matter Emissions. The stack should confirm to the emission standards notified for de-dusting units. Water sprinkling arrangement should be provided at raw material heaps and on land around the crushing and screening units. (c) Work area including the roads surrounding the plant shall be asphalted or concreted. (d) Enclosure should be provided for belt conveyors and transfer points of belt conveyors. The above enclosures shall be rigid and permanent (and not of flexible/ cloth type enclosures) and fitted with self- closing doors and close fitting entrances and exits, where conveyors pass through the enclosures. Flexible covers shall be installed at entry and exit of the conveyor to the enclosures, minimizing the gaps around the conveyors. In the wet system, water sprays/ sprinklers shall be provided at the following strategic locations for dust suppression during raw material transfer: 33 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State - Belt conveyor discharge/ transfer point - Crusher/screen discharge locations
EIA Report
3.4.8.6 Waste Heat Recovery Boiler (WHRB) Sponge Iron Plants of capacity more than 100 TPD kilns shall use Waste Heat Recovery Boiler (WHRB) for generation of power. M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd is proposed to set up a one more 150 TPD kiln after obtaining the necessary approvals and commencement of production. At this stage the management will install the 12.0 Captive power plant by utilizing the waste flue gases from DRI plant by installing WHR boiler and FBC boiler will utilize entire Char generated from the plant. 3.4.8.7 Cooler Discharge and Product Separation Unit Permanent and rigid enclosures shall be provided for belt conveyors and transfer points of belt conveyors. Dust extraction cum control system preferably bag filters or ESP to arrest product loss in cooler discharge and product separation area shall be installed. 3.4.8.8 Char based Power Plant For plant having capacity of 200 TPD of cumulative kiln capacity, the power production through FBC boiler using char as a part of fuel, is a viable option. Power generation through FBC boiler using char as a part of fuel be implemented in a phased manner within 4 years of commissioning and targeting for 100% utilization of char. Individual Sponge Iron Plants of capacity upto 100 TPD and located in cluster can install a common char based power plant collectively. 3.4.8.9 New Sponge Iron Plants (i) No New Sponge Iron Plant will be commissioned without installation of Pollution control systems as stipulated in the Standards. The concerned State Pollution Control Board will accord consent to operate only after Physical verification of the adequacy of the 34 M/s. Global Enviro Labs, Hyderabad
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Installed pollution control systems for meeting the standards and stipulated conditions in the consent to establish. (ii) All new kilns shall have the independent stack with the kiln or multi-flue stacks in case two or more kilns are joining the same stack for better dispersion of pollutants. (iii) Any entrepreneur having more than 2x100 TPD kiln may install WHRB for power generation, as it's a techno-economic viable option. For plants having capacity of 200 TPD or more, power generation using char in FBC Boiler as part of fuel is techno-economic viable option, therefore, new plants must install FBC boiler for power generation at the time of installation of the industry. (iv) Any new sponge iron plant being installed along with the other downstream facilities of converting the sponge iron into steel with/without further processing the steel should meet the target of 100% utilization of sensible heat of DR (Direct Reduction) Gas and Char for power generation. Wet scrubbing system for kiln off-gas treatment for such plants should not be opted. 3.4.8.10 General Guidelines (a) Extensive plantation/Green belt shall be developed along the roads and boundary line of the industry. A minimum 15 m width Green Belt along the boundary shall be maintained. However, the green belt may be designed scientifically depending upon the requirement and local and mix species of plants may be selected for the green belt. (b) Monitoring of stack emissions, fugitive emissions, trade effluent and noise level shall be done as per CPCB regulations. (c) Pollution control systems shall be operated as an integral part of production to ensure minimum emissions. Pollution Control System shall start before conveyor
operation/operation of plant. Similarly pollution control system shall be stopped only after completion of conveyor operation/operation of plant so that possibility of dust settlement in ducts can be eliminated. Continuous evacuation of dust (from Dust catchers, ESPs, Bag filter hopper etc.) shall be organized.
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3.4.8 ENVIRONMENTAL POLICY OF M/s. BASJIPL In order to fulfill the promise, an Environmental Policy will be adopted by BASJIPL and as fallows: a) Prevent pollution in its activities associated with manufacturing and supply of sponge iron. b) Continually improve environmental performance c) Comply with environmental legislations and regulations. These shall be implemented by a) Reducing the waste and fugitive pollutants emissions though extensive monitoring. b) Conserving energy and other resources through optimum utilization and waste minimization. c) Training and involving the employees for development of Clean and Green Environment.
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4. BASELINE ENVIRONMENT
The baseline environmental quality represents the background environmental scenario of various environmental components such as air, noise, water, land and socio economic status of the study area. The general study area covers 10 km radius of the BASJIPL plant site 4.1 MICRO METEOROLOGY OF STUDY AREA Meteorology of the study area plays an important role in the air pollution studies. The prevailing micro meteorological conditions at the proposed project site will regulate the dispersion and dilution of air pollutants in the atmosphere. The predominant wind directions and the wind speed will decide the direction and distance of the most affected zone from the proposed activity. The meteorological data collected during the monitoring period is very useful in interpretation of baseline as input for dispersion models for predicting the Ground Level Concentrations. (GLC) An auto weather monitoring station was installed during the months of December 2009 to February 2010 to record various meteorological parameters on hourly basis to understand the wind pattern, Temperature variation, Solar insulation and relative humidity variation etc. Percentage frequencies of wind in 16 directions have been computed from the recorded data of the study period to plot wind rose diagram. Figure 3.0 represents the wind pattern of the study period.
4.1.1 Wind pattern during Study Period (December 2009 to February 2010)
Predominant Wind directions during this period were from the W to NNE sector accounting to about 75% of the total time. Wind speeds during this period were varying between 2.0 11 kmph and some time more than 11.0 kmph. The wind of less than 2.0 kmph were treated as calm, and calm conditions are nil. 37 M/s. Global Enviro Labs, Hyderabad
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Climatology: In the study area the maximum and minimum temperatures are 44oC & 16oC and maximum and minimum relative humidity values are 45 & 75 were recorded during the study period. The climate of the region is characterized by hot summer and is generally dry except during the southwest monsoon season, between the months of July and September.
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Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 4.2 AMBIENT AIR QUALITY
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In order to identify the background air quality data and also to represent the interference from various industrial and local activities, screening techniques have been used for identification of air quality stations in the study areas. The following points have been considered for the selection of air quality monitoring stations. Predominant wind directions Topography of the study area Terrain and sensitive areas Populated areas near to the project area Magnitude of the surrounding industries
Identifications of various industrial operations in the study area:
The area experiences dry climate and most of the roads in the area are unmetalled. There are few large scale & small-scale industries located in the 10 km radius of the study area. Topography / Terrain and sensitive areas of the study area: The site is located at an elevation of 230 m above mean sea level (MSL). There are no sensitive areas with the study area. Based on the above, the AAQ stations have been identified and location of ambient air quality stations are presented in Table 5. Identification of Ambient air Quality Monitoring Stations
Ambient air quality of the study area has been assessed through a network of 8 ambient air quality locations. These stations are designed keeping in view of the climatological conditions of the study region.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Table 5: AMBIENT AIR QUALITY MONITORING STATIONS S. No. Code Name of Sampling Location Distance (km) w.r.t Project -SEE SW WWN NW NNE SE NNW
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Direction w.r.t Project -1.0 1.5 2.2 3.7 3.5 2.9 5.1
Core Zone 1 A-1 Buffer Zone 2 A-2 3 A-3 4 A-4 5 A-5 6 A-6 7 A-7 8 A-8
Project Site Chikka bagnal Lachankeri Kunikeri Kunikeri tanda Hire bagnal Karkihalli Halavaru
The above monitoring stations are located such that a representative background ambient air quality levels are obtained. Figure 4.0 shows the location of ambient air quality monitoring stations in the study area (Buffer & Core Zone). Pre-calibrated R.D. Samplers and High Volume Samplers have been used for monitoring the existing AAQ status. Maximum, Minimum, Average and Percentile values have been computed from the raw data collected at all individual sampling stations to represent the Ambient Air Quality Status. The Ambient Air Quality studies were carried out during December 2009 to February 2010. The significant parameters viz. Suspended Particulate Matter (SPM), Respirable Suspended Particulate Matter (RSPM), Sulphur dioxide (SO2), Oxides of Nitrogen (NOx) and Carbon monoxide (CO) were monitored in the core and buffer zones. The data thus obtained is considered for preparing this report. Sampling & Testing Methodology Below table gives the standard procedures adapted for sampling and testing. The procedures are in compliance with CPCB & MoEF. Parameter SPM and RSPM SO2 NOx CO Duration of Sampling 24 hours - continuous 8 hours continuous 8 hours - continuous Grab Sample 41 M/s. Global Enviro Labs, Hyderabad Recommended Analytical Procedure Gravimetric Method as per IS: 5182 Pararosaniline Colorimetric method Modified Jacob & Hochheiser method As per IS 5182
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Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 4.2.1 ANALYSIS OF BASELINE CONCENTRATIONS
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BUFFR ZONE Suspended Particulate Matter - SPM Suspended particulate matter monitored in the study area showed 98th percentile values in the range of 105.4 133.08 g/m3. Highest value of 134 g/m3 was recorded at Chikka bagnal
Respirable Suspended Particulate Matter - RSPM Suspended particulate matter monitored in the study area showed 98th percentile values in the range of 29.0 46 g/m3. Highest value of 50 g/m3 was recorded at Chikka bagnal. Sulphurdioxide - SO2 98th percentile value of Sulphur dioxide in the study area from the monitored data was in the range of 4.45 9.05 g/m3. Maximum value of sulpurdioxide of 9.1 g/m3 obtained near the sampling location Chikka bagnal. The values of SO2 monitored in the study area are well within the limits of NAAQ standards.
Oxides of Nitrogen - NOx Ambient air quality status monitored for nitrogen oxides in the study area were in the range with 98th percentile values between 6.65 12.2 g/m3. A maximum value of 12.2 g/m3 was prevailing at the time of sampling at Chikka bagnal sampling station.
Carbon Monoxide - CO CO concentration at all the locations was found to be less than 1 ppm
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State CORE ZONE
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Ambient air monitoring has been assessed during summer season in one station in the core zone.
Suspended Particulate Matter - SPM Suspended particulate matter monitored in the core zone showed 98th percentile value is 159.54 g/m3. The highest value of SPM level 160 g/m3 was observed. The SPM concentration in the study area was found to be well within the norms prescribed by NAAQ.
Respirable Suspended Particulate Matter - RSPM RPM value monitored in mine lease area showed the 98th percentile value 64.54 g/m3. Highest value of 65 g/m3 was observed. Sulphur dioxide - SO2 98th percentile value of Sulphur dioxide in the core zone is 13.92 g/m3. The maximum value of sulphur dioxide of 14.2 g/m3 was observed. The values of SO2 monitored in the study area are well within the limits of NAAQ standards. Oxides of Nitrogen - NOx 98th percentile value of Nitrogen oxides in the core zone is 16.21 g/m3. The maximum value of nitrogen oxides of 16.4 g/m3 was observed. Carbon Monoxide - CO CO concentration in the plant area was found to be less than 1 ppm.
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Summary of AAQ monitoring at each location is given in Table - 7 and Percentile values of ambient air quality is enclosed in Annexure - A. Table 7: SUMMARY OF AAQ MONITORING Locations SPM Project Site Chikka bagnal Lachankeri Kunikeri Kunikeri tanda Hire bagnal Karkihalli Halavaru 159.54 133.08 120.54 113 117.54 105.4 110.08 120.0 98th Percentile Values RPM 64.54 49.08 45.54 35 39.54 29.0 31 36.0 SO2 13.92 9.054 7.3 6.1 6.07 4.45 6.40 6.75 NOx 16.21 12.2 10.54 8.50 6.65 7.26 7.5 8.76
Note: CO at all locations was found <1.0 ppm AMBIENT AIR QUALITY PERMISSIBLE LIMITS SPECIFIED BY CENTRAL POLLUTION CONTROL BOARD Pollutants Time-weighed Average Annual Average * 24 hours ** Annual Average * 24 hours ** Annual Average * 24 hours ** Annual Average * 24 hours ** Annual Average * 24 hours ** Concentration in ambient air Industrial Residential Sensitive Areas Areas Areas 80 g/m3 60 g/m3 15 g/m3 120 g/m3 80 g/m3 30 g/m3 3 3 80 g/m 60 g/m 15 g/m3 120 g/m3 80 g/m3 30 g/m3 3 3 360 g/m 140 g/m 70 g/m3 500 g/m3 200 g/m3 100 g/m3 120 g/m3 150 g/m3 5.0 g/m3 10 g/m3 60 g/m3 100 g/m3 2.0 g/m3 4.0 g/m3 50 g/m3 75 g/m3 1.0 g/m3 2.0 g/m3
Sulphur Dioxide (SO2) Oxides of Nitrogen as NO2 Suspended Particulate Matter (SPM) Respirable particulate Matter (RPM) CO Concentration
It has been observed that during study period the RPM and SPM values are with in the limits, in the villages which use fuel wood for domestic purposes. The villages are surrounded by barren area & gardens on all sides causing amount of wind blown dust, especially in the dry seasons to some extent. 45 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 4.2.2 Poly Aromatic Hydrocarbons (PAHs):
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PAH (Polycyclic Aromatic hydrocarbon) are environmental carcinogens and constitute an important class of organic aerosol components generated in a variety of combustion process and are emitted into the atmosphere preferentially associated with sub micron size particles. Polycyclic aromatic hydrocarbons (PAHs) are chemical compounds that consist of fused aromatic rings and do not contain heteroatoms or carry substituents. These compounds can be point source pollutants (e.g. oil spill) or non-point source (e.g. atmospheric deposition) and are one of the most widespread organic pollutants. Some of them are known or suspected carcinogens, and are linked to other health problems. They are primarily formed by incomplete combustion of carbon-containing fuels such as wood, coal, diesel, fat, tobacco, or incense. Tar also contains PAHs. Since human civilization relies so heavily on combustion, PAHs are inevitably linked to our energy production. In this sense, PAH can be thought of as marker molecules as their abundance can be directly proportional to combustion processes in the region and therefore directly related to air quality. Different types of combustion yield different distributions of PAHs in both relative amounts of individual PAHs and in which isomers are produced. Thus, those produced from coal burning are different from those produced by motor-fuel combustion, which differ from those produced by forest fires. Some PAHs occur within crude oil, arising from chemical conversion of natural product molecules, such as steroids, to aromatic hydrocarbons. 4.2.2.1 Sources of PAHs The sources of atmospheric PAHs are both natural and anthropogenic. The natural sources are forest fire, volcanic activities and bacterial decay of organic materials. The anthropogenic sources include Industries, Automobiles, Domestic, Diesel Exhaust Particles, Human Habitats.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 4. 2.2.2 Major Sources of PAHs in the Environment:
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Combustion of Fossil Fuels Automobile Engine Exhausts Atmospheric fallout of fly ash particulate. Coal Tar and other processing wastes. Aluminum Plants Sponge Iron Industries Refinery and Oil Storage wastes Accidental Spills from Oil tankers and other ships Tobacco and Cigarette smoke Refuse and waste incineration Coal gasification and liquefaction process Creosote and other wood preservative wastes. Petrochemical industrial effluents Forest Fire Rural and Urban sewage sludge Smoke, Charcoal broiled or pan fried foods River borne pollution Commercial and pleasure boating activities. 4.2.2.3 Fate of PAHs in the Environment:
PAHs enter the air mostly as releases from burning coal, coke oven plants, automobile exhausts and wood fire. PAH remains in the air attached to dust particles. Most PAHs do not dissolve easily in water. They stick to solid particles and settle to the bottom of lakes or rivers. Microorganisms break down PAHs in soil or water after a period of weeks to months. In soil, PAHs are most likely to stick tightly to particles. Certain PAHs move through soil to contaminate Groundwater. 47 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 4. 2.2.4 Route of Exposure of PAHs:
EIA Report
Breathing air containing PAHs in the work place of coking coal, tar and asphalt production plants, smoke houses and municipal incinerators. Breathing air containing PAHs from Cigarette smoke, wood smoke, vehicle exhaust and asphalt. Coming in contact with air, water or soil, near Hazardous waste site . Eating contaminated cereals, flour, bread, vegetables, fruits, meats. Drinking contaminated water or milk. Nursing infants of mothers living near Hazardous waste sites may be exposed to PAHs through their Mothers milk. 4. 2.2.5 Methodology of Measurement (Sampling & Analysis): This method is designed to collect particulate phase PAHs in Ambient Air and fugitive emissions and to determine individual PAH compounds. It is a High volume (1.2 m3/min) method capable of detecting sub.ng/m3 concentration of PAH with sampling volume 480 m3/min of air. 4. 2.2.6 Sampling of PAHs Particulate laden PAH samples have been collected on Whatman Glass Fibre Filter (EPM 2000) using High Volume Sampler (HVS) at a flow rate of more than 1m3/min for a period of 24 Hrs with 8 hourly samples with a frequency of twice a month. The sampling height maybe between 10-15 ft from the Ground Level for Ambient Air quality Monitoring. 4. 2.2.7 Sample Extraction, Processing and Analysis: Samples were extracted with Toluene using Ultrasonic bath for about 30 min and repeated thrice for complete extraction. Alternatively sample can be extracted using soxhlet extraction apparatus for about 8 hours. Extracted samples are pooled and concentrated using rotary evaporator and further cleaned up with Cyclohexane using silica gel Column Chromatography and finally analyzed on Gas Chromatograph (GC) using capillary column (HP-Ultra-2, 30 m) and Flame Ionization Detector (FID). Alternatively samples may be analysed using HPLC or more confirmatively with GC-MS. 48 M/s. Global Enviro Labs, Hyderabad
EIA Report
Sample Extraction, Clean-Up, Concentration And Analysis Sequence
Whatman EPM-2000 Filter
Ultrasonic Extraction with Toluene (50ml x 3 times)
Filter and dry with Anhydrous Sodium Sulphate
Concentration with Rotary Vacuum Evaporator
Clean-up with Silica Gel Column Chromatography
Elution with a CycloHexane (5 ml x 3 times)
Concentration with Rotary Vacuum Evaporator
Evaporated to nearly Dryness under Nitrogen
Re-dissolved in 0.5-1.0 ml of Toluene
Redissolved in 2-5 ml Methanol
Capillary GC-FID or GC/MS
HPLC-UV/Florescence Detector
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4. 2.3 Proposed Ambient Limits for PAH in India: An expert working group was constituted to propose Ambient Air Quality Standards for Benzene and BaP for 2005, 2010. The meeting of the expert working group on Ambient Air Quality Standards (Benzene and BaP) was held on March 27, 2002 at CPCB, Parivesh Bhawan, Delhi- 32. Finally following recommendations were made unanimously for long term Ambient Air Quality Standards for Benzene and B(a)P by the expert group.
Proposed Ambient Limits for PAH in India
Sl. No
Air Toxic Pollutants
Ambient Air Quality Standard upto 2005 10 g/m3 5 ng/m3
Ambient Air Quality Standard upto 2010 10 g/m3 5 ng/m3
1 2
Benzene
Benzo(a) Pyrene i.e, B(a)P
Analysis of PAH (Benzene soluble fraction) in SPM Code A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 Locations Project Site Chikka bagnal Lachankeri Kunikeri Kunikeri tanda Hire bagnal Karkihalli Halavaru SPM (Benzene Soluble fraction) (ng/m3) 4.7 2.4 1.2 2.1 1.5 2.6 1.7 2.3
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 4.3 NOISE ENVIRONMENT
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The acoustical environment varies dynamically in magnitude and character through out most communities. The noise level variation can be temporal, spectral and spatial. The residential noise level is that level below which the ambient noise does not seem to dropdown during the given interval of time and is generally characterized by unidentified sources. Ambient noise level is characterized by significant variations above a base or a residential noise level. The maximum impact of noise is felt on urban areas, which is mostly due to the commercial activities and vehicular movement during peak hours of the day. Measured noise levels displayed as a function of time provides a useful scheme for describing the acoustical climate of a community. Noise levels records at each station with a time interval of about 30 minutes are computed for equivalent noise levels. Equivalent noise level is a single number descriptor for describing time varying noise levels. The equivalent noise level is defined as mathematically. 10Log1/ T (10Ln/10) Where L = sound pressure level a function of time dB (A) & T = Time interval of observations Noise levels during the night time generally drop, therefore to compute Equivalent noise levels for the night time, noise levels are increased by 10 dB (A) as the night time high noise levels are judged more annoying compared to the day time. Noise levels at a particular station are represented as Day- Night equivalent (Ldn). DayNight equivalent is the single number index designed to rate environmental noise on daily /24 hourly basis. Mathematically Ldn is given by Ldn = 10 log {1/24 (15 x 10(Ld/10) + 9 x 10 (Ln + 10)/10)} Where Ld = A weighed equivalent for day time period (7 am to 10 pm) Ln = A weighed equivalent for night time period (10 pm to 7 am) 51 M/s. Global Enviro Labs, Hyderabad
EIA Report
Noise levels were measured near highways, residential areas and other settlements located within 10 km radius around the Mine site. In order o know the baseline noise levels, in and around the proposed project site, Noise levels were measured at the project site and also at 7 villages in the study area. The day equivalent noise levels were found to be relative high due to local activities in the villages. Noise levels recorded in the nighttime were found to be less. In order to assess the noise levels in the study area, monitoring was carried out at 8 different locations within 10 km radius of the study area. Noise levels were recorded at each station with a time interval of one minute for about 30 minutes in each hour and were computed for equivalent noise levels for day-equivalent, night-equivalent & day-night equivalent. Details of noise monitoring stations are given in Table 8.0. The noise recording stations are shown in Figure 5 and the summary of the minimum, maximum, day - equivalent, night - equivalent and day-night equivalent values computed for various location in the study area is given in Table 9.0 Table 8: NOISE MONITORING STATIONS S. No. Code Location Distance (km) w.r.t Project -Direction w.r.t Project Within site Predominant Activity
Core Zone 1 N-1 Buffer Zone 2 3 4 5 6 7 8 N-2 N-3 N-4 N-5 N-6 N-7 N-8
Project Site
Vehicular movement & Construction activity Vehicular movement & local activity Vehicular movement & local activity Vehicular movement & local activity Vehicular movement & local activity Vehicular movement & local activity Vehicular movement & local activity Vehicular movement & local activity
Chikka bagnal Lachankeri Kunikeri Kunikeri tanda Hire bagnal Karkihalli Halavaru 52
SEE SW WWN NW NNE SE NNW
1.0 1.5 2.2 3.7 3.5 2.9 5.1
M/s. Global Enviro Labs, Hyderabad
EIA Report
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Table 9: EQUIVALENT NOISE LEVELS IN THE STUDY AREA Code Location Day Equivalent 57.5 52.5 51.4 47.2 53.5 50.6 51.3 52.7 dB (A) Night Equivalent 50.2 47.5 45.2 41.0 46.5 42.9 40.5 47.5 Day-Night Equivalent 54.0 49.3 47.1 43.5 51.2 48.7 44.6 50.1
EIA Report
N1 N2 N3 N4 N5 N6 N7 N8
Project site Chikka bagnal Lachankeri Kunikeri Kunikeri tanda Hire bagnal Karkihalli Halavaru
It is observed that the noise values obtained were within the prescribed Ambient Air Quality Standards with respect to Noise. AMBIENT NOISE LEVEL STANDARDS Area Code A B C D Category of Area Industrial Area Commercial Area Residential Area Silence Zone Limits in dB(A) Leq Day Time Night Time 75 70 65 55 55 45 50 40
4.4 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) Analysing water samples collected for physico-chemical and biological parameters The surface water sources in the study area are Tungabhadra reservoir located at about 2.2 km from the project site. Assessment of water quality in the study area includes the quality assessment of parameters as per the Indian standard IS 10500 (drinking water standard). The locations of water sampling are shown in Figure 6. 54 M/s. Global Enviro Labs, Hyderabad
EIA Report
9 water samples from various locations in and around the project site within 10 km radius were collected for assessment of the physico-chemical and bacteriological quality. Methodologies adopted for sampling and analysis were according to the IS methods. Field parameters such as pH, Temperature, Taste and odour were monitored on site. The parameters thus analysed were compared with IS 10500. Details of water sampling locations are given in Table 10. Table 10: WATER SAMPLING LOCATIONS
Code
Location
Source
W-1 W-2 W-3 W-4 W-5 W-6 W-7 W-8 W-9
Project site Chikka bagnal Lachankeri Kunikeri Kunikeri tanda Hire bagnal Karkihalli Halavaru Tungabhadra reservoir
Bore well Bore well Bore well Bore well Bore well Bore well Bore well Bore well Surface
Distance (km) w.r.t Project -1.0 1.5 2.2 3.7 3.5 2.9 5.1 2.2
Direction w.r.t Project -SEE SW WWN NW NNE SE NNW SEE
Usage
Domestic/Industrial Domestic Domestic Domestic Domestic Domestic Domestic Domestic Domestic
Annexure - B represents the water quality data at the above locations. The summary of the same is given below: Surface Water Sample Within 10 km Radius: pH of the surface water samples collected was in the range between 8.80 Total dissolved solids in the samples were in the range between 600 mg/l. Total hardness was found to vary between 89 mg/l. Chlorides concentration was found to vary between 136 mg/l.
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Fluoride concentration was found to vary between 0.5 mg/l. Sulphates concentration was found to vary between 63 mg/l. Heavy metal concentration in all the samples were found to be well within the limits. Surface water samples collected at Ayyavanipalli tank showed compliance of all parameters with the drinking water standard of IS 10500
Water Sample at Project Site: pH of the ground water samples collected in the site area is 7.3 Total dissolved solids in the samples was 1230 mg/l. Total hardness of the water was 320 mg/l. Chlorides concentration was 70 mg/l. Fluoride concentration was 0.9 mg/l. Sulphates concentration was 45 mg/l. Heavy metal concentration in all the samples was found to be well within the limits. Groundwater Samples Within 10 km Radius: pH of the ground water samples collected was in the range between 6.91 7.68 Total dissolved solids in the samples were in the range between 1000 - 1836 mg/l. Total hardness was found to vary between 310 - 375 mg/l. Chlorides concentration was found to vary between 95 - 220 mg/l. Fluoride concentration was found to vary between 0.7 1.3 mg/l. Sulphates concentration was found to vary between 80 168 mg/l. Heavy metal concentration in all the samples were found to be well within the limits. Ground water samples collected from 8 locations within 10 km radius of the proposed site showed all parameters well within the drinking water standards specified in IS 10500.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 4.4.1 HYDROLOGY
EIA Report
Numerous small streams flowing in southern direction towards the Tungabhadra Reservoir. The back waters of Tungabhadra dam is located at a distance of 1.5 km from the project site. The study area does not have any manmade big water tanks except for the small ponds. Due to the scanty rainfall over the last few years, the ponds and streams hold water only during and just after monsoon season. 4. 4.1.1 Occurrence and Movement of Ground water in Rock Formations The joints and other openings in gneiss and granites, the pore spaces in the zone of eathering and bedding planes of the metamorphosized sediments determine the rate of percolation of water into sub-surface and the yield of the wells in the region. Black cotton soil allows water to infiltrate slowly after saturation. The impervious calcareous clay bed, below the black cotton soil prevents the downward movement of water. Whereas, the areas covered by red loam/sandy solid have relatively greater percolation because of its relatively high porosity and permeability. Occurrence of groundwater is mainly controlled by water table conditions. The recharge of the ground water is mainly due to the rainfall, which is scanty in the region. Therefore, the depth of water table level in the area is between 30-40m below the ground level. Considering the overall features, the ground water movement appears to be from North-east to South and from South-west towards the Tungabhadra Reservoir. 4. 4.1.2 Depth of Ground water and Seasonal variation: Dug wells are more common and popular in the study area. Nearly 33% of the wells are of shallow type and water table is within 10m depth, The deep dug wells are upto a depth of 18m. The study of fluctuating ground water level by the Ground Water Board (GWB) reveals that the fluctuation is in the order of 1.65 m to 4.42 m with average fluctuation of 3.13m. 4. 4.1.3 Ground Water Potential Ground Water potential has been assessed as per the data collected from the State Ground 58 M/s. Global Enviro Labs, Hyderabad
EIA Report
Water Department. The entire region is mainly underlain granite, gneisses and Dharwar schists that are known to be hard rocks, which have least porosity. Ground water is found in pockets in the area in the zones of weathered, jointed and fractured rocks. The dug wells in the area generally tap on the weathered zone. The thickness of the weatherd zone varies few centimeters to 18 m. The average area of the cross section of a domestic well is 6 Sq.m and that of irrigation well varies between 40 Sq.m to 180 Sq.m. The yield of dug wells range from 12 m3 /day to 250 m3 /day for a pumping period of 4 to 6 hours. Bore wells in the area are of 150mm dia and are normally upto a depth of 30m to 80 m. The yield of these wells is maximum 30 m3 /hr and the pumping period varies from 6 to 8 hours/day. State Public Health Engineering Department (PHED) indicate that nearly 80% of the bore wells yield between 0.6 to 9 m3 /hr and the maximum yield is obtained from bore wells drilled between 40 to 60 m depth. Most of the dug wells, dug-cum-bore and shallow bore wells upto 30 m tap the shallow aquifers and the bore wells deeper than 30 m, tap the water from fractures occurring between 30 m to 80 m depth which tap medium to deep aquifers. 4.4.2. Evaluation of Ground Water Resources Ground water is the major source of water for both irrigation as well as domestic purpose in the study area of 10 km. radius. The ground water potential in the area has not been exploited to an optimum extent and there is plenty of scope for exploitation. Dynamic ground water resources are that amount of water, which is found in the natural zone of fluctuation in an aquifer due to ground water recharge. Total dynamic ground water recharge of the area estimated with the following components. RT = Rr + RC + RI + RS Where RT = Total recharge Rr = Recharge from rainfall RC = Recharge from confined aquifer RI = Recharge fro irrigation due to ground water RS = Recharge from irrigation from rainfall is considered For computation purpose, only recharge from rainfall is considered. Rr = Area x Average Annual water level fluctuation x specific yield 59 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Area in 10 km. radius Average Seasonal water level fluctuation Specific yield Rr = 314 x 3.5 x 0.19 : 314 sq. km : 3.5 m : 19 %
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= 208.81 Million cum / Annum Ground water draft (utilization) 1) Industrial purpose The following will be the industrial ground water requirement in the area. 1. M/s. Druvadesh Meta Steel & Power Pvt. Ltd 2. M/s. Hare Krishna Metallics 3. M/s. KMMI Steels Pvt Ltd 4. M/s. Hospet Ispat Ltd 5. M/s. Trivista Steels & Power Pvt Ltd 6. M/s. Vanya Steels Pvt Ltd 7. M/s. Bhadra Steel Pvt Ltd 0.031 M. Cum/annum 0.075 M. Cum/annum 0.052 M. Cum/annum 0.031 M. Cum/annum 0.027 M. Cum/annum 0.031 M. Cum/annum 0.031 M. Cum/annum
_____________________________________________________________________ Total annual industrial water consumption 0.278 M. Cum/annum _____________________________________________________________________ 2) Domestic Purpose The study area comprises of 55 villages and hamlets Total no. house holds Total population Per capita water consumption : : : 19,572 1,08,616 135 lit/day
Total annual water requirements for 1,08,616 people : 5.35 M. cum/Annum 3) Agriculture purpose In the study area major crops are rice in Kharif and irrigated dry crops like maize, pulses and groundnut in Kharif & rabi seasons. 60 M/s. Global Enviro Labs, Hyderabad
EIA Report
Area under irrigation for paddy 1075 x 10 sq. m Area under irrigation for other crops 1550 x 104sq. m Delta of the crop for paddy Total water requirement for other crops Total water requirement for paddy Total water requirement for other crops
4
1075 hectares
1550 hectares
: : : :
120 cm = 1.2 m 40 cm = 0.4 m 12.9 M. cum 6.2 M. cum
________________________________________________________ Total water requirement for paddy & other Irrigated crops : 19.1 M. cum _________________________________________________________ 4) Live stock purpose Cows, buffaloes, sheep, goat, dogs are considered for estimation of water consumption by live stocks. Water consumption for cows & buffaloes Water consumption for sheep, goats & other No. of cows & buffaloes in the area Water consumption for cows & buffaloes No. of sheep & goats in the area Water consumption for sheep & goats Total water consumption of live stock 5) Evaportraspiration In the study area the ground water draft that occurs due to evapotranspiration is assumed as 1 % of the total ground water recharge. Total draft due to Evapotranspiration : 2.08 M cum/Annum : : : : : : : 50 lpcd 25 lpcd 35,500 0.64 M. cum/Annum 20,000 0.18 M. cum/Annum 0.82 M. cum/Annum
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Water budget for the study area S. No. Demand for Ground water recharge (M cum/ Annum) -----208.81 Ground water consumption (M cum / annum) 0.278 5.35 19.1 0.82 2.08 27.628
1. 2. 3. 4. 5. 6.
Industrial Domestic Agriculture Livestock Evapotranpiration Total
The total ground water utilization in the study area vis--vis the total ground water recharge is, 13.23% and the surplus available is 181.182 M.cum. Considering the ground water regulatory norm of 85% utilization, the net utilizable ground water resource available in the study area is 154.00 M.cum/Annum. Water requirement for the proposed steel plant The water only used for cooling and domestic purpose only. The total water requirement is in the order of 70.0 m3/day for the existing plant operations is met by ground water table through bore well located in the plant premises. During the proposed expansion of sponge iron production the water requirement will be increased to 116 m3/day and this will be met from the abundantly available ground water sources.
4.5 LAND ENVIRONMENT 4.5.1 SOIL QUALITY The study area is covered with red sandy clay soils. Representative soil samples were collected from 8 sampling locations within an area of 10 km radius around the proposed project for analysis of the physico-chemical characteristics of the soil quality. Fig 7 and Table 11 shows the location of soil sampling stations.
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Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Table 11: SOIL SAMPLING STATIONS S. No. Code Location Distance (km) w.r.t Project
1 2 3 4 5 6 7 8 S-1 S-2 S-3 S-4 S-5 S-6 S-7 S-8 Project site Chikka bagnal Lachankeri Kunikeri Kunikeri tanda Hire bagnal Karkihalli Halavaru --1.0 1.5 2.2 3.7 3.5 2.9 5.1
EIA Report
Direction w.r.t Project

--SEE SW WWN NW NNE SE NNW
The following are the highlights of soil quality in the study area: Soil Samples within 10 km Radius: pH of the soil samples were found to be in the range of 7.02 8.0. Soluble salts were found to be in the range of 141 - 250 mg/kg Organic content of the soil samples was found to be medium exhibiting in the range of 0.63% - 0.78% and average fertility Soils in the area were found to be clayey sandy loam in texture with sand percentage in the range between 38 - 50%, silt between 32 - 40% and Clay 45 - 63%. Chloride content of the soil samples were in the range of 62 - 180 mg/kg Results of soil sampling analysis shown best for fertility and are given in Annexure C.
SOIL CLASSIFICATION
Sl. No. 1. Soil Tests pH Classification <4.50 extremely acidic 6.50 7.30 neutral 4.50 5.00 very strongly acidic 7.30 7.80 slightly alkaline 5.00 5.50 strongly acidic 7.60 8.50 moderately alkaline 5.50 6.00 moderately acidic 8.50 9.00 strongly alkaline 6.00 6.50 slightly acidic 9.00 very strongly alkaline Upto 1.00 average 1.01 2.00 harmful to germination 2.02 3.00 harmful to crops sensitive to salts Upto 0.2 : very less 0.61-0.8 : on an average sufficient 0.21-0.4 :less 0.81-10 : Sufficient 0.41-0.5 : medium >1.0 : more than sufficient Upto 50 very less 151-300 better 51-100 less Above 300 sufficient 101-50 medium Upto 15 very less 51-65 on an average sufficient 16-30 less 65-80 sufficient 31-50 medium Above 80 more than sufficient 0-120 very less 241-300 average 120-180 less 301-360 better 181-240 medium Above 360 more than sufficient
2.
3.
Electrical Conductivity (mmhos/cm) Organic Carbon
4.
Nitrogen (kg / ha)
5.
Phosphorus (Kg/ha) Potash (Kg/ha)
6.
Fertility status of soil samples at representative sampling stations are medium. 64 M/s. Global Enviro Labs, Hyderabad
EIA Report
4.5.2 DESCRIPTION OF LAND USE/LAND COVER CLASSESS IN THE STUDY AREA For the study of land use, using the standard land use classification system proposed by NRSA, about five classes of level I, twelve of level II and four of level III land use / land cover classes were identified and mapped using satellite data in the present study. The imagery is interpreted and ground checked for corrections. The land use / land cover of M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikka baganal village, Koppal taluk & district of Karnataka State is given in below table. Figure 8.0 shows the Satellite imagery and Figure 9.0 shows the land use and land cover map of the study area. In the study area, Built up land occupies about 3.768 sq .km, Water bodies occupy around 116.808 sq. km., crop land around 151.976 sq. km and wastelands occupy around 41.448 Sq. km. Most of the land is under crop land and water bodies. There are no sanctuaries within the study area. Statistics of Land use/Land cover of the study area S.No. 1 LANDUSE BUILT UP LAND A. Settlements B. Industrial area WATERBODIES Tank/River/etc. CROP LAND A. Single crop B Double crop WASTELANDS A. B. C. D. Land without scrub Land without scrub Mining area Sheet rock area TOTAL 65 M/s. Global Enviro Labs, Hyderabad AREA IN Q2 Km. PERCENTAGE
3.454 0.314
1.1 0.1
2.
116.808
37.2
3.
123.088 28.888
39.2 9.2
5.
9.734 12.874 6.908 11.932 314
3.1 4.1 2.2 3.8 100
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Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 4.6 BIOLOGICAL ENVIRONMENT
EIA Report
An ecological survey of the study area was conducted particularly with reference to recording the existing biological resources. Secondary data was collected from forest department. 4.6.1 Flora The general vegetation along road and agricultural lands is primarily due to plantation of both exotic and native species of trees having commercial importance. Some of the commonly encountred species along the road side are azardirachta indica, eucalyptus, acacia auriculiformis and prosohis juliflora The list of flora in the 10 km radius of the study area is given in Annexure- D 4.6.2 Fauna Domesticated animals of the area includes cattle, buffaloes, goats, cats, dogs etc. cows and ducks are also common. No endangered faunal species are found in the area. The list of the fauna in the 10 km radius of the study area is given in Annexure E 5.7 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 socioeconomic profile of the study area (10 km radius), which is also a part of environmental Impact Assessment study for the project.
EIA Report
A detailed socio-economic survey was conducted covering all villages in the 10 km radius from the center. The information of socio-economic aspects has been compiled from various secondary sources including various government and semi-government offices. A brief summary of the same is given below.
There are 55 villages in the study area. As per the 2001 census data, the population in the study area is 1,08,616 The density of population in the study area is 345 persons per square kilometer. Female population is more than the Male population in 1000:980 ratios. Literacy status of the area is found to be a total of 46.97% of the population. Male and Female literacy is about 29.85% and 17.12% of the total 46.97% literacy.
Occupational status in the study area is in agriculture and industrial side and little in commercial side. 39.45% of total population of the study area falls under main workers category, 10.37% marginal workers. Out of 39.45% main workers, 22.38% are agricultural labors.
Agricultural activities are in all seasons. Major crops in the area are paddy, groundnut, sugarcane, cotton, sunflower, etc.
Medical facilities are adequate, only few villages have the primary health care centers. For any major health care, the people of the area has to go to Koppal. The common diseases are diarrhea, malaria, gastro-enteritis and eye and skin diseases.
Educational facilities are also adequate. The nearest educational center is Koppal. This region is well connected by rail and road. Many villages are adequately provided with protected water supply but lack efficient sewage disposal system.
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5. PREDICTION OF IMPACTS
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 physical, ecological and socio-economic environments. Such predictions are superimposed over the baseline (pre-project) status of environmental quality to derive the ultimate (post-project) scenario of environmental conditions. The prediction of impacts helps in minimizing the impacts on environmental quality during the post project execution. Environmental impacts have been assessed for the proposed unit i.e. proposed 1 x 75 TPD of Rotary Kiln. 5.1 AIR ENVIRONMENT As the atmosphere controls the incoming solar radiation reaching the surface of the earth and the outgoing terrestrial radiation that escapes into space, atmospheric boundary layer (zone between the surface of the earth and the free atmosphere where the most of the energy transmission will be occurred) region is governing the transport and dispersion of air pollutants at a place. The atmospheric temperature profile has an important effect on wind structure and turbulence in the atmospheric boundary layer. In the troposphere the temperature normally decreases with increasing altitude, because of the decrease in pressure in pressure with height. If a parcel of dry air moves upward in a hydro statically stable atmosphere then it expands slowly to lower pressure with no gain or loss of heat. At this delicate neutral equilibrium, the influence of surface heating and large scale phenomena usually results in a temperature profile different from the reference temperature profile. If the temperature decreases faster with height than the reference temperature profile, instability will occur in the air parcel and if the temperature profile of the air parcel decreases slowly with height than the reference temperature profile, stability of the parcel will occur. The absorption of radiation by gases is one of the important aspects of both global meteorology and atmospheric chemistry. The most important aspects of both global 70 M/s. Global Enviro Labs, Hyderabad
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meteorology and atmospheric chemistry. The most significant absorbing species in the atmosphere are oxygen, ozone, water vapor, carbon dioxide and dust. The absorbing spectra are quite complex, but they do indicate that only for certain wavelengths radiation may be transmitted through the atmosphere without applicable loss of energy through absorption. Absorption is so stronger in some spectral regions, that no solar energy in those regions reaches the surface of the earth. The ozone in the upper atmosphere almost effectively absorbs all solar radiation below 290 nm, where as water vapour and SO2 which are in the boundary layer of the atmosphere, absorb much of the outgoing long wave radiations. 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 examples 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. The phenomena of direct interest in predicting the dispersion of air pollutant is turbulent diffusion. Actually it is something of misnomer. It refers to the observed spreading of a cloud of marked particles in a turbulent fluid at a fate of many times magnitude greater then that from molecular diffusion alone. The spreading is not really due to a diffusion phenomenon such as results from molecular collisions but rather is a result of the rapid, irregular motion of macroscopic lumps of fluid (eddies) in turbulence. Thus a scale of lengths in turbulent diffusion are much greater than the molecular diffusion. With the contribution of the latter to the dispersion of pollutant in the planetary boundary layer increases with increased wind speed, surface roughness and instability. Turbulence,
therefore arises from both mechanical forces (wind shear, surface friction) and the thermal forces (buoyancy forces). Prediction of impacts is the most important component is the environmental impact assessment studies. Several scientific techniques and methodologies are available to
predict impacts of development activities on physico, ecological and socioeconomic 71 M/s. Global Enviro Labs, Hyderabad
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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 commissing the proposed expansion of the sponge iron plant with Co-generation power 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. The mathematical model used for predictions in the present study include, steady state Gaussian Plume dispersion model designed for multiple point sources for air quality, Wave divergence and federal Highway Administration (FHWA) models for noise levels. In case of water, land, biological and socioeconomic environments the prediction have been made based on available scientific knowledge and judgments. 5.1.1 Impact on Topography and climate 5.1.1.1 Impact on Topography The major envisaged topographical changes would be limited in and immediate vicinity of the proposed plant. The change in topography will be only due to man made 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. 5.1.1.2 Impacts on Climate As the temperature of the effluent gases will not be high, generally this will not cause any thermal imbalance, as the proposed project authorities will implement plantations programmes in 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 climatologically changes of any consequence. 72 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 5.1.2 Prediction of impacts on Air Environment
EIA Report
It is absolutely essential to study the impacts of air pollution on its environs due to the proposed plant with Co-generation power project. These impacts are predicted with the help of Guassian Mathematical model. These models stimulate the relationship between air pollutant emissions from the stack and the resultant impact on the air quality within the study zone. The pollutants emitted into the atmosphere get diluted immediately and is transported and mixed with the surrounding air. The basic purpose of these mathematical models are to represent these processes mathematically. Computer models are used for predicting the Ground Level Concentrations (GLC) for spatial variations. An attempt has been made to predict the incremental rise of various ground level concentrations above the baseline status in respect of air pollution. The mathematical models used for predictions in the present study is an EPA approved ISCST3 model which is used on steady state Gaussian Plume Dispersion Model designed for point sources and area sources for air quality. The predicted ground level concentrations computed using EPA approved ISCST3 model and plotted as isopleths concentrations. BASJIPL is presently operating 1 x 100 TPD Rotary Kiln and is in the process of implementation of one more 75 TPD Rotary Kiln for enhancement of Sponge Iron production. As the proposed kiln is not operational, for estimation of impacts the proposed kiln which is under implementation, was considered. Sources of Air Emissions: The main sources of fugitive emissions are raw material unloading, raw material handling, product house, crushers of Iron ore and coal, material transfer points, storage bind, etc. Dust generated from raw material unloading areas is controlled by spraying of water. In other areas specified above dust extraction system with bag filters will be provided to control the particulate emission. The Exhaust emissions of proposed rotary kiln will pass through an Electrostatic Precipitators (ESP) to bring down the particulate matter to less than 100 mg/Nm3. The emissions from the proposed 75 TPD rotary kiln after treating in ESPs will be let out into the atmosphere through the existing stack, height of 60 m. 73 M/s. Global Enviro Labs, Hyderabad
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The details of emissions considered for estimation of impacts are given below. Emission Details of proposed 75 TPD Rotary Kiln: Stack attached Dia Height Temp. of Velocity of flue SPM SO2 to (m) (m) flue gas (C) gas (m/sec) (g/s) (g/s) 75 TPD Rotary 2.5 60 120 1.02 0.57 0.40 Kiln NOx (g/s) 0.20
5.1.1 STACK HEIGHT ESTIMATION The height of the stack is calculated based on the formula prescribed by CPCB i.e., H=14 (Q)
0.3
on SO2 basis, where H is the physical height of the stack in meters and Q is
emission rate of SO2 Kg/hr. The stack height is calculated for the fuel Coal with 0.5% Sulphur content with consumption of 175 TPD for the proposed expansion. The height of the stack is calculated as fallows. To represent the worst scenario 175 TPD (100%) of coal will be used after implementation of the proposed expansion of the sponge iron plant Total coal consumption Max. Sulphur content in coal : 175 TPD : 0.5% (By mass)
SO2 emission (Q)
: 175 x 1000 x 0.5 x 2/24 x 100 : 72.91 kg/hr : H=14 (72.91) 0.3 = 50.69 m
Stack height calculated (SO2)
Based on the above formula, the required stack height is estimated to be 50.69m to exhaust the emissions after implementation of the proposed expansion of the sponge iron plant The management of BASJIPL has already been constructed 60 mt of stack to the existing 100 TPD rotary kiln. So the management has decided to provide the emissions from the proposed 75 TPD rotary kiln also will be let out through the existing stack height of 60 mt also. 74 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 5.1.2 METEOROLOGICAL DATA
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The meteorological data recorded continuously during the months of December 2009 to February 2010 on hourly basis on wind speed, wind direction and temperature has been processed to extract the 24 hourly mean meteorological data as per the guidelines of IMD and MoEF for application of ISCST3 model. Stability classes computed for the mean hours are based on guidelines issued by CPCB on modeling. Mixing heights representative of the region have been taken from the available published literature. The meteorological data input considered as per the IMD guidelines is enclosed as Annexure G 5.1.3 MODEL EMPLOYED Prediction of cumulative ground level concentration due to emissions from expansion of the sponge iron plant have been computed using EPA approved ISCST3 model. 5.1.3.1 APPLICATION OF ISCST3 FOR PREDICTION OF GROUND LEVEL CONCENTRATION ISCST3 Model with the following options has been employed to predict the ground level concentration due to emissions from the proposed expansion programme.

Area being rural, rural dispersion parameters are considered. Predictions have been carried out to estimate concentration values over radial distance of 10 km around the sources
Polar receptor network has been considered Emission rates from the point sources and area sources were considered as constant and during the entire period.
Consideration of settling velocity of the particles The ground level concentrations computed were as is basis without any consideration of decay coefficient.
Calm winds recorded during the study period were also taken into consideration 24 hourly (for 24 hour mean meteorological data as per guidelines of IMD and MoEF) mean ground level concentrations were estimated for the summer season using the mean meteorological data of December 2009 to February 2010. 75 M/s. Global Enviro Labs, Hyderabad
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5.1.4 EMISSION SOURCES CONSIDERED FOR SIMULATIONS Since the baseline concentrations monitored in the REIA study includes the emission of the existing 100 TPD Sponge Iron unit, only additional emission from the proposed 1 x 75 TPD Rotary Kiln have been considered for prediction of impacts. 5.1.5 MAXIMUM GROUND LEVEL CONCENTRAIONS Ground level concentrations of SPM, SO2 and NOx were estimated using the mean meteorological data to project the incremental increase of concentration above baseline concentrations due to emission from the proposed expansion progaramme. The following table shows the summary of the same. Suspended Particulate Matter Incremental Ground Level 7.72 Concentration due to 1 x 75 TPD Rotary Kiln & 8.0 MW Captive Power Plant Distance of Maximum 0.7 concentrations from source, km Sulphur Dioxide 4.87 Oxides Nitrogen 2.4 of
0.8
0.8
Figure 8 - 10 represents the spatial distribution of the predicted ground level concentrations of SPM, SO2, and NOx due to emissions from the proposed expansion programme. 5.1.6 POST PROJECT SCENARIO
Maximum ground level concentrations are predicted considering 24-hourly mean meteorological data of December 2009 to February 2010, superimposed on the maximum baseline concentrations obtained during the study period to estimate the post project scenario, which would prevail at the post operations phase. The Overall Scenario with predicted concentrations over the maximum baseline concentrations is shown below. 76 M/s. Global Enviro Labs, Hyderabad
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OVERALL SCENARIO WITHIN STUDY AREA (g/m3)
24 Concentrations
Hourly
Suspended Particulate Matter (SPM)
Sulphur Dioxide (SO2)
Oxides of Nitrogen (NOx)
Baseline Scenario (Max) Predicted Ground Level Concentration (Max) Overall Scenario (worst case)
160 7.72
14.2 4.87
16.4 2.4
167.72 (200)
19.07 (80)
18.8 (80)
5.1.7 IMPACT ON VILLAGES
It may be observed that the maximum predicted concentrations are falling within 0.8 km from the source. The nearest village is located at a distance of about 1.0 km, which is beyond the impact zone
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* There are 7.0 nos. of steel sponge iron plants are located within 10 km distance of the study area of M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd. The total capacity of all the units for manufacturing of sponge iron is 1625 TPD including the BASJIPL. All the units are functioning effectively pollution control equipments such as ESPs, & Bag Filters etc. and all the units are located more than 1.0 km from the different villages. The cumulative predicted incremental ground level concentrations of SPM due to all the projects are 23.0 ug/m3 and SO2 are 15.0 ug/m3 and NOx are 10.0 ug/m3 within 10 km distance of the study area. * There is no generation of wastewater from the sponge iron manufacturing process. Only domestic effluent is generated from all the units and this domestic effluent is sent to septic tank fallowed by soak pit in all the industries. There is no discharge of effluents from these industries. Hence impact of water environment within 10 km distance is nil. * All the solid waste generated from all the units within 10 km distance of the study area are utilizing for the captive power generation/power plant, cement plants and brick manufacturing units and some portions are reusing in the process. Hence impact of land environment within 10 km distance is nil. 5.2 NOISE ENVIRONMENT During construction, no significant impact is envisaged as most of the construction equipment produce noise level below 80 dB(A). The noise generated is expected to be intermittent and of short duration. During operational phase after the proposed expansion the major noise generating sources are plant machinery. These sources will be located far off from each other. Under any circumstances the noise level from each of these sources will not exceed 75 dB(A). The present noise levels monitored at proposed plant are in the range of 50.2 57.5 dB(A) (Lp total) Prediction of anticipated noise levels have been computed using point source model. Basic phenomena of the model is the geometric attenuation of sound. Noise at a point generates 81 M/s. Global Enviro Labs, Hyderabad
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spherical waves which are propagated outward from the source though the air at a speed of 1,100 ft/sec, with the first wave making an ever increasing sphere with time. As the wave spreads the intensity of noise diminishes as the fixed amount of energy is spread over an increasing surface area of the sphere. The assumption of the model is based on point source relationship i.e. for every doubling of the distance the noise levels are decreased by 6 dB (A). Point source propagation is defined by the following equation: Lp2 = Lp1 - 20 log r2/r1 Where Lp1 and Lp2 are sound pressure levels at points located at distances r1 and r2, respectively, from the source. Noise level at the plant boundary, calculated from the above equation, is expected to be less than 65 db(A). Predictions carried out are on as is basis without taking into consideration any attenuation factors. Additional attenuation is expected, due to atmospheric effect or its interaction with objects in the transmission path. Noise levels generated during this proposed expansion is confined within the BASJIPL unit and is further reduced due to attenuation of greenbelt. Noise level at the plant boundary, calculated from the above equation, is expected to be less than 60 dB(A) without considering any attenuation factors. BASJIPL has developed greenbelt in an area of 7.5 acres within the BASJIPL premises. Boundary plantation already developed will act as a barrier and further reduce the noise levels. 5.3 WATER ENVIRONMENT The present water requirement of BASJIPL plant is 70 m3/day. The water requirement of the proposed expansion of sponge iron plant is estimated to 46 m3/day. With the above consumption for different sources the water requirement of the plant after proposed expansion will increase from 70 m3/day to 116 m3/day. This includes make-up water for Cooling domestic and gardening purpose will be met from the ground water sources.
EIA Report
There is no generation of wastewater from this sponge iron manufacturing process. Cooling tower water is continuously re-circulated in the cooling water circuits, heat exchangers and discharged to the sump or holding tank through cooling towers where evaporation losses, drift losses and spillages are encountered. Only 5.0 KL/Day of Domestic effluent is generated from the existing process and this is sent to septic tank fallowed by soak pit. After implementation of the proposed expansion also cooling tower water will be continuously re-circulated in the cooling water circuits, heat exchangers and discharged to the sump or holding tank through cooling towers where evaporation losses, drift losses and spillages will be encountered. During the proposed expansion domestic effluent generation will be increased from 5.0 KL/day to 7.0 KL/day and this will also sent to septic tank fallowed by soak pit. CHARACTERISTICS OF SANITARY WASTE WATER PARAMETER pH BOD COD TDS 5.4 LAND ENVIRONMENT BASJIPL owns about 13.37 acres of land near Chikka baganal Village housing the Sponge Iron Plant. The proposed enhancement of production will be coming within the existing premises of BASJIPL. As there are no endangered species in the vicinity of the proposed activity, there should not be any concern for the loss of important germoplasm that needs conservation. One ESP will be provided to the proposed 75 TPD Rotary Kiln to bring down the SPM level in the exhaust to less then 100 mg / Nm3 To control the fugitive emissions dust extraction system and dust suppression system will be installed at all the possible dust emanating areas. Hence it will not have any impact on near by topsoil. 83 M/s. Global Enviro Labs, Hyderabad CONCENTRATIOIN 7.0 8.5 200 250 mg/l 300 400 mg/l 800 900 mg/l
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The effluent generated will be utilized for ash conditioning; dust suppression system will be discharge outside the plant premises. Hence there will not be any adverse impact on land environment due to the proposed expansion activity. The land use pattern of the study area will certainly improve due to the proposed activity. Land prices in the area will increase and will benefit the local people. This industry may attract some ancillary works also which will also help in improving the land use pattern of the area. Greenbelt is considered essential for maintaining the stability of the environment of the area. 4.7 acres of extensive greenbelt will be developed within the plant site acquired. 5.4.1 SOLID WASTE GENERATION The main solid waste generated from this unit is Char, Dust from ESP & Bag Filters and Sludge from Wet Scrapper and Kiln accretion. Details of the present and proposed solid waste generation from SSSIPL are given below: Quantity (TPD) Particulars Dolochar Iron Ore fines Sludge from Wet Scrapper Dust from Bag filters Kiln Accretion Total Present 35 16.3 01 5.2 0.5 58 After Proposed Expansion 61.25 28.52 02 8.86 0.87 101.5
Details of disposal of solid waste are given in EMP. 5.5 SOCIO ECONOMIC ENVIRONMENT Socio Economic status in the study area is found to be moderate with respect to livelihood, amenities etc. The local areas will be benefited by way of generation of employment opportunities, increased demand for local products and services. There will be an overall improvement in the income level if the local people. 84 M/s. Global Enviro Labs, Hyderabad
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The project creates employment to about 100 persons once the proposed expansion is implemented and for 150 persons during construction stage. Skilled and semiskilled workers are to be drawn from the local areas. With the development of this Sponge Iron Plant there will be lot of scope for more industrial investments, which in turn will benefit the nation. The project proponent intends to provide welfare activities recreational facilities in the surrounding villages once the proposed activity commences production. The project
authorities intend to conduct regular health checkups in the surrounding villages. Therefore there will be a certain enhancement of educational and medical standards of people in the study area. There will be generally positive and beneficial impacts by way of economic improvements, transportation, aesthetic environment and business generation. 5.6 PRDICTION OF IMPACT ON ECOLOGY There are no National Parks, Reserved forests and wild life sanctuaries within 10 Km. radius of the project site. Hence there will not be any impact of SPM, SO2 & NOx on flora & fauna due to the proposed activity. 5.6.1 GENERAL IMPACTS Sulphur Dioxide High doses of SO2 produces adverse effects on plants where as low doses of SO2 have beneficial effects on plants. At very high concentration of SO2 interveinal necrosis and skeletonised leaves are formed. The dead tissue may become almost black. Nitrogen Oxides High temperature reactions in the presence of air form NOx. NOx is known to cause eye and nosel irritations. 25 ppm of NOx causes pulmonary discomfort. Suspended Particulate Matter Distance in plant metabolism due to the deposition of dust particles in foliar surfaces leads to reduction plant growth. 85 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 5.6.2 Impacts on Terrestrial Ecology
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There will not be any loss of biomass during construction phase of the activity. Removal of herbaceous vegetation loosens the topsoil, might cause soil erosion and will be minimized by adopting mitigative measures like paving, surface treatment water sprinkling and plantation program. Construction activities will lead to migration of labour force in the area and thus there would be pressure on trees in the area due to increase in fuel demand. In order to prevent felling of trees in the nearby areas, alternate fuel arrangement shall be made to the labour force. There is no fauna in the proposed project site. Hence the impact of construction activities on fauna will be insignificant.
Higher doses of SPM, SO2 & NOx are injurious to health of human beings, plants & animals. Adequate stack height has been provided for effective dispersion of sulphur dioxide in to the atmosphere. State of the art Electro Static Precipitators will be provided for bringing down the particulate emission in the exhaust flue gases of rotary kiln to less than 100 mg/Nm3. The net concentrations (Max. base line concentration + Max. predicted incremental rise in concentrations) of SPM, SO2 & NOx are well with in the NAAQS. Hence there will not be any adverse impact on the eco system of the study area due to the proposed project. Greenbelt is proposed to be developed extensively in 4.7 acres of the land with in the proposed project site. This will help in further mitigating impacts by acting as a noise barrier and pollution sink. 5.7 PREDICTION OF IMPACT ON HEALTH The emissions of concern due to the project are SPM, SO2, NOx & noise levels. Adequate air pollution & noise control measures will be provided to confirm to regulatory standards. Employees working in high noise generation area would be provided with earplugs for ensuring minimum impact on human health.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 5.8 PRIDICTION OF IMPACT OF HAZARDOUS CHEMICALS
EIA Report
Chemicals like HCL, NaOH, LDO will be required for various operations in the plant. The storage & handling of all the chemicals / fuels will be in accordance with the safety guidelines. The operators will be trained to handle hazardous chemicals to prevent
accidents. Fire fighting systems will be provided near the storage. Hence the impact due to the hazardous chemicals will be insignificant. 5.9 PREDICTION OF IMPACT ON AQUATIC ENVIRONMENT The effluent generated from the proposed expansion predominantly consists of service water and sanitary wastewater. After primary treatment of the effluent as suggested in Environmental Management Plant (EMP) it will be routed to a holding tank and will be utilized for greenbelt development. 5.9.1 Thermal Impact There will not be any effluent discharge into any of the surface water bodies. Hence there will not be any thermal impact on aquatic environment due to the proposed project. 5.9.2 Impact due to effluent discharge These effluents will be used for ash conditioning, dust suppression and for greenbelt development. After ensuring the quality of effluent to be within the standards prescribed by Karnataka State Pollution Control Board (KSPCB), the treated effluent will be utilized for on land for irrigation.
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6. ENVIRONMENTAL MANAGEMENT PLAN

The major objective and benefit of utilizing Environmental Impact Assessment in project planning stage itself, is to prevent avoidable losses of environmental resources and values as a result of Environmental Management. Environmental Management includes protection /mitigation/enhancement measures as well as suggest revision of project site or operation to avoid adverse impacts or often additional project operations may have to be incorporated in the conventional operation. The industrial development in the study area needs to be intertwined with judicious utilization of non-renewable resources of the study area and with in the limits of permissible assimilative capacity. The assimilative capacity of the study area is the maximum amount of pollution load that can be discharged in the environment without affecting the designated use and is governed by dilution, dispersion, and removal due to Physico-chemical and biological processes. The Environment Management plant (EMP) is required to ensure sustainable development in the study area of the proposed plant site, hence it needs to be an all encompassive plan for which the proposed industry, Government, Regulating agencies like pollution control Board working in the region and more importantly the affected population of the study area need to extend their cooperation and contribution. It has been evaluated that the study area has not been affected adversely and is likely to get new economical fillip. The affected environmental attributes in the region are air quality, soil, land use, ecology and public and public health. The Management Action plan aims at controlling pollution at the source level to the possible extent with the available and affordable technology followed by treatment measures before they are discharged. Environmental Management aims at the preservation of ecosystem by considering the pollution abatement facilities at the plant inception. In the upcoming modern Sponge Iron Plant, pollution abatement has become an integral part of planning and design along with Techno economic factors. 88 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 6.1 MANAGEMENT DURING CONSTRUCTION PHASE
EIA Report
Environmental pollution is inevitable during the construction phase. The project proponent should take appropriate steps to control pollution during construction phase. The following are the factors requiring control during construction phase. 6.1.1 Site Preparation At the time of construction there will be a substantial quantity of soil and debris and produce large quantities of unstable material. The disturbed slopes shall be well stabilized before the on set of the monsoon. The leveling operation will also involve piling up of backfill materials. Use of dust suppressant spraying to minimize fugitive dust during construction activities is recommended. 6.1.2 Water Supply and Sanitation The employees at the proposed project site shall be provided with water for their requirement and for the construction activities. The proposed construction site shall be provided with sufficient and suitable toilet facilities to allow proper standards of hygiene. These facilities would preferably be connected to a septic tank and shall maintained properly to have least environmental impact. 6.1.3 Noise Noise pollution is anticipated during the construction phase due to the usage of various construction equipment such as mechanical vibrator, mixers etc. The noise effect on the nearest inhabitations due to construction activity will be negligible. However, it is advisable that onsite workers working near the noise generating equipment shall be provided with noise protection devices like earplugs. 6.1.4 Maintenance of Vehicles One should be very careful in selecting the site for vehicle maintenance, so as to prevent the ground water contamination due to the spillage of oil. Both diesel and petrol engine vehicles shall be maintained properly. Unauthorized dumping of waste oil should be prohibited. Wastes should be disposed off in an approved dump. M/s. Global Enviro Labs, Hyderabad 89
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6.1.5 Waste The solid waste shall be collected, segregated and all the combustible waste shall burnt in a controlled manner. 6.1.6 Storage of Hazardous Material The following hazardous materials need to be stored at the site during construction. a. Gas for welding purpose b. LDO c. Painting materials All these materials would be stored as per international safety standards. 6.1.7 Land Environment The proposed expansion in sponge iron plant with co-generation power plant will not create any major impact on land environment. As soon as the construction activity is over the surplus earth will be utilized to fill up low-lying areas, the rubbish will be cleared and all in built surfaces will be reinstated. Appropriate vegetation will then be planned and all such areas shall be landscaped. 6.2 POST CONSTRUCTION PHASE 6.2.1 Air Emission Management
The main sources of dust pollution are crushing operations of raw materials (such as Iron ore, Coal, limestone) and their transfer points and product house. A separate dedusting system will be provided to control the dust from various material transfer points by means of suitable ducting connected to an Induced Draught fan. The dust that is drawn from various points will be passed through bag filters. The control equipment proposed at various sections are shown below.
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Hot flue gases from existing 100 TPD Kiln
ESP 60 m (height) ID fan
Common Stack Hot flue gases from proposed 75 TPD Kiln ESP ID fan
Material unloading Operations
Dust suppression
Material Handling points, Raw material storage, Cooler Discharge, product area, etc
Dust extraction system followed By bag filters
All conveyors
Covered with GI sheets
All storage bins
Totally packed & covered
AIR POOLLOUTION CONTROL SYTEMS PROPOSED S. No 1 Source 75 TPD Rotary Kiln Source 2 3 4 5 Coal Injection Cooler Discharge Stock House Product House Existing Stack Stack height (m) (m) 60 2.5 Stack (m) 15 15 15 15 height Stack (m) 0.5 0.5 0.5 0.5 diameter Control Equipment 1 no. of Electro Static Precipitator diameter Control Equipment Bag Filter Bag Filter Bag Filter Bag Filter
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The flue gases from the Kilns will pass through an Electro Static Precipitator.
The
particulate matter at the outlet of Electro Static Precipitator will be less than 100 mg/Nm3. The flue gases after treatment in ESPs will be let out through the existing stack with a height of 60 m in to the atmosphere. All the CREP recommendations will be implemented & followed strictly. Dust Extraction and Dust Suppression System S. No. 1 Location Coal screen house Crusher House Junction houses and surge hopper Iron ore screen house and bins Product discharge Junction House & SMS bins Junction houses and truck hoppers Pollution control system proposed Each of these areas will be provided with Dust extraction systems each comprising of pulse jet type bag filter, centrifuged fan and motor, duct work including suction hoods, duct supports, stack, dust hopper rotary air lock valves etc. Dust suppression system with plain water comprising of spray nozzles, piping network, valves, pumps, instrumentation &controls, water tank etc. Dust suppression system with plain water comprising piping network, valves pumps, instrumentation &control, water tank etc.
Stock piles DR route
6.2.1.1 TECHNICAL SPECIFICATIONS OF EXISTING ELECTRO STATIC PRECIPITATOR For 1x100 TPD Rotary Kiln Gas flow rate, m3 / hour Flue gas temperature (0c) Inlet dust concentration, gm/nm3 Guaranteed outlet dust Concentration, mg/Nm3 Design pressure, mm wg Number of fields Pressure drop across the ESP, mm wg Gas velocity, m/sec. No. of gas passages Collection efficiency 92 M/s. Global Enviro Labs, Hyderabad 85,000 220 20 100 at max. flow conditions 500 3 25 (max) 0.51 3 nos. 99.67 %
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6.2.1.2 TECHNICAL SPECIFICATIONS OF EXISTING BAG FILTERS 1. Location: Coal crusher Volumetric flow rate Inlet dust concentration Outlet dust concentration Design efficiency Number of bags Air to cloth ratio Pressure drop across bag filter 2. Location: Stock House Volumetric flow rate Inlet dust concentration Outlet dust concentration Design efficiency Number of bags Air to cloth ratio Pressure drop across bag filter 3. Location : Cooer discharge Volumetric flow rate Inlet dust concentration Outlet dust concentration Design efficiency Number of bags Air to cloth ratio Pressure drop across bag filter 14,000 m3/hr 10 g/Nm3 50 mg/nm3 99.49% 120 1.31 m3/min/m2 200 mm WG 14,000 m3/hr 10 g/Nm3 50 mg/nm3 99.49% 120 1.31 m3/min/m2 200 mm WG 20,000 m3/hr 10 g/Nm3 50 mg/nm3 99.49% 180 1.31 m3/min/m2 200 mm WG
4. Location: Product separation & storage bins Volumetric flow rate Inlet dust concentration Outlet dust concentration Design efficiency Number of bags Air to cloth ratio Pressure drop across bag filter 20,000 m3/hr 10 g/Nm3 50 mg/nm3 99.49% 180 1.31 m3/min/m2 200 mm WG
Note: Pressure drop across bag filter will be installed. 93 M/s. Global Enviro Labs, Hyderabad
EIA Report
6.2.1.3 TECHNICAL SPECIFICATIONS OF PROPOSED ELECTROSTATIC PRECIPITATOR Item ESP SIZE / MODEL Number of mechanical fields in series Number of gas passages Field length per ESP Field height per ESP Gas passage width Total available collection area Aspect ratio per ESP TR rating (mA / kV) Type of collecting electrode Collecting electrode thickness Discharge electrode type Type of suspension arrangement Number of rapper Insulators per ESP Type of rapper arrangement Gas distribution arrangement Drive rating of rapping for CE & DE FLUE GAS ANALYSIS : Composition CO2 H2O N2 O2 DUST ANALYSIS: Constituents Iron ore Fixed Carbon Coal ash PARTICLE SIZE DISTRIBUTION (Assumed) + 250 250 180 180 125 125 190 90 63 63 45 < 63 micron : micron : micron : micron : micron : micron : micron : 17 35.8 21.95 0.80 1.0 2.95 20.50 % % % % % % % % by weight 33 9 58 % v/v 17 15 65.60 2.40 Data for 1 x 75 TPD ELEX 3407/ 3F 3 9 4.5 m 5m 400 mm 1458 sq. m 2.7 250 mA/ 110 kV 2 nos. ELEX SIGMA TYPE ELEX RIGID RS TYPE 4 point 12 nos. 3 nos. Tumbling hammer At inlet (3nos) and at outlet (1no) 0.12 KW & 0.18 KW
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State BASIS OF DESIGN OF ESP WITH GCT IN CIRCUIT Process data at ABC Outlet: Sr. No. 1. 2. 3. 4. 5. 6. Parameter Gas Volume Gas Temperature Suction Pressure Inlet Dust Load Outlet Dust load (wet basis) ESP casing design temperature / Pressure Unit Nm3/hr Deg.C mmWG gm / Nm3 mg / Nm3 Deg. C / mmWG Data
EIA Report
24000 220 (Mas.) (-) 200 30-35 50 275 / 250
GCT Specification & Technical Data Sheet Parameter / Item Gas Volume NM3/Hr Inlet Gas Temperature GCT diameter (Recommended) GCT Effective Height (Recommended) Desired Outlet gas Temperature Calculated Water Qty (M3/Hr) Water Pressure at ring main No & Type of spillback Nozzle Material of Construction Detail 24000 950 oC(Max) 3.8 Meters 12 Meters 1801 200oC 11.5 35 bars 4 Nos. & Type 260,844,17.00 Lechler Single spillback lances RS4 with heat protection shield in material SS-310 suitable upto 1100oC 9 meters Max (with 950oC max.) 200 NM3/Hr at 0.6 bar pressure (Motor rating 10 HP) 19 M3/Hr at 385 m head ( 1 working + 1 standby) 2 Nos. 45 KW, 2 Pole, TEFC, Foot Mounted From outlet of the tank to the Lechler skid Inlet - 2 NB SCH4O From outlet of the Lechler skid to the Lances 2 NB SCH4O From Lances to control valve manifold on Lechler skid and back to tank 2 NB SCH4O Air line from Root Blower to Lances - 1 NB SCH4O 95 M/s. Global Enviro Labs, Hyderabad
Evaporation Height (Gas Cool) Qty of Barrier air required for lance cooling High Pressure Water Pump Drive Motor for Pumps Pipeline Sizes
EIA Report
TECHNICAL SPECIFICATION FOR PROPOSED PULSE JET BAG FILTERS

APPLICATION AREA Gas Volume, m3/hr. Gas temperature, deg.C Inlet dust loading, gms/Nm3 Moisture content Anticipated flange to flange pressure drop, mm wg Emission at stack, mg/Nm3 BAG FILTER Bag Filter Model No. of module No. of bags Filter area per bag, m2 Total filtration area, m2 Air to cloth ratio, m3/min/m2 Spare capacity BAG TYPE (Bag Material) Product House 15000 Ambient 10 - 15 Negligible 130 Within 115 mg/Nm3 EC 90 - 12 One 90 1.73 155.7 1.60 20% extra Polyster needle felt 2 500 gm/m 150 mm ID x 3660 mm long 550 135 16 - 20 Cooler Discharge 8000 80 10 - 15 Negligible 130 Within 115 mg/Nm3 EC 48 - 12 One 48 1.73 83.04 1.60 20% extra Polyster needle felt 500 gm/m2 Stock House 10000 Ambient 10 - 15 Negligible 130 Within 115 mg/Nm3 EC 60 - 12 One 60 1.73 103.8 1.60 20% extra Polyster needle felt with antistatic finish 500 gm/m2 150 mm ID x 3660 mm long 550 135 16 - 20 Coal Injection 8000 Ambient 10 - 15 Negligible 130 Within 115 mg/Nm3 EC 60 - 12 One 60 1.73 103.8 1.28 20% extra Polyster needle felt with antistatic finish 500 gm/m2 150 mm ID x 3660 mm long 550 135 16 20
Bag Dimenstions
Weight, gms/m2 Temperature resistant Max. Opt. temp. deg C Air permeability m3/min/m2@ 20 mm wg Corrosivity
150 mm ID x 3660 mm long 550 135 16 - 20
All bags are manufactured with non corrosive Polyster needle felt and the dust collected in bag filters are iron ore fines, coal fines, dolomite, sponge iron dust and these dust will not contain any corrosive chemicals Provided 40 NB 0.33
BAG CLEANING Venture Size of pulse valve Compressed air requirement FAD in m3/min at 5-7 kg/cm2 max.) Nos. of pulse and solenoid valve Dust disposal arrangement Sequential controller RAV (200 mm dia) provided DRIVE FOR RAV, provided
40 NB 0.50
40 NB 0.26
40 NB 0.33
Through motorized RAV - To be provided for automatic air pulse cleaning 1 1 1 0.5 HP TEFC geared motor with chain and sprocket
Note: Pressure drop across bag filter will be installed. 96 M/s. Global Enviro Labs, Hyderabad
EIA Report
Details of Air Pollution Control Measures to be adopted for arresting fugitive emissions from various sources S. No. AREA OF AIR POLUTION 1 RAW MATERIAL PLANT Measures adopted for control
1.All vibrating screens will be totally covered, to prevent the leakages of dust. 2.Through out the length, the conveyor is covered with G.I. Sheets to prevent the dust pollution 3. All the material handling systems will be connected with de dusting system. All the 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. 4.DUST SUPPRESSION SYSTEMIt is the most effective and successful system to prevent the fly-off dust. Dust suppression system will be adopted to control the fugitive dust emanated during raw material unloading operations. 1. All conveyors will be covered with G.I. Sheets to control the RAW dust. MATERIAL 2. All bins will be totally packed and covered, so that there will STORAGE not be any chance of dust leakage. SYSTEM i) Weight feeders will be kept below the hopper and used to feed the known quantity of raw material per hour, it also seals the discharge area. ii) All discharge and feed points wherever the possibility of dust generation is there, will be provided with dust suppression system. iii) All material transfer points will be connected with dust suppression water nozzles to avoid the pollution. KILN FEED The raw material will be fed into the kiln through a double pendulum valve, which seals the false air entry into the rotary kiln SYSTEM and gas leakage from the kiln. The chute will be sealed with a double pendulum flap. Sealed system to avoid false air entry as well as exit. So that the MAIN desired quality can be produced. PROCESING So, there will not be any chance for pollution in this area. SYSTEM KILN The transfer point between kiln to coolers is completely sealed to KILN avoid the false air entry and gas leakages. COOLER TRANSFER BUILDING 1. The water will be circulated again and again. Hence there will ROTARY not be any water pollution problem COOLER 2. There will be slip seals at cooler inlet & cooler outlet. The seals are also being lubricated to avoid falls sir entry and gas leakages. 3. Cooler discharge and feed points wherever the possibility of 97 M/s. Global Enviro Labs, Hyderabad
EIA Report
dust generation is there will be provided with de dusting system. WASTE GAS AFTER BURNING CHAMBER Then the gas passes through the after burning chamber in which CLEANING the combustion of carbon monoxide and un burnt carbon takes SYSTEM place by supplying required air. The basic purpose of after burning chamber is to reduce the carbon monoxide content waste flue gases. If the WHRB boiler is not in operation the waste gas from the kiln passes through heat exchanger and cool down and then passes through ESP. ELECTRO STATIC PRECIPITATOR Then the flue gas will pass through an electro static precipitator in which the gas is cleaned to achieve<100 mg/Nm3 Particulate emission the exhaust. The clean gas will be emitted into the atmosphere through the chimney. The total conveying of gas from kiln & WHRB Boiler to chimney is done by the induced draft fan located between E.S.P. and chimney. 1. All conveyors will be covered with G.I. Sheets, to control the PRODUCT SEPARATION dust emission. 2. All bins will be totally packed and covered. So that there will SYSTEM: not be any chance for dust leakage. 3. Telescopic chutes will be provided below the hopper to discharge the product directly into the truck for dispatch to avoid the pollution. 4.All the above material handling system will be connected with de- dusting system 5. All discharge points and feed 6. The collected dust will be taken by pneumatic conveying system and stored in a covered dust storage bin. 7. Bag housing system In the bag house the dry dust will be collected in an enclosed housing containing fabric filter bags which are suspended inside the unit. The dust laden air will be pushed or pulled through the filter bags, formatting a dust cake to separate the particulate from the clean air. The collected dust will be taken by a pneumatic dust will be taken by a pneumatic conveying system and stored in a covered dust storage bin. This dust will be used in the waste heat recovery boiler for generating electricity.
EIA Report
IN PLANT DE- DUSTING SYSTEM LIST- OF SUCTION POINTSSUCTION POINT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 TOTAL EQUIPMENT Belt conveyor feed Belt conveyor feed Weight feeder Belt conveyor feed Weight feeder Belt conveyor feed Weight feeder Belt conveyor feed Belt conveyor discharge Belt conveyor feed Belt conveyor feed Oversize chute Belt conveyor feed Belt conveyor discharge Bucket elevator Intermediate bin Belt conveyor discharge Belt conveyor feed Vibratory feeder Belt conveyor feed Belt conveyor discharge Screen Screen discharge Magnetic separator Magnetic separator Belt conveyor feed Belt conveyor feed Belt conveyor feed Belt conveyor discharge Bin Belt conveyor feed Belt conveyor discharge Bin MATERIAL
ORE ORE DOLOMITE DOLOMITE COAL COAL ORE, COAL ORE, COAL DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI DRI Non magnetic Non magnetic Non magnetic DRI FINES DRI FINES DRI FINES
Good House Keeping: Good house keeping practices will be maintained in all section of the plant. Whenever Air pollution control systems fail, production in that unit will be stopped till that air pollution control system is rectified. 99 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Emission Details of Existing Stack: S.No Stack attached to Dia (m)
EIA Report
1.
100 TPD Rotary 2.5 Kiln,
Height Temp. of Velocity SPM SO2 (m) flue gas of flue (g/s) (g/s) (C) gas (m/sec) 60 100 1.6 0.66 0.53
NOx (g/s)
0.26
Emission Details of Existing Bag Houses: Sl. No. Stack Attached to: Bag house of Raw Material Crusher Bag house at Coal Injection Bag house of Stock House Bag house of Cooler Discharge Bag house of Product House Stack Height (mt) 15 15 15 15 15 Diameter of Temp. of Exit Stack (mt) exhaust Velocity gases (oC) (m/sec) 0.50 42 4.10 0.5 0.50 0.50 0.50 40 46 49 44 4.32 4.51 4.25 4.37 SPM (Mg/Nm3) 40 43 41 40 45
1 2 3 4 5
Emission Details of Proposed Bag House at Cooler Discharge: Emission Details of Proposed Bag Houses: Sl. No. Stack Attached to: Bag house at Coal Injection Bag house of Stock House Bag house of Cooler Discharge Bag house of Product House Stack Height (mt) 15 15 15 Diameter of Temp. of Exit Stack (mt) exhaust Velocity o gases ( C) (m/sec) 0.5 46 5.3 0.5 0.5 41 52 5.5 4.57 SPM (Mg/Nm3) 49 48 44
1 2 3
15
0.5
50
4.76
42
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Recommendations
EIA Report
a) The proposed air pollution control equipment should be installed prior to commissioning the plant. b) Online Continuous monitoring system for SPM should be provided. c) Pressure drop measuring system across the bag filters will be installed. d) All the internal roads shall be asphalted to reduce the fugitive dust to truck movement. 6.2.2 Water Pollution Management
There is no generation of wastewater from the sponge iron process. only 7.0 KLD of domestic effluent will be generated from this plant after implementation of the proposed expansion. This domestic effluent will be sent to septc tank fallowed by soak pit Recommendations a) Minimise the quantity of effluent through reuse to the maximum possible extent. b) Inlet and outlet effluent samples shall be collected monthly and shall be analysed to ascertain the efficiency of ETP and meet the statutory requirements. 6.2.3 Solid waste
6.2.3.1 The following are the slid wastes generated in the BASJIIPL after the implementation of the proposed expansion of Sponge Iron Plant. S. No 1. Type of solid waste Char Quantity (in TPD) 61.25 Disposal proposed The entire char will be used in own brick manufacturing plant. Some portion will be reused in the process and some portion will be sold to cement plants. Given to brick manufactures Given to brick manufactures/ briquetting Used for the road formations M/s. Global Enviro Labs, Hyderabad
2.
Iron Ore fines
28.52
3. 4. 5.
Sludge from Wet Scrapper Dust from Bag filters Kiln Accretion
02 8.86 0.87 101
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 6.2.3.2 Composition of Solid waste S. No 1 Description Char Chemical Composition (% by weight) Carbon : 25% Hydrogen : 0.75% Nitrogen : 0.74% Sulphur : 0.30% Moisture : 9.5% Ash : 60% GCV : 2,200 Normal biomass ash Characteristics Fe + Fe2O3 : 20 to 25% Fixed Carbon + Coal Char : 20 to 40% CaO + SiO2 : 35 to50%
EIA Report
3 4
Ash Dust from Bag filters
6.2.3.4 Action plan on Solid waste Management A. Iron ore fines Quantity of wet scraper sludge generation : 28.52 TPD
Some portion of iron ore fines will be reused in the process and some portion of iron ore fines will be given to cement plants in the area. B. Wet scraper sludge Quantity of wet scraper sludge generation Disposal This wet scraper sludge will be given to local brick manufacturers. C. Dust from Bag filters Total quantity of dust generation from bag filters at different areas : 8.86 TPD Disposal This dust will be disposed of to brick manufactures / Agarbathi manufactures in the area. There is a lot of brick manufacturing activity within 20 km radius of the plant site. D. Char Total quantity of char generation from DRI Kiln Disposal The entire char will be used in own brick manufacturing plant. 102 M/s. Global Enviro Labs, Hyderabad : 61.25 TPD : 2.0 TPD
EIA Report
* M/s. Baba Akhila Sai Jyothi Industries Pvt. Ltd is proposed to set up a one more 150 TPD kiln after obtaining the necessary approvals and commencement of production. At this stage the management will install the 12 MW Captive power plant by utilizing the waste flue gases from DRI plant by installing WHR boiler and FBC boiler will utilize entire Char generated from the plant. 6.2.4 Noise Level Management
The predominant noise levels are confined to the work zones in the plant. The noise levels at all the sources will not exceed 75 dB (A). All these machinery will be manufactured keeping in view the MOEF International Standards on noise levels. The major noise levels will be confined to the working zones of the proposed activity. The Leq of eight hours will be within the prescribed standards. Community noise levels are not likely to be effected due to the existing belt and attenuation due to the physical barriers. As the nearest habitation is about 1.0 km from the project site, there will not be any adverse impact on habitations due to the proposed activity. Recommendations a) The impact can reduced by adopting shock-absorbing techniques. b) The Noise absorption will improve by using hollow concrete blocks in the construction of the sponge iron plant. c) By making use of absorbing material on roof walls and floors, the noise reflection can be reduced. d) Earplugs shall be provided to the workers and this shall be enforced strictly. e) Increase the distance between source and receiver, by altering the relative orientation of receiver and the source. f) Extensive greenbelt shall be developed for further attenuating the noise levels. 6.2.5 LAND ENVIRONMENT
All the required Air pollution control systems will be provided in the proposed plant. Hence there will not be any impact on land environment due to the proposed project. The 103 M/s. Global Enviro Labs, Hyderabad
EIA Report
solid waste generated from the project will be disposed to cement plants / brick manufacturers. Hence there will not be development will have positive impact on land environment. Land prices in the area will increase due to the proposed project. Recommendations a) Landscaping can be done around the Administrative building This will help in preserving the ecological conditions. b) The treated sanitary effluent shall be used for green belt development. 6.2.6 Measures for Improvement of Ecology
There are no ecologically sensitive areas within 10 Km. radius of the proposed plant. No significant vegetation occurs in and around the project site. No significant fauna exists in the area. Hence there will not be any adverse impact on flora & fauna due to the proposed expansion of sponge iron plant. Recommendations Plantation programme should be undertaken at several areas. They should include plantation in the proposed plant premises and along the external roads and people should be educated and trained in social forestry activities by local governmental and nongovernmental organizations. Plantation for Aesthetics Extensive greenbelt will be developed in the acquired site for the proposed expansion. The greenbelt shall developed simultaneously with the plant construction. This will further mitigate the pollution impacts. 30 m wide greenbelt on average will be developed all around the plant. A detailed greenbelt plant will be developed in consulation with local DFO.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Greenbelt plantation
EIA Report
Greenbelt will be developed in asset of rows of trees planted in such that they form an effective barrier between the plant and the surroundings. The main purpose of greenbelt development is to contribute to the following factors. To maintain the ecological hemeostatus. To attenuate the air emissions from the kilns and the fugitive dust emissions. To prevent the soil erosion. To attenuate the noise levels. To utilize the treated effluents. Plantation of grass, flowers, bushes and trees will be taken up to reduce the generation of dust from the bare earth and to enhance the aesthetic value. Plantation species Plantation species will be considered based on the following. Suitable to the Geo-climatic conditions of the area. Mix of round, spreading, oblong and conical canopies. Ever green trees. Different heights ranging from 4m to 20m. Plantation for Arresting dust Trees particularly having compact branching closely arranged leaves of simple elliptical and hairy structure, shiny or waxy leaves and hairy twigs are efficient filters of dust. The following species are suggested to arrest the dust Alstonia Scholaris Bauhinia purpurea Cassia siamea Peltoferrum ferrugineum 105 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Butea monosperma Tamarindus indica Azadirachta indica Plantation to absorb SO2 emissions The following plants are suggested for plantation to absorb SO2 in the air. Azadirachta indica Albizia lebbeck Alstonia scholaris Lagerstroemia flosregineae Melia azedarach Minusops elangi Poloyalthia longifloia Plantation to reduce noise pollution
EIA Report
Trees giving thick and flushy leaves with petioles are suitable. Heavier branches and trunks of trees also deflect the sound waves. The following plant species are suggested to reduce noise pollution. Alstonia scholaris Azadirachta indica Melia monomperma Grevillea peridifolia Tamarindus indica Greavillea robusta Plantation along the roads (Avenue plantation) Alstonia scholaris Cassia fistula Bauhinia purpurea Mimusops elangi Pogamia pinnata 106 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Polyalthia longifolia Poluferrum ferrugineum Lagerstroemia flosreginea Cassea siamea Greenbelt development plan Local DFO will be consulted in developing the green belt. A greenbelt of 4.5 acres will be developed in the plant premises.
EIA Report
A 50 m wide greenbelt on average will be developed all around the plant. The tree species to be selected for the plantation are pollutant tolerant, fast growing, wind firm, deep rooted. A three their plantation is proposed comprising of an outer most belt of taller trees which will act as barrier, middle core acting as air cleaner and the innermost core which may be termed as absorptive layer consisting of trees which are known to be particularly tolerant to pollutants. Greenbelt will be developed simultaneously with the construction of the plant. 1500 species will be planted per hectare. 6.2.7 Rainwater harvesting Rainwater harvesting structures has been constructed to harvest the run-off water from roof top and from the plant area & by laying a separate storm water drainages system for recharging of ground water. 6.2.8 OCCUPATIONAL SAFETY & HEALTH MANAGEMENT Under Occupational Safety and Health Management, BASJIPL has taken all the necessary steps to provide better working environment. Regular health checkup is done for all employees and contract workers.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 6.3 POST PROJECT MONITORING
EIA Report
Pollution monitoring program includes periodic analysis of air, ground water, soil and wastewater samples. Ground water and soil samples at representative locations within and nearby the project site shall be periodically analyzed to detect contamination if any. In the event of any contamination, concerned authorities shall be notified immediately and appropriate corrective action in consultation with an approve consultant shall be initiated. 6.3.1 Monitoring Strategy The monitoring of various environmental parameters is necessary and is a part and parcel of the environmental protection measures. Monitoring is as important as that of control of pollution since the efficiency of control measures can only be determined by monitoring. A well-defined environmental monitoring program would be employed with trained and qualified staff to monitor the ambient air as well as stack gas quality to check whether the quality of effluents is maintained within the permissible limits. A comprehensive monitoring program is suggested underneath. Environmental attributes should be monitored as given below: Air pollution and meteorological aspects. Water and waste water quality. Noise levels. Soil characteristics. Ecological preservation and upgradation. Locations and frequency of monitoring should be as per the guidelines of APPCB and MOEF. Stack Monitoring The exit gas temperature, velocity and pollutant concentrations from the stack will be measured regularly any unacceptable deviation from the design values will be examined and appropriate action will be taken. 108 M/s. Global Enviro Labs, Hyderabad
EIA Report
Ambient Air Monitoring As per MOEF there is a need to identify 3 ambient air stations at 120o angle keeping the main source in the center. The ground level concentrations of suspended particulate, sulphur dioxide and nitrogen oxides in the ambient air outside the project boundaries and in the adjoining villages will be monitored at regular intervals. Any deviation from predicted/expected values will be investigated and necessary action will be taken. Noise Monitoring Noise levels in the workspace environment will be monitored periodically. If any deviation is observed necessary corrective measures will be taken. Monitoring noise levels is essential to assess the efficacy of maintenance of schedules undertaken to reduce noise levels and noise protection measures. A good quality sound pressure level meter is essential for this purpose. This work can be handled by plant authorities themselves or by hiring services. Noise surveillance is for the benefit of the workers well being and to keep track of machine wear. Micro Meteorological Observations The plant will have a permanent a weather station installed within the premises. Meteorological parameters like dry bulb temperature, wet bulb temperature, wind speed, wind direction and rainfall will be recorded daily. Monitoring of Outlet Cooling Water The cooling water exit temperature will not exceed 5oc over the inlet temperature. The exit temperature will be monitored and recorded daily. Any abnormal increase will be investigated and the necessary measures will be taken. These measures may include
operational and design modifications. The temperature of water body around the cooling water discharge point will be monitored once a month.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Monitoring of Effluents Streams
EIA Report
The quality of the effluents from the plant would be periodically analyzed on a weekly basis. The effluent from the plant will be monitored for BOD, TSS & pH. These data will be documented and compared against the design specifications. Necessary corrective action will be promptly taken. Monitoring of Water Quality Ground water near the project site will be routinely tested for its quality. No contamination of ground water and surface water is expected. However these waters will be periodically tested for any change of water quality. The effluents coming out of the process should be monitored regularly. Ground water is recommended to be monitored in at least two villages in the direction of ground water flow to keep surveillance on the ground water quality. 6.3.2 Infrastructure for Environmental Protection It is proposed to have a full-fledged environmental cell to supervise and implement the environment related issues. This should be supported by a fully equipped laboratory and required personnel to carry out the analysis. The proposed cell should have following manpower on regular basis. 1) Senior Manager He should be a qualified engineer with adequate experience. He will be responsible for implementing and monitoring the environmental impacts. He should be a liaison officer between the proposed plant and with regulatory agencies like KSPCB, CPCB etc. 2) Manager (Environment & Safety) He should be qualified in industrial safety. He will be responsible for all the safety aspects and risk, and for the implementation of disaster management.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 3) Chemist
EIA Report
He should be a qualified chemist to carry out the analysis of various samples. Any chemist from other laboratory from the plant can also be utilized for the analysis purpose. All the above-mentioned personnel should be reportable to the General Manager of the plant. 6.4 ENVIRONMENTAL MANAGEMENT CELL The Environmental Management Cell of the plant will starts with two officers look after the pollution control activities and they directly report to the factory manager. The environmental management group will have the sufficient no. of personnel. In plant, Personal computers and programmable logic controllers should control the process. The Managing Director heads the Environment Cell in M/s. BABA AKHILA SAI JYOTHI INDUSTRIES PVT. LIMITED. They should held meetings periodically to assess the condition of environment and to take any action arising out of any deviation. The Environmental Monitoring should be do once in a month through out side laboratory and the data so generated will record and kept as a tool for review purposes. 6.5 BUDGET FOR IMPLEMENTATION OF ENVIRONMENTAL MANAGEMENT PLAN Sl. No: Component Capital Cost for the Recurring Cost per proposed expansion Annum Rs. in Lakhs Rs. in Lakhs 10.0 5.0 250 35.0 ---10.0 3.0 & --2.0 --270.0 3.00 48.0
1 2 3 4 5 6 7.
Dust Suppression Pollution control equipment Chimney Greenbelt Development Environmental Monitoring Management Occupational Health Total
EIA Report
6.6 CONCLUSION The Rapid Environmental Impact Assessment study reveals that, M/s. BABA AKHILA SAI JYOTHI INDUSTRIES PVT. LIMITED has successfully implemented a well designed Environmental Management Plan and it was found to comply with Environmental Guidelines issued by KSPCB/CPCB/MoEF The Management has always to be remained in the limelight for its best performance in different fields like good house keeping and conservation Energy & Environment The management is fully conscious of maintaining industrial hygiene for its work force in order to ensure their good health. It is also aware of the occupational hazards and the safety issues involved. Adequate steps have been planned to take care of the same. With the same commitment and dedication, BASJIPL will commission the proposed enhancement of Sponge Iron Plant with Cogeneration Power Plant. BASJIPL proposes to maintain the ISO quality towards protection of environment in implementing the proposed expansion programme. Hence the project may be accorded Environmental Clearance.
EIA Report
7. DISASTER / EMERGENCY MANAGEMENT PLAN

7.1 INTRODUCTION Risk analysis deals with the identification and quantification of risks, the plant equivalent and personnel are exposed to, due to accidents resulting from the hazards present in the factory. Hazard analysis involved the identification and quantification of the various
hazards that likely to occur in the factory. Both hazard and risk analysis very extensive studies, and require a very detailed design and engineering information. The various hazard analysis techniques that may be applied are hazard and Operability (HAZOP) studies, Fault Tree Analysis (FTA), event tree analysis and, failure and effects mode analysis, Risk analysis follows an extensive hazard analysis. It involves the identification and assessment of risks the neighboring populations are exposed to as result of hazard present. This requires a through knowledge of failure probability, credible accident scenario, vulnerability of populations etc. Much of this information is difficult to get or generate. Consequently, the risk analysis is often confined to maximum creditable accident studies. 7.2 SCOPE OF THE STUDY The scope of study includes the study of proposed operations, storage and handling of raw materials with respect to Hazard Identification. Risk Assessment and preparation of Disaster Management Plan. Bases on the Hazard Identification and analysis, the major disaster scenarios would be worked out to estimate the consequence of failure. A Disaster Management Plan (DMP) would also be evolved to meet the emergency situation including the occupational health and safety. 7.3 FLAMMABLE MATERIAL STORAGE A list of flammable/corrosive materials likely to be used are given below: 113 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State LDO Hydro Chloric Acid Sodium Hydroxide 7.4 FIRE PROTECTION SYSTEM
EIA Report
The following Fire Protection system has been proposed for the proposed expansion of sponge iron plant with co-generation Power plant. Hydrant system covering the entire plant including all-important auxiliaries and buildings is proposed. The system will be complete with piping, valves
instrumentation, hoses, nozzles and hydrants, valves etc. HVWSS will be provided near LDO storage tanks. Sprinkler system for cable galleries / vaults / spreader room etc. Automatic / Manual high velocity water spray system will be provided for all the transformers located in transformer yard and those located with in the plant premises, etc. Portable extinguisher such as pressurized water type, carbon dioxide type and foam type will be located at strategic locations through out the plant. Modular type carbon dioxide panel injection fire extinguishing system will be provided in control equipment room cable space below control room and at other unmanned electrical and electronic equipment room. The following pumps will be provided in the fire protection system. Fire water pumps. (Fire water reservoir is part of the main tank) a) AC motor driven fire water pumps for hydrant, medium velocity water spray system and foam system. b) c) d) AC motor driven fire water pumps for high velocity water spray system. Diesel engine driven pump as stand by for the above. Jackey pump 1 no. (AC motor driven) for maintaining pressure.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 7.5 FIRE ALARM SYSTEM The fire alarm system proposed is given as following.
EIA Report
Cable areas, control room will be provided with Ionization and photoelectric smoke detectors. The above system will be designed as per the requirements of Tariff Advisory Committee (TAC) of Insurance companies of India. Suitable number of electric motor driven and diesel engine operated hydrant and spray pumps with automatic starting will be provided for the above systems. The firewater pumps will take suction from the firewater reservoir to be created in the plant area. 7.6 METHODOLOGY OF MCA ANALYSIS The MCA Analysis involved ordering and ranking of various sections in terms of potential vulnerability. The following steps were involved in MCA Analysis. Preparation of an inventory of major storage sections and representative failure cases from the vessels and the pipelines. Identification of potentially hazardous storage sections and representative failure cases from the vessels and the pipelines. Visualization of chemical release scenarios. Effect and damage calculation from the release cases through mathematical modeling. Inventory Analysis and Fire & Explosion and Toxicity Index (FETI) are the two techniques employed for hazard identification process. 7.7 FIRE & EXPLOSIONAND TOXICITY INDEX The role of Fire & Explosion Index (FEI) aids quantitative hazard identification. The FEI is calculated by evaluating the loss potential of all the units in the storage area and the hazardous areas were classified accordingly. The role of FEI is Identification of the equipment/areas that could likely contribute to the creation or escalation of incident and relatively rank the incidents. 115 M/s. Global Enviro Labs, Hyderabad
EIA Report
Quantification of the expected damage of potential fire and explosion incidents. Preparation of guidelines for mitigating fire hazards. The loss potential which could actually be experienced under the most adverse operating conditions is quantitatively evaluated. The FEI is used for any operation in which a flammable or reactive material is stored, handled or processed. FEI = MF * GPH * SPH Where MF: Material factor GPH: General Process Hazard SPH: Special Process Hazard TOXICITY INDEX The Toxicity Index is calculated using the Nh, Ts, GPH and SPH. TI is calculated by the following formula.
TI
(Nh + Ts) * (1 + GPH + SPH) ------------------------------------100
7.8 ASSESSMENT OF RISK AT M/s. BASJIPL Bases on the storage inventory the following areas are identified as potential safety risk areas are shown in below table. POSSIBLE RISKS FROM THE SPONGE IRON PLANT S. NO. 1. 2. 3. 4. Area Transformer Coal handling plant Coal storage LDO tank farms Capacity/ quantity --5000 tones 1 x 3 m3 Hazards Identified Explosion & fire Fire and or dust explosion Fire, spontaneous combustion Fire
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The degree of hazard is identified bases on FEI & TI range as per the criteria given below. FEI RNAGE 0 60 61 96 97 127 128 158 159 & Above IT RANGE 05 5 10 > 10 DEGREE OF HAZARD LIGHT MODERATE INTERMEDICATE HEAVY SEVERE DEGREE OF HAZARD LIGHT MODERATE SEVERE
Fire and Explosion are the likely hazards, which may occur due to the fuel storage. Hence F&EI has been calculated for storage capacities of fuels in the plant and are shown in elow table. FIRE & EXPLOSIONAND TOXITY INDEX FOR STORAGE FACILITIES Fuel LDO Total quantity of storage 1 x 5 m3 F & EI 1.5 Category Light TI -Category --
Depending on the category of hazard preventive and protective systems will be recommended. 7.8.1 COAL HANDLING PLANT DUST EXPLOSION Coal dust when dispersed in air and ignited will explode. Crusher houses and conveyor systems are most susceptible to this hazard. The minimum of explosive concentration of coal dust (28% volatiles) is 40 grams/m3. Failure of dust extraction & suppression systems may lead to abnormal conditions and increasing the concentrations of coal dust to the explosive limits. The sources of ignition are incandescent bulbs, electric equipment & 117 M/s. Global Enviro Labs, Hyderabad
EIA Report
cables, friction & spontaneous combustion in accumulated dust. Dust explosion may occur without any warning with maximum explosion pressure up to 6.4 bars. Another dangerous characteristic of dust explosions is that it sets off secondary explosions after the occurrence of initial dust explosion. Stack pile area shall be provided with automatic garden type sprinklers for dust suppression as well as to reduce spontaneous ignition of coal stock piles, necessary water distribution net work will be provided for distributing water at all transfer points, crusher house, control room, etc. A centralized control room with microprocessor bases control system has been envisaged for operation of the coal handling plant. Except locally controlled equipment like traveling tripper, dust extraction / dust suppression / ventilation equipment, sump pumps, water distribution system all other in line equipment will have provision for local control as well. All necessary inter local control panels will be provided for safe and reliable operation of the coal handling plant.
Control measures for coal yard The entire quantity of coal will be stored in separate stack pile, which proper drains around to collect washouts during the monsoon. Water sprinkling system will be installed on stocks of pile to prevent spontaneous combustion and consequent fire hazards. The stack geometry will be adopted to maintain minimum exposure of stock pile areas towards predominant wind direction temperature will be monitored in the stock piles regularly to detect any at normal rise in temperature inside the stock pile to be enable to control the same. 7.9 RISK & CONSEQUENCE ANALYSIS OF FIRE The principle objective of this study is to identify the potential hazards estimate the effects of hazards to people both with in and outside the plant premises.
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Identification of possible failure cases of the facilities, which might affect the population and property within the plant boundary. Assessment of consequential effect on surrounding population, property et., due to onset of such failures. Suggest recommendations bases on consequence analysis relevant to the situations. 7.9.1 Methodology The hazards expected from this plant include the pool fire situation due to the leakage of LDO from the storage tank. There will be one no. of LDO storage tank of 5 KL capacity. The tank will be made of Mild steel and will be provided with dyke around the tank. The most credible failure is due to the rupture of the pipe connecting the storage stank. The worst case can be assumed as when the entire contents leak out into the dyke forming a pool, which may catch fire on finding source of ignition. LDO STORAGE TNAK POOL FIRE SCENARIO The maximum quantity of LDO stored at site will be 5 m3 capacity. In the even of tank spilling its contents through a small leakage or due to rupture of pipeline connecting the tank and on ignition fire will ensue. As the tank is provided with dyke, the fire will be confined with in the dyke. Threshold limit for first degree burns is 4.5 kw/m2. Bases on these results it may be concluded that the vulnerable zone in which the thermal fluxes above the threshold limit for first degree burns (4.5 kw/m2) is restricted to 37.4 m. The hazard distances for various radiation intensities are given below. HAZARD DISTANCES (Fire scenario) Radiation intensity 37.5 Kw/m2 25.0 Kw/m2 12.5 Kw/m 4.5 Kw/m2
2
HAZARD DISTANCES 100% lethality) 50% lethality) 1% lethality) 1st degree burns) 119 M/s. Global Enviro Labs, Hyderabad 4.5 m .5 m 14.5 m 26.6 m
EIA Report
The hazard distances for Thermal radiation are confined to the plant premises only. Hence there will not be any thermal radiation impact on outside the population due to the pool fire scenario. 7.9.2 GENERAL FIRE HAZARDS WITHIN THE SPONGE IRON PLANT The potential hazardous operations and processes in the system are listed below: 1. Hazards in Generators Electrical hazards leading to fire and explosion. Accidents will occur in switchgear and other equipment mainly due to failure of circuit breakers, insulators, and fuses and due to poor maintenance. The accidents will also occur in the transformers due to open arcing, insulator failure, overloading, failure of air-cooling system etc. However all these lead to localized accidents only. 2. Cable Galleries For containment of fire and preventing it from spreading in the cable galleries, unit wise fire barriers with self- closing fire resistant doors with minimum fire rating of approximately 90 minutes are planned. The ventilation system provided in the cable galleries would be interlocked with the fire alarm system so that, in the event of a fire alarm, the ventilation system is automatically switched off. Also to avoid spreading of fire, all cable entries / openings in cable galleries, channels, barriers etc. will be sealed with no inflammable / fire resistant sealing material. Instrument cables will be fire resistant low smoke type. 3. Transformer Section This section includes generator transformer, station reserve transformer, unit auxiliary transformer and switchgear bays. Temperature rise detectors will be used for detection of fire for transformers and the lube oil storage area, while automatic type-high velocity sprinkler protection system is planned to put out the fires. 120 M/s. Global Enviro Labs, Hyderabad
EIA Report
6.9.3 Effective Controls Ignition sources in the vicinity. Pressurization of building not having explosion proof fittings, switching off power supply from a central place, blanket ban on smoking, proper maintenance of flame proof fittings. The thick green belt to be development will help to mitigate the radiation intensity level outside plant boundary. 7.10 DISASTER MANAGEMENT PLAN 7.10.1 Disasters A disaster is catastrophic situation in which suddenly, people are plunged into helplessness and suffering and as a result, need protection, clothing, shelter, medical and social care and other necessities of life. Disasters can be divided into two main groups. In the first, are Disasters resulting from natural phenomena like earthquakes, volcanic eruptions, cyclones, tropical storms, floods, avalanches, landslides etc. The second group includes disastrous events occasioned by man, or by mans impact upon the environment. Examples are industrial accidents, radiation accidents, factory fires, explosions and escape of toxic gases or chemical substances, river pollution, mining or other structural collapses, air, sea, rail and road transport accidents and can reach catastrophic dimensions in terms of human loss. There can be no set criteria for assessing the gravity of a disaster in the abstract it depends to a large extent on the physical, economic and social environment in which it occurs. What would be considered a major disaster in developing country, will be equipped to cope with the problems involved, may not mean more than temporary emergency elsewhere. However all disasters bring in their wake similar consequences that call for immediate action, whether at the local, national or international levels, for the rescue and relief of the victims. This includes the search for the dead and injured, medical and social care, removal of the debris, the provision of temporary shelter for the homeless food, clothing and medical supplies, and the rapid reestablishment of essential services. 121 M/s. Global Enviro Labs, Hyderabad
EIA Report
7.10.2 Objectives of disaster Management of Plan The disaster Management plan is aimed to ensure safety of life, protection of environment, protection of installation, of production and salvage operations in this same order of priorities. For effective implementation of Disaster Management plan, it will be widely circulated and personnel training through rehearsals. The Disaster Management plan would the probable consequential severity of undesired event due to deteriorating conditions or through knock on effects. Further the management should be able to demonstrate that their assessment of the consequences uses good supporting evidence and based on currently available and reliable reports of out side agencies. To tackle the consequences of a major emergency inside the factory or immediate vicinity of the factory, a Disaster Management plan has to be formulated and this planned emergency is called Disaster Management plan. The objective of the Industrial Disaster Management plan is to make use of the combined resources of the plant and the outside services to achieve the following: - Minimise damage to property and the environment. - Effect the rescue and medical treatment of causalities. - Provide for the needs of relatives. - Provide authoritative information to news media. - Secure the safe rehabilitation of affected areas. - Safeguard other people. Initially contain and then ultimately bring the situation under the control. Preserve subsequent records and equipment for subsequent enquiry the cause and circumstances leading to emergency.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 7.10.3 Emergencies 7.10.3.1 General, Industrial, Emergencies The emergencies that could be envisaged in the plant are as follows:
EIA Report
i. Situation of fire hazard due to pool fire scenario (HSD/LDO) ii. Contamination of food /water. iii. Sabotage / social disorder. iv. Slow isolated fires. 7.10.3.2 Specific Emergencies Anticipated During the study of risk assessment, the probability of occurrence of hazards are worked out along with the nature of damage. This is the reason why one should study risk assessment in conjunction with DMP. 7.10.3.3 Emergency Organization It is recommended to setup an Emergency Organization. A Senior executive who has control over the affairs of the Plant would be heading the Emergency Organization. He would be designated as Site Controller. In the case of stores, utilities, open areas which are the not under the control of production heads, executive responsible for maintenance of utilities would be designated as Incident Controller. All the Incident Controllers would be reporting to the site controller. Each Incident Controller, for himself, organizes a team responsible for controlling the incident with the personnel under his control. Shift in-charge would be the reporting Officer, who would bring the incident to the notice of the Incident Controller and the Site Controller. Emergency Coordinators would be appointed who would undertake the responsibilities like fire fighting, rescue, rehabilitation, transport and support services. For this purposes,
Security in-charge, Personal Department, Essential services personnel would be engaged. Al these personnel would be designated as key personnel.
EIA Report
In each shift, electrical supervisor, electrical fitter, pump house in-charge and other maintenance staff would be drafted for emergency operations. In the event of Power communication system failure, some of staff members in the office / Plant offices would be drafted and their services would be utilized as messengers for quick passing of communications. All these personnel would be declared as essential personnel 7.10.3.4 Emergency communication Whoever notices an emergency situation such as fire, growth of fire, leakage etc. would inform his immediate superior and Emergency Control Center. The person on duty in the Emergency Control Center would appraise the site controller. Site controller verifies the situation from the Incident Controller of that area or the shift in-charge and takes a decision about implementing on Site Emergency Coordinators. Simultaneously, the emergency warning system would be activated on the instructions of the site controller. 7.10.3.5 Emergency Responsibilities The responsibilities of the key personnel are appended below: 7.10.3.5.1 Site Controller On receiving information about emergency he would rush to Emergency Controller Center and take charge of ECC and the situation and assesses the magnitude of the situation on the advice of incident controller and decides. Whether affected area needs to be evacuated. Whether personnel who are at assembly points need to be evacuated. Declares Emergency and orders for operation of emergency siren Organizes announcement by public address system about location of emergency. Assesses which areas are likely to be affected, or need to be evacuated or to be altered. Maintains a continuous review of possible development and assesses the situation in consultation with Incident Controller and other key personnel whether shutting 124 M/s. Global Enviro Labs, Hyderabad
EIA Report
down the Plant or any section of the Plant required and if evacuation of persons is required. Directs personnel of rescue, rehabilitation, transport, fire brigade, medical and other designated mutual support systems locally available for meeting emergencies. Controls evacuation of affected areas, if the situation is likely to go out of control or effects are likely to go beyond the premises of the factory, informs to District Emergency Authority, Police, Hospital and seeks their intervention and help. Informs Inspector of factories, Deputy Chief Inspector of factories, APPCB and other statutory authorities. Given public statement if necessary. Keeps record of chronological events and prepares an investigation report an preserves evidences. On completion of on site Emergency and restoration of normalcy, declares all clear and order for all clear signal.
7.10.3.5.2 Incident Controller Assembles the incident control team Directs operations within the affected areas with the priorities for safety to personnel, minimize damage to the Plant, property and environment and minimize the loss of materials. Directs the shutting down and evacuation of Plant and areas likely to be adversely affected by the emergency. Ensures that all-key personnel help is sought. Provides advice and information to the Fire and Security officer and the local Fire Services as and when they arrive. Ensures that all non-essential workers / staff of the effected areas evacuated to the appropriate assembly points and the areas are searched for causalities. Has regard to the need for preservation of evidence so as to facilitate any enquiry into the cause and circumstances, which caused or escalated the emergency. 125 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Coordination on with emergency services at the site. Provides tools and safety equipments to the team members.
EIA Report
Keeps in touch with the team and advise them regarding the method of control to be used. Keep the site Controller of Emergency informed of the progress being made. 7.10.3.5.3 Emergency Coordinator Rescue, Fire Fighting On knowing about emergency, rushes to Emergency Control Centre. Helps the incident controller in containment of the emergency. Ensure fire pumps is operating conditions and instructs pump house operator to be ready for any emergency. Guides the fire fighting crew i.e. Firemen trained Plant personnel and security staff. Organizes shifting the fire fighting facilities to the emergency site, if required. Takes guidance of the Incident Controller for fire fighting as well as assesses the requirements of outside help. Arranges to control the traffic at the gate and the incident area / Directs the security staff to take part in the emergency operations under his guidance and supervision. Evacuates the people in the Plant or in the near by areas as advised by site controller. Searches for casualties and arranges proper aid for them. Assembles search and evacuation team. Arranges for safety equipments for the members of his team. Decides which paths the evacuated workers should follow. Maintains law and order in the area, and if necessary seeks the help of police. 7.10.3.5.4 Emergency Coordinator Medical, Mutual Aid, Rehabilitation, Transport and Communication In the event of failure of electric and there by internal telephone, Sets up communication point and establishes contact with the Emergency control Center (ECC). 126 M/s. Global Enviro Labs, Hyderabad
EIA Report
Organizes medical treatment to the injured and if necessary will shift the injured to near by hospitals. Mobilizes extra medical help from outside, if necessary Keeps a list of qualified first aiders of the factory and seek their assistance. Maintains first aid and medical emergency requirements. Makes sure that all safety equipment are made available to the emergency team. Assists Site Controller with necessary data and to coordinate the emergency activities. Maintains liaison with Civil Administration. Ensure availability of canteen facilities and maintenance of rehabilitation centre. He will be in liaison with site Controller / Incident Controller. Ensure availability of necessary cash for rescue / rehabilitation and emergency expenditure. Control rehabilitation of affected areas on discontinuation of emergency. Makes available diesel petrol for transport vehicles engaged in emergency operation. 7.10.3.5.5 Emergency Coordinator Essential Services He would assist Site Controller and Incident Controller Maintains essential services like Diesel Generator, Water, Fire Water, Compressed Air / Instrument Air, power supply for lighting. He would plan alternate facilities in the event of power failure, to maintain essential services such as lighting, etc. He would organize separate electrical connections for all utilities and during emergency be coordinates that the essential services and utilities are not effected. Gives necessary instructions regarding emergency electrical supply, isolation of certain sections etc to shift in-charge and electricians. Ensure availability of adequate quantities of protective equipment and other emergency materiel, spares etc.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 7.10.3.5.6 General Responsibilities of Employees during an Emergency
EIA Report
During an emergency, it becomes more enhanced and pronounced when an emergency warning is raised, the workers if they are incharge of process equipment, should adopt safe and emergency shut down and attend any prescribed duty as an essential employee. If no such responsibility is assigned, he should adopt a safe course to assembly point and await instructions. He should not resort to spread panic. On the other hand, he must assist emergency personnel towards objectives of DMP. 7.10.3.6 Emergency Facilities 7.10.3.6.1 Emergency Control Center For the time being office block is identified as Emergency control center. It would have external Telephone, Fax facility. All the Incident controller officers, senior personnel would be located here. The following information and equipment are to be provided at the Emergency control Center (ECC). Intercom, telephone P&T telephone Fire suit / gas tight goggles / gloves / helmets Factory layout, site plan Emergency lamp / torchlight Plan indicating locations of hazard inventories, Plant control room, sources of safety equipment, work road plan, assembly points, rescue location vulnerable zones, escape routes. Hazard chart Safe contained breathing apparatus Hand tools, wind direction, wind velocity indications Public Address Megaphone, Hand bell, Telephone directories (Internal, P&T). Address with telephone numbers and key personnel, Emergency coordinator.
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Important addresses, telephone numbers such as experts from outside, government agencies neighboring industries etc. Emergency shut down procedures. Nominal roll of employees. 7.10.3.6.2 Emergency Power Supply Plant facilities would be connected to Diesel Generator and would be placed into auto mode. 7.10.3.6.3 Fire Fighting Facilities First Aid Fire Fighting equipment suitable for emergency should be maintained as per statutory requirements per TAC Regulations. Fire hydrant line converting major areas would be laid. It would be maintained as 6 kg / sq.cm pressure. 7.10.3.6.4 Location of Wind sock On the top of production block and on the top of administrative block wind socks would be installed to indicate direction of wind during emergency period. 7.10.3.6.5 Emergency Medical Facilities Gas masks and general first aid materials for dealing with chemical burns, fire burns etc. would be maintained in the medical centre as well as in the emergency control room. Private medical practitioners help would be sought. Government hospital would be approached for emergency help. Apart from plant first aid facilities, external facilities would be augmented. Names of Medical personnel, Medical facilities in Koppal town would be prepared and updated. Necessary specific medicines for emergency treatment of burns patients, and for those affected by toxicity would be maintained. Breathing apparatus and other emergency medical equipment would be provided and maintained. The help of near by industrial management in this regard would be taken on mutual support basis. 129 M/s. Global Enviro Labs, Hyderabad
EIA Report
7.10.3.6.6 Ambulance An ambulance with driver availability in all the shifts, Emergency shift, Vehicle would be ensured and maintained to transport injured or affected persons. Number of persons would be trained in first aid so that, in every shift first aid personnel would be available. 7.10.3.7 Emergency Actions 7.10.3.7.1 Emergency warning Communication of emergency would be made familiar to the personal inside the plant and people outside. An emergency warning system would be established. 7.10.3.7.2 Emergency shutdown There are number of facilities which can be provided to help in dealing with hazard conditions. The suggested arrangements are # Stop feed # Deluge contents # Remove heat # Transfer contents Methods of removing additional heat include removal the normal cooling arrangements or use of an emergency cooling system. Cooling facilities which is vaporizing liquid may be particularly effective, since a large increase in vaporization can be obtaine4d by dropping pressure. 7.10.3.7.3 Evacuation of personnel The area would have adequate number of exits and staircases. In the event of an emergency, unconnected personnel have to escape to assembly point. Operators have to take emergency shutdown procedure and escape. The office maintains a copy of deployment of employees in each shift at emergency communication centre. If necessary, personas can be evacuated by rescue teams. 130 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 7.10.3.7.4 All Clear Signal
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At the end emergency, after discussing with incident Controllers and Emergency Coordinators, the site controller orders an all clear signal 7.11 OCCUPATIONAL HEALTH AND SURVEILLENCE Large industries where multifarious activities are involved during construction, erection, testing, commissioning, operation and maintenance, the men, materials and machines are the basic inputs. Along with the booms, the industrialization generally brings several problems like occupational health and safety. 7.11.1 Occupational Health Occupational health needs attention both during construction and operation phases however the problem varies both in magnitude and variety in the above phases. 7.11.2 Construction & Erection The occupational health problems envisaged at this stage can mainly be due to constructional and noise. To overcome these hazards, in addition to arrangements required to reduce it within TLVS, personnel protective equipments should also be supplied to workers. 7.11.3 Operation &Maintenance The working personal should be given the following appropriate personnel protective equipments. Industrial Safety helmets Crash helmets Face shield with replacement acrylic vision Zero power plain goggles with cut type filters on both ends Zero power goggles with cut type filters on both ends Welders equipment for eye and face protection 131 M/s. Global Enviro Labs, Hyderabad
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State Cylindrical type earplug Ear plugs Canister gas masks Self contained breathing apparatus Leather apron Boiler suit Safety belt/ Line mans safety belt Leather hand gloves Asbestos hand gloves Acid /Alkali proof rubberized hand gloves Canvas cum leather hand gloves with leather palm Industrial safety shoes with steel toe Electrical safety shoes without steel toe and gum boots
EIA Report
Pre employment medical examination shall be conducted. Full fledged hospital facilities shall be made available round the clock for attending emergency arising out of accidents, if any. All workers shall be medically tested once in a year and at the end of his term of employment. Medical records of all employees will be maintained. 7.12 SAFETY PLAN Safety of both men and materials during construction and operation phases is of concern. The preparedness of an industry for the occurrence of possible disasters is known as emergency plan. The disaster in project is possible due to collapse of structures and fire / Explosion etc. the details of fire fighting equipments to be installed are given below. Carbon dioxide Foam type DCP Soda acid type Fire buckets Fire hydrants 132 M/s. Global Enviro Labs, Hyderabad
EIA Report
Keeping in view the safety requirement during construction, operation and maintenance phases, M/s. Baba Akhila Sai Jyothi Industries Pvt, Ltd. has formulated safety policy with the following regulations. i. To take steps to ensure that all known safety factors are taken into account in the design, construction, operation and maintenance of plants, machinery and equipment. ii. To allocate sufficient resources to maintain safe and healthy conditions of work. iii. iv. To ensure that adequate safety instructions are given to all employees. To provide where ever necessary protective equipment, safety appliances and clothing and to ensure their proper use. v. To inform employees about materials, equipments or processes used in the their work which are known to be potentially hazardous to health and safety. vi. To keep all operations and methods of work under regular review for making necessary changes form the safety point of view in the light of experience and up to date knowledge. vii. To provide appropriate facilities for first aid and prompt treatment of injuries and illness at work. viii. To provided appropriate instructions, training and supervision to employees health and safety, first aid and to ensure that adequate publicity is given to these matters. ix. To ensure proper implementation of fire preventive methods and an appropriate fire fighting service along with training facilities for personnel involved in this service. x. To publish / notify regulation, instructions and notices in the common language employees. xi. xii. To prepare safety rules for each type of process involved. To ensure regular safety inspection by a competent person at suitable intervals of all buildings, equipments, work places and operations.
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State 7.12.1 Safety Organization 7.12.1.1 Construction and Erection Phase
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A highly qualified and experienced safety officer will be appointed. The responsibilities of the safety officers include identification of the hazardous conditions and unsafe acts of workers and advise on corrective actions, conduct safety audit, organize training programmes and provide professional expert advice on various issues related to occupation safety and health. In addition to employment of safety officer, every contractor, who employees more than 150 workers, should also employ one safety officer to ensure safety of the workers in accordance with the conditions of the contract.
7.12.1.2 Operation &Maintenance phase When the construction is completed the posting of safety officers should be in accordance with the requirement of factories act and their duties and responsibilities should be as defined there of. 7.12.1.3 Safety Circle In order to fully develop the capabilities of the employees in identification of hazardous processes and improving safety and health, safety circle would be constituted in each area of work. The circle would consist of 5-6 employees from that area. The circle normally should meet for about an hour every week. 7.12.1.4 Safety Training A full fledged training centre will be established at M/s Baba Akhila Sai Jyothi Industries Pvt, Ltd. Safety training will be provided by the safety officers with the assistance of faculty members called from professional safety institutions and universities. In addition to regular employees, limited contractor labors will also given safety training.
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To create safety awareness safety films will be shown to workers and leaflets etc. will be distributed. 1. Compartmentation of the cable galleries, use of proper sealing techniques of cable passages and crevices in all directions would help in localizing and identifying the area of occurrence of fire as well as ensure effective automatic 2. Spread of fire in horizontal direction would be checked by providing fire stops for cable shafts. 3. Reliable and dependable type of fire detection system with proper zoning and interlocks for alarms are effective protection methods for conveyor galleries. 4. Housekeeping of high standard helps in eliminating the causes of fire and regular fire watching system strengthens fire prevention and fire fighting. 7.12.1.5 Health and Safety Monitoring Plan All the potential occupational hazardous work places will be monitored regularly. The health of employees working in these areas will be monitored once in a year.
EIA Report
AMBIENT AIR QUALITY Station: A1,Project Site TSPM RSPM SO2 (g/m3) 3 3 (g/m ) (g/m ) 06-14 15-22 23-06 hrs hrs hrs 131 57 15 11.6 13.2 152 46 12.6 10.7 11.9 143 62 11.7 10.5 10.7 120 45 14.2 11.8 15.0 129 53 11.0 12.0 14.3 140 47 12.3 11.9 13.5 157 54 13.6 13.2 12.1 136 62 14.3 15 11.0 152 59 12.7 14.3 12.3 160 49 10.8 12.6 14.2 133 64 11.1 11.3 13.2 147 61 12.0 10.6 11.8 159 48 10.5 12.2 13.5 123 56 13.3 13.7 10.7 138 60 14.5 14.6 11.8 145 48 10.8 10.9 13.2 156 53 11.7 11.8 10.5 127 46 12.9 13.0 12.6 131 57 13.8 12.7 14.5 144 65 14.5 14.2 11.9 128 50 10.7 13.4 14.5 158 47 11.5 10.7 13.3 132 61 12.7 11.3 12.7 141 52 13.5 15 14.3 SPM RPM SO2 NOx 120 45 10.9 13.9 160 65 14.2 16.4 140.91 54.25 12.55 15.07 127.3 46.3 11.46 14.12 131.9 48.9 11.98 14.79 140.5 53.5 12.5 15.1 158.85 63.7 13.6 15.98 159.54 64.54 13.92 16.21
EIA Report
Annexure A NOx (g/m3) 15-22 23-06 hrs hrs 15.2 14.7 14.8 15.8 13.0 16.5 13.2 13.7 13.7 14.7 14.2 15.7 15.3 16.8 16.9 13 17.0 15.5 16.7 14.0 15.7 17 14.8 15.7 16.2 16.5 15.7 13.3 13.2 14.3 14.3 15.7 16.3 13.7 14.0 14.6 15.3 15.3 14.2 16.7 16.8 15.9 13.4 13.6 14.3 13.7 17.0 14.3 CO ppm <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1
S.No.
Month
Week
Day 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
1 December 2009
st
2nd 3rd 4th 1st
January 2009
2nd 3rd 4th 1st
February 2010
2nd 3rd 4th
24 hrs average 13.2 11.7 10.9 13.6 12.4 12.5 12.9 13.4 13.1 12.5 11.8 11.4 12.0 12.5 13.6 11.6 11.3 12.8 13.6 13.5 12.8 11.8 12.2 14.2
06-14 hrs 17.0 16.3 15.2 14.8 16.3 15.7 14.7 13.3 14.3 15.3 16.6 13.9 15.0 16.7 14.5 15.1 14.2 13.5 17.6 15.4 14.7 16.3 15.2 13.6
24 hrs average 15.6 15.6 14.9 13.9 14.9 15.2 15.6 14.4 15.6 15.3 16.4 14.8 15.9 15.2 14.0 15.0 14.7 14.0 16.0 15.4 15.8 14.4 14.4 14.9
Min Max Mean 10th percentile 30th percentile 50th percentile 95th percentile 98h percentile
M/s. Global137 Enviro Labs, Hyderabad
EIA Report
AMBIENT AIR QUALITY Station: A2, Chikka bagnal RSPM SO2 (g/m3) (g/m3) 06-14 15-22 23-06 hrs hrs hrs 105 42 8.7 7.7 7.4 127 50 7.9 9.5 9.4 130 36 9.5 7.1 8.0 116 47 7.3 8.2 7.8 121 34 8.7 9.3 9.0 103 38 9.6 7.8 7.1 113 48 9.7 8.3 8.2 134 33 7.7 7.5 7.6 127 44 8.5 9.0 9.4 125 36 9.2 9.7 8.5 131 43 7.6 8.0 7.3 122 34 9.5 8.2 9.5 118 45 7.8 7.6 8.6 109 38 8.7 8.3 7.9 120 47 9.0 7.5 9.3 131 39 7.6 9.6 9.7 107 35 8.2 7.5 8.5 117 48 9.3 8.7 7.5 123 36 7.1 9.2 7.6 132 41 9.5 8.3 9.2 115 37 8.4 7.5 8.3 110 40 7.5 9.3 8.5 106 39 9.2 8.5 7.6 125 42 8.3 7.6 9.5 SPM RPM SO2 NOx 103 33 7.6 9.9 134 50 9.1 12.2 115.7 40.5 8.3 11.12 106.3 34.3 7.76 10.52 114.8 36.9 8.0 10.9 120.5 39.5 8.4 11.05 131.85 48.0 9.0 12.15 133.08 49.08 9.054 12.2 TSPM (g/m3) NOx (g/m3) 15-22 23-06 hrs hrs 12.7 12.5 10.2 11.7 12.4 9.5 10.5 11.5 11.4 9.7 9.2 10.0 12.4 11. 2 11.6 10..5 10.5 12..5 12.5 11.8 10.9 10.3 12.4 11.0 11.3 12.0 9.8 12.3 10.7 9.9 11.0 10.7 12.5 11..3 10.8 12..5 11.3 10..5 12.2 11.7 11.0 9.8 10.9 12..2 12.3 10.4 10.5 11.5
S.No.
Month
Week
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
1st December 2009 2nd 3rd 4th 1st January 2009 2nd 3rd 4th 1st February 2010 2nd 3rd 4th
24 hrs average 7.9 8.9 8.2 7.7 9.0 8.1 8.7 7.6 8.9 9.1 7.6 9.0 8.0 8.3 8.6 8.9 8.0 8.5 7.9 9.0 8.0 8.4 8.4 8.4
06-14 hrs 11.4 12.3 10.5 11.5 12.0 11.3 9.5 12.3 9.3 12.4 11.6 10.3 12.5 10.7 12.0 11.7 10.3 12.8 10.5 9.7 12.2 10.7 11..3 9.2
24 hrs average 12.2 11.4 10.8 11.1 11.0 10.1 10.9 11.9 9.9 12.2 10.9 11.2 11.9 10.9 10.8 11.1 11.4 11.8 10.9 11.2 11.0 10.8 11.3 10.4
CO Ppm <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1
Min Max Mean 10th percentile 30th percentile 50th percentile 95th percentile 98th percentile
EIA Report
AMBIENT AIR QUALITY Station: A3, Lachankeri RSPM (g/m3) 06-14 hrs 118 37 6.8 102 41 7.5 120 36 6.6 111 42 7.4 100 28 6.7 114 38 8.0 102 44 6.3 118 36 7.5 106 43 6.7 109 29 8.0 104 32 5.8 117 46 7.7 101 41 6.0 114 30 7.5 105 31 0.7 119 40 7.5 112 37 5.9 103 28 7.6 121 45 5.8 113 35 6.2 108 42 7.5 120 29 5.9 116 31 6.3 107 28 7.3 SPM RPM SO2 100 28 4.8 121 46 7.3 110.83 36.20 6.72 102 28.3 6.16 105.9 31.0 6.6 111.5 36.5 6.8 120 44.85 7.28 120.54 45.54 7.3 TSPM (g/m3) SO2 (g/m3) 15-22 23-06 hrs hrs 6.0 7.6 6.4 6.6 7.0 7.4 7.2 6.5 7.3 5.9 5.8 6.9 6.6 7.6 7.0 6.4 6.5 7.2 7.5 6.3 5.9 6.8 6.9 7.5 7.4 6.3 8.0 6.4 6.5 7.3 7.5 6.8 6.8 5.8 7.3 6.6 6.5 7.6 7.4 6.9 6.5 7.5 7.3 5.9 5.9 6.7 6.5 8.0 NOx 7.7 11.6 8.47 7.93 8.1 8.3 9.24 10.54 NOx (g/m3) 15-22 23-06 hrs hrs 7.4 9.7 8.5 8.7 7.8 7.5 9.1 9.5 8.3 8.3 7.1 7.9 7.5 8.9 8.7 9.4 9.0 7.3 8.0 8.6 7.6 7.2 8.4 9.1 9.2 8.0 8.6 8.3 7.3 9.4 9.7 7.7 9.4 8.7 8.3 7.6 7.4 8.5 8.6 9.5 7.4 7.1 8.7 7.5 9.5 7.6 7.3 9.2
S.No.
Month
Week
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
24 hrs average 6.8 6.8 7.0 7.0 6.6 6.9 6.8 6.9 6.8 7.2 6.1 7.3 6.5 7.3 4.8 7.2 6.1 7.1 6.6 6.8 7.1 6.3 6.3 7.2
06-14 hrs 17.9 9.7 8.8 9.4 7.6 9.5 8.3 7.6 9.5 8.5 9.0 7.2 8.5 9.6 7.5 8.7 7.6 9.6 8.4 7.5 9.3 7.1 7.5 8.6
24 hrs average 11.6 8.9 8.0 9.3 8.0 8.1 8.2 8.5 8.6 8.3 7.9 8.2 8.5 8.8 8.0 8.7 8.5 8.5 8.1 8.5 7.9 7.7 8.2 8.3
CO Ppm <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1
EIA Report
S.No.
Month
Week
TSPM (g/m3) 97 100 113 104 109 98 107 95 104 112 105 111 96 107 100 113 109 113 99 106 112 103 110 97 SPM
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
1 December 2009
st
2nd 3rd 4th 1st
January 2009
2nd 3rd 4th 1st
February 2010
2nd 3rd 4th
AMBIENT AIR QUALITY Station: A4, Kunikeri RSPM SO2 (g/m3) 3 (g/m ) 06-14 15-22 23-06 24 hrs hrs hrs hrs average 24 5.2 4.3 4.1 4.5 26 6.4 5.7 5.0 5.7 32 5.7 6.4 6.4 6.1 27 4.3 4.8 5.6 4.9 23 6.5 5.3 4.4 5.4 30 5.4 6.6 6.2 6.0 21 4.7 4.5 5.3 4.8 26 6.5 5.7 4.8 5.6 34 5.3 6.0 5.5 5.6 25 5.0 5.5 6.3 5.6 32 6.4 4.1 5.7 5.4 35 5.8 4.8 6.7 5.7 21 4.6 5.7 4.7 5.0 33 5.7 6.3 5.7 5.9 23 6.2 4.8 6.2 5.7 34 4.3 6.3 5.7 5.4 22 6.0 5.0 4.3 5.1 27 4.1 6.2 4.6 4.9 35 5.3 4.7 5.3 5.1 31 6.5 5.5 4.8 5.6 20 4.7 4.5 6.2 5.1 28 5.5 6.4 4.6 5.5 32 6.2 4.3 5.7 5.4 29 5.3 6.5 6.5 6.1 RPM SO2 NOx 20 35 27.91 21.3 24.9 27.5 34.85 35 4.5 6.1 5.42 4.9 5.1 5.45 6.08 6.1 6.9 8.6 7.53 6.9 7.19 7.6 8.34 8.50
06-14 hrs 8.4 6.7 7.5 8.7 8.8 8.0 6.9 7.0 8.3 7.6 6.7 7.9 8.8 8.3 6.6 7.6 8.5 6.8 7.4 8.3 6.9 8.0 7.3 6.5
NOx (g/m3) 15-22 23-06 hrs hrs 8.8 8.1 7.6 8.5 8.5 7.6 8.0 6.8 7.0 7.0 7.3 8.8 6.9 6.9 8.2 8.3 7.7 7.5 6.5 6.8 6.6 7.4 7.0 6.7 8.5 8.6 6.8 6.4 7.5 7.4 6.7 8.6 8.4 6.8 7.6 6.5 8.2 7.3 6.9 8.3 7.3 6.6 7.9 7.0 8.6 6.8 7.5 8.5
24 hrs average 8.4 7.6 7.8 7.8 7.6 8.0 6.9 7.8 7.8 6.9 6.9 7.2 8.6 7.1 7.1 7.6 7.9 6.9 7.6 7.8 6.9 7.6 7.5 7.5
CO Ppm <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1
95 113 105 97 100 105.5 113 113
EIA Report
AMBIENT AIR QUALITY Station: A5, Kunikera tanda RSPM SO2 (g/m3) (g/m3) 06-14 15-22 23-06 hrs hrs hrs 118 30 3.9 4.3 5.7 94 28 6.2 3.3 4.6 111 23 5.3 6.2 5.3 92 39 3.8 6.4 6.5 105 29 6.3 6.0 3.9 95 27 3.3 5.1 4.7 90 37 6.0 5.0 5.8 117 34 6.2 6.5 6.4 103 24 5.2 2.5 7.0 116 32 3.4 4.7 4.6 108 35 4.7 5.3 3.8 110 29 5.5 6.1 5.8 102 37 6.0 4.5 6.2 98 28 3.8 6.2 4.7 112 31 4.7 5.6 3.9 97 25 5.6 4.2 5.7 114 33 3.9 3.5 6.3 98 40 6.4 5.0 4.5 115 27 5.3 6.3 3.9 93 39 3.5 5.6 3.3 117 25 6.3 4.0 5.0 100 38 3.7 3.7 3.7 99 36 5.3 5.3 4.3 113 22 6.5 4.7 5.3 SPM RPM SO2 NOx 90 22 3.7 5.0 118 40 6.3 6.7 104.87 31.16 4.99 5.92 93.3 24.3 4.23 5.43 98 27.9 4.69 5.59 104 30.5 5.0 5.8 117 39.0 5.77 6.58 117.54 39.54 6.07 6.65 TSPM (g/m3) NOx (g/m3) 15-22 23-06 hrs hrs 6.5 7.1 6.3 6.0 6.6 6.2 7.1 5.5 6.8 6.8 5.9 5.0 4.8 5.2 6.7 6.5 5.7 4.8 4.9 7.0 6.5 5.9 6.3 4.7 5.8 6.3 7.0 5.5 5.7 6.2 4.8 5.7 6.6 7.4 5.7 6.5 7.0 5.7 6.3 4.8 4.8 5.3 5.8 6.5 4.7 5.2 6.4 4.8
S.No.
Month
Week
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
24 hrs average 4.6 4.7 5.6 5.5 5.4 4.3 5.6 6.3 4.9 4.2 4.6 5.8 5.5 4.9 4.7 5.1 4.5 5.3 5.1 4.1 5.1 3.7 4.9 5.5
06-14 hrs 5.9 4.8 5.6 7.1 6.4 5.3 6.5 7.0 6.3 7.1 4.7 6.9 5.7 6.5 4.8 6.4 5.6 4.7 6.7 5.2 4.9 7.0 6.6 5.3
24 hrs average 6.5 5.7 6.1 6.5 6.6 5.4 5.5 6.7 5.6 6.3 5.7 5.9 5.9 6.3 5.5 5.6 6.5 5.6 6.4 5.4 5.0 6.4 5.5 5.5
CO Ppm <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1
EIA Report
AMBIENT AIR QUALITY Station: A6, Hire bagnal RSPM (g/m3) 06-14 hrs 83 29 4.1 92 23 3.0 97 27 2.9 88 26 3.6 89 21 4.2 86 28 3.9 100 20 4.3 95 25 4.2 110 23 3.7 89 29 3.3 90 19 4.3 94 22 2.8 98 27 4.2 91 24 3.0 89 23 4.5 90 18 3.2 92 28 4.4 87 26 3.5 93 18 4.0 86 21 2.8 97 20 4.3 88 25 2.9 93 19 3.6 100 22 4.7 SPM RPM SO2 83 18 3 110 29 4.5 92.37 23.45 3.67 86.3 19 3.3 89 21 3.49 91.5 23 3.7 100 28.85 4.35 105.4 29.0 4.45 TSPM (g/m3) SO2 (g/m3) 15-22 23-06 hrs hrs 4.2 3.8 4.4 4.3 3.5 2.8 3.9 3.2 2.9 3.6 4.1 4.4 3.9 3.0 3.0 4.2 3.7 3.3 4.3 3.8 4.7 4.5 3.7 3.7 4.2 2.9 3.3 3.6 3.9 3.0 4.0 4.5 4.6 4.2 3.4 3.5 3.5 2.9 3.2 4.7 4.5 3.1 2.9 4.0 2.1 4.3 2.8 3.6 NOx 5.3 7.4 6.47 5.93 6.39 6.5 7.08 7.26 NOx (g/m3) 15-22 23-06 hrs hrs 6.9 7.2 5.9 5.3 7.4 7.4 5.4 5.4 6.7 6.5 7.4 5.1 5.6 7.2 6.8 6.8 7.5 5.3 5.1 7.6 6.9 6.6 7.2 7.3 6.2 6.0 7.2 5.5 6.5 6.8 7.0 7.4 6.8 6.5 5.5 5.6 7.7 7.3 6.6 5.5 7.3 6.8 6.5 7.3 5.3 7.7 7.7 5.3
S.No.
Month
Week
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
24 hrs average 4.0 3.9 3.0 3.5 3.5 4.1 3.7 3.8 3.5 3.8 4.5 3.4 3.7 3.3 3.8 3.9 4.4 3.4 3.4 3.5 3.9 3.2 3.3 3.7
06-14 hrs 5.7 6.5 7.4 5.2 6.2 7.3 6.8 7.2 5.4 6.7 7.5 5.5 5.3 6.4 5.1 6.5 5.9 7.0 6.3 7.4 6.6 5.7 7.7 6.2
24 hrs average 6.6 5.9 7.4 5.3 6.4 6.6 6.5 6.9 6.0 6.4 7.0 6.6 5.8 6.3 6.1 6.9 6.4 6.0 7.1 6.5 6.9 6.5 6.9 6.4
CO Ppm <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1
EIA Report
AMBIENT AIR QUALITY Station: A7, Karkihalli RSPM (31m3) 06-14 hrs 108 31 5.9 105 29 4.7 92 24 6.4 101 30 5.6 94 31 4.6 108 25 6.6 95 26 4.7 106 27 6.7 102 30 5.3 107 24 6.4 91 28 6.0 99 31 5.5 98 30 6.2 90 24 5.0 96 23 5.3 93 25 4.9 111 26 6.5 100 28 4.6 92 24 6.4 103 26 5.7 95 29 4.8 94 30 6.0 91 27 5.5 109 23 4.5 SPM RPM SO2 90 23 4.9 111 31 6.5 99.16 27.12 5.53 91.3 24 5.2 94 25 5.39 98.5 27 5.5 108.85 31 6.24 110.08 31 6.40 TSPM (g/m3) SO2 (g/m3) 15-22 23-06 hrs hrs 4.9 5.7 5.5 4.7 4.5 5.3 6.1 5.1 5.7 5.5 6.4 6.7 5.3 6.5 5.7 4.6 4.6 6.6 6.0 6.5 5.8 5.7 4.7 4.8 6.4 5.0 6.7 4.5 5.5 5.3 6.0 6.4 5.7 5.7 6.3 4.8 4.8 5.2 5.5 6.5 6.3 5.7 4.6 6.0 5.4 4.7 4.8 6.3 NOx 6.6 7.5 7.11 6.8 7.0 7.1 7.5 7.5 NOx (g/m3) 15-22 23-06 hrs hrs 6.6 8.0 7.0 7.3 6.8 6.7 6.7 7.5 7.5 6.4 7.3 7.7 8.0 7.6 7.7 6.7 8.1 6.4 6.4 7.5 6.7 8.1 7.9 6.6 8.1 7.3 7.3 6.7 7.6 8.0 6.5 7.7 7.6 6.6 6.5 7.4 7.6 7.5 6.8 6.8 6.2 7.9 7.9 8.1 7.5 7.0 6.5 6.7
S.No.
Month
Week
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
24 hrs average 5.5 4.9 5.4 5.6 5.2 6.5 5.5 5.6 5.5 6.3 5.8 5.0 5.8 5.4 5.3 5.7 5.9 5.2 5.4 5.9 5.6 5.5 5.2 5.2
06-14 hrs 6.8 7.3 6.7 8.1 6.8 5.0 6.2 7.8 6.4 7.5 6.5 7.0 7.2 6.6 6.2 7.7 6.9 7.3 6.4 8.1 7.5 6.7 8.0 7.3
24 hrs average 7.1 7.2 6.7 7.4 6.9 6.6 7.2 7.4 6.9 7.1 7.1 7.1 7.5 6.8 7.2 7.3 7.0 7.0 7.1 7.2 7.2 7.5 7.5 6.8
CO Ppm <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1
EIA Report
AMBIENT AIR QUALITY Station: A8, Halavaru RSPM (g/m3) 06-14 hrs 101 31 5.9 120 27 7.1 110 32 6.5 103 33 5.7 114 28 6.8 108 35 7.0 98 26 7.2 120 36 6.3 111 27 5.8 114 32 7.0 116 25 7.1 118 34 5.4 115 31 6.8 112 36 5.7 117 30 6.4 98 32 5.5 110 29 6.9 112 26 5.8 106 30 6.5 119 27 5.1 107 35 6.7 100 28 5.9 99 25 7.0 113 33 6.3 SPM RPM SO2 98 25 5.4 120 36 6.8 110.04 30.3 6.23 99.3 26.0 5.86 106.9 27.9 6.18 111.5 30.5 6.3 119.85 35.85 6.7 120.0 36.0 6.75 TSPM (g/m3) SO2 (g/m3) 15-22 23-06 hrs hrs 5.1 5.3 5.7 5.4 6.3 6.3 7.1 5.9 5.4 6.0 7.2 6.4 6.9 5.3 5.8 6.5 5.2 7.0 5.5 6.8 6.7 5.2 7.0 6.6 5.1 7.2 7.2 5.7 6.5 6.7 5.5 7.1 7.1 6.3 6.8 7.6 5.6 5.3 7.1 6.6 5.2 7.2 6.3 5.3 5.8 7.0 7.1 5.5 NOx 7.1 8.9 7.82 7.3 7.69 7.8 8.55 8.76 NOx (g/m3) 15-22 23-06 hrs hrs 8.5 7.4 7.3 8.4 7.0 8.3 8.2 7.4 7.7 8.7 8.6 6.9 6.9 8.5 7.5 7.1 8.1 7.0 7.2 8.0 8.6 8.3 7.8 7.5 8.0 8.5 7.6 7.7 8.3 6.9 7.5 8.1 8.8 7.5 8.5 8.0 7.6 7.7 8.7 9.0 8.2 8.3 7.5 6.9 6.9 7.4 9.0 8.6
S.No.
Month
Week
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
24 hrs average 5.4 6.0 6.3 6.2 6.0 6.8 6.4 6.2 6.0 6.4 6.3 6.3 6.3 6.2 6.5 6.0 6.7 6.7 5.8 6.2 6.3 5.8 6.6 6.3
06-14 hrs 6.9 6.3 8.8 7.6 9.6 7.7 6.9 7.0 9.0 8.1 7.0 8.5 7.4 8.4 6.9 7.6 8.5 7.3 8.0 9.0 8.3 6.9 8.7 7.5
24 hrs average 7.6 7.3 8.0 7.7 8.6 7.7 7.4 7.2 8.0 7.7 7.9 7.9 7.9 7.9 7.3 7.7 8.2 7.9 7.7 8.9 8.2 7.1 7.6 8.3
CO Ppm <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1 <1
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State SURFACE WATER ANALYSIS S.No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
EIA Report
Annexure B
Description
pH Electric conductivity (Mcrosiemens/cm) Total Dissolved Solids Total hardness as CaCO3 Calcium as Ca Magnesium as Mg Total Alkalinity Chemical Oxygen Demand Biochemical Oxygen Demand Dissolved Oxygen Oil & Grease Chlorides as Cl Flourides as F Nitrates as NO3 Nitrites as NO2 Sulphates as SO4 Phosphates as PO4 Sodium as Na Potassium as K Iron as Fe Boron as B Copper as Cu Lead as Pb Zinc as Zn Chromium as Cr Aluminium as Al Total Coliforms Feacal Coliforms E. coli (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L)
Tungabhadra Water
8.80 959 600 89 36 4.3 68 41 17 6.0 21 136 0.9 6.03 1.02 63 8.20 83 3.5 7.31 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 80 13 17 IS:3025 (Part10) 1984 IS:3025 (Part16) 1984 IS:3025 (Part21 1983 IS:3025 (Part40) 1991 IS:3025 (Part13) 1964
IS:3025 (Part32) 1988 IS:3025 (Part23) 1964 IS:3025 (Part34) 1988 IS:3025 (Part24) 1986
IS:3025 (Part32) 1964 IS:3025 (Part29) 1964 IS:3025 (Part36) 1964 IS:3025 (Part39) 1964 IS:3025 (Part38) 1964 IS:3025 (Part31) 1964
Proposed Enhancement of Sponge Iron Plant from 100 TPD to 175 TPD at M/s. Baba Akhila Sai Jyothi Industries Pvt. Limited, Chikkabaganal (V) & Kunikeri (V) Koppal (Tq & Dist), Karnataka.State GROUND WATER ANALYSIS
S.No. Description 1 pH 2 Electric conductivity (Mcrosiemens/cm) 3 Total Dissolved Solids 4 Total hardness as CaCO3 5 Calcium as Ca 6 Magnesium as Mg 7 Total Alkalinity 8 Dissolved Oxygen 9 Chlorides as Cl 10 Flourides as F 11 Nitrates as NO3 12 Sulphates as SO4 13 Phosphates as PO4 14 Sodium as Na 15 Potassium as K 16 Iron as Fe 17 Boron as B 18 Copper as Cu 19 Lead as Pb 20 Zinc as Zn 21 Chromium as Cr 22 Aluminium as Al 1 7.3 1580 (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) 1230 320 206 40 315 4.6 70 0.9 6.3 45 7.5 83 3.2 0.6 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 2 7.1 1300 1000 310 200 52 199 5.3 95 1.2 9.2 80 3.1 100 3.6 0.18 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 3 7.52 1940 1836 321 200 59 310 6.2 135 0.8 10.3 158 8.7 95 4.2 0.19 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 4 7.68 1630 1780 350 250 53 290 5.6 180 0.7 8.8 165 7.0 88 3.3 0.16 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
EIA Report
5 7.13 1570 1340 310 220 49 320 4.5 160 1.0 8.0 141 4.2 101 4.3 0.23 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
6 7.50 2010 1780 372 216 82 270 6.5 220 1.3 11.5 168 7.3 125 4.9 0.20 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
7 7.32 1227 1118 325 180 56 180 5.5 102 0.6 9.2 94 7.5 110 3.5 0.22 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
8 6.91 1257 1075 333 171 59 192 5.3 201 1.02 10.3 128 8.6 105 4.0 0.17 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
IS:3025 (Part10) 1984
IS:3025 (Part16) 1984 IS:3025 (Part21 1983 IS:3025 (Part40) 1991 IS:3025 (Part13) 1964 IS:3025 (Part32) 1988 IS:3025 (Part23) 1964 IS:3025 (Part34) 1988 IS:3025 (Part24) 1986
IS:3025 (Part32) 1964 IS:3025 (Part29) 1964 IS:3025 (Part36) 1964 IS:3025 (Part39) 1964 IS:3025 (Part38) 1964 IS:3025 (Part31) 1964
1. Plant Bore well
2. Chikka bagnal Bore will
3. Lachankeri bore well
4. Kunikeri Bore well 8. Halavaru Borewell
5. Kunikeri tanda Bore well
6. Hire bagnal Bore well
7. Karkihalli Bore well
EIA Report
SOIL ANALYSIS
Annexure C 2 7.02 120 141 102 53 181 100 400 76 67 0.64 45 37 56 Clayey sandy 0.92 0.20 0.15 3 7.2 119 200 120 45 200 95 323 57 85 0.63 43 32 52 Clayey sandy 0.73 0.16 0.10 4 8.02 170 182 135 47 195 116 300 64 98 0.75 46 39 49 Clayey sandy 0.82 0.15 0.20 5 7.20 131 160 115 53 132 99 273 60 70 0.73 45 38 56 Clayey sandy 0.90 0.20 0.25 6 8.00 200 182 110 68 183 100 302 72 180 0.72 38 43 45 Clayey Loam 0.73 0.20 0.15 7 7.80 120 142 95 50 180 92 320 72 62 0.72 42 32 52 Clayey Sandy 0.72 0.20 0.12 8 7.3 150 166 120 53 170 99 320 66 76 0.78 50 40 63 Clayey sandy 0.90 0.18 0.10
S. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Parameters Ph (1:2 Soil water Extract) Electrical conductivity (micro mhos) (1:2 Soil water Extract) Total soluble salts, mg/kg Nitrates as N, (mg/kg) Phophorous as (P2O5) (mg/kg) Potassium as (K2O) (mg/kg) Sodium as Na2O (mg/kg) Calcium as Ca (mg/kg) Magnesium as Mg (mg/kg) Chlorides as Cl (mg/kg) Organic carbon (%) Texture Sand (%) Silt (%) Clay (%) Type of Soil Copper as Cu mg/kg Zinc as Zn mg/kg Maganese as Mn mg/kg
1 7.6 210 250 120 67 123 90 360 45 90 0.73 49 36 53 Clayey sandy 0.92 0.18 1.03
1. Plant 2. Chikka bagnal
3. Lachankeri
4. Kunikeri
5. Kunikeri tanda
6. Hire bagnal
7. Karkihalli
8. Halavaru
FLORA Annexure D
EIA Report
TECHNICAL NAME FAMILY FREQUENCY Kydia Calycina Roxb. Malvaceae Occasional Arqemone mexicana Linn. Papavaraceae Abundant Cleome Viscosa Cleommaceae Frequent Potulaca Oleracea Linn Potulacaceae Common Ailanthus excelsa Roxb. Simaroubeceae Frequent Oxalis Corniculata Linn Oxalidaceae Abundant Murraya Koeniqii, Sperg Rutaceae Occasional Aeqlemarmelos corr Rutaceae Frequent Buchanaia Lanzan Spreng Anacardiaceae Frequent Maquifer Indica Linn Anacardiaceae Common Semecarpus Anacardium Linn. Anacardiaceae Common Sida Cordifolia Linn Malvaceae Frequent Sida rhombifolia Linn Malvaceae Occasional Anona Aquamosa Linn Annonaceae Occasional Polylathia longifolia Anonaceae Planted Rare Haccopetallum Tomentum Anonaceae Occasional Abutilon Indicum Malvaceae Frequent Salmalia Malabarica Malvaceae Occasional Sida accua Burm. F. Malvaceae Abundant Azadirchta Indica A. Juss. Melicaceae Rare Boswellia Serrata Roxb. Sunariybeceae Frequent Cassia tora Linn Streculiceae Common Sterculia urens Roxb. Streculiceae Common Cassis tora Linn Caesalpinaceae Occasional Tamarindus Indica Linn Caesalpinaceae Frequent Hardwickia binata Rob. Caesalpinaceae Occasional Acacia Catachu Wild. Mimoceae Rare Albizzia Lebbek Benth Mimoceae Frequent Alysicarpus mnilifer. Fabaceae Frequent Indigofera unifolia Rotz. Fabaceae Frequent Pterocarpus Maraspium Roxb. Fabaceae Frequent Pongamia Pinnata Pierre Fabaceae Common Oueinia dalbergioides Fabaceae Common Butea Monsperma Taub Fabaceae Frequent Diospyors Melanoxylon Roxb. Ebenaceae Frequent Nyctanthes arbor tristis Linn Oleaceae Common Achanthospermum hispidum DC. Asteraceae Abundant Xanthium stromarium Linn Asteraceae Abundant Mitrayana Pavifolia Rubiaceae Frequent The following notations have been used to represent the frequency of occurrence. Very abundant Over 50 Common Over 20 Abundant Over 40 Occasional Over 10 Frequent Over 30 Rare Below 10
EIA Report
FAUNA Common Name Cotton Tea Pariah kite Scope owl Small Blue Fisher Garden Lizard Kriet Kobra Rat Snake Wiper Hare House sparrow Grey Jungle Fowl Cattle Egret Barn Owl Banded Kriet Beck Chameleon Indian tree shure House Crow Scientific Name Nettepus corom Nilvus migras gorinda Octus bakkamoena Alcede Ottis Calotes Verricolor Bangarus Caureleus Naja naja Pytes mucosus Biere russeli Lepus nigiri collis Passer domestious Gallous souneratie Babulcus Ibis Tyta Alba Bangaruss Fasdiciatus Exnochrophis discolor Chemeleon Zeylanciay Anthene elliothi Cerrus Solleedens
Annexure E Telugu Name Tell Bathu Gradda Chinnagudlaguda Chinnacekumkipetta Tonda Katlapamu Nagapamu Jerripotu Katukarekula Pode Chevula Pilli Pitchuka Adavi Pitta Tella Konga Tell Gudlaguda Bangaram Pammu Neetipamu Usaavelli Chunchu Kaki
EIA Report
EIA Report
DEMOGRAPHIC PROFILE OF THE STUDY AREA (10 km radius)

Name Total/ Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Number of households
141 1,281 272 132 333 663 165 677 191 180 271 706 131 351 1,268 120 195 196 340 94 160 100 229 266 354 336 452 172 112
Annexure - F
SC Population Total SC% ST Population Total ST%
Total
Total Population Male Female
Sex ratio
991 978 1037 1032 955 1010 950 998 1069 936 941 1010 936 1040 956 1069 934 933 978 979 1053 937 836 952 950 961 1008 996 923
0-6 years aged population Total Male Female
Gudigera Kawaloor Handral Hanwal Wadganhal Halgera Katrahalli Hiresindogi Chiksindogi Dombarhalli Belur Bisarhalli Bikanhalli Mainahalli Alwandi Murlapur Ghatreddihal Belgatti Hatti Raghunathanhalli Hydernagar Keslapur Halwagali Nilogipur Tigari Hunkuntiakkapur Bochanhalli Bhairapur Kampli
904 6,985 1,646 772 1,961 3,486 827 3,624 1,115 931 1,599 4,085 697 1,883 6,907 596 1,050 1,241 1,980 471 768 521 1,212 1,456 1,989 1,794 2,626 934 598
454 3,532 808 380 1,003 1,734 424 1,814 539 481 824 2,032 360 923 3,532 288 543 642 1,001 238 374 269 660 746 1,020 915 1,308 468 311
450 3,453 838 392 958 1,752 403 1,810 576 450 775 2,053 337 960 3,375 308 507 599 979 233 394 252 552 710 969 879 1,318 466 287
171 1,034 295 112 319 529 134 649 183 128 269 654 116 362 937 101 163 170 427 103 137 68 223 274 374 364 528 149 50
85 543 155 54 163 262 71 324 85 68 146 341 65 186 494 50 87 82 223 53 59 32 124 142 192 187 249 75 25
86 491 140 58 156 267 63 325 98 60 123 313 51 176 443 51 76 88 204 50 78 36 99 132 182 177 279 74 25
256 1,295 165 21 165 305 43 547 78 150 289 1,081 197 284 1,155 168 203 13 24 51 626 65 137 156 173 274 328 0 21
28.3 18.5 10.0 2.7 8.4 8.7 5.2 15.1 7.0 16.1 18.1 26.5 28.3 15.1 16.7 28.2 19.3 1.0 1.2 10.8 81.5 12.5 11.3 10.7 8.7 15.3 12.5 0.0 3.5
0 726 225 0 84 127 35 187 87 98 176 89 28 32 323 69 127 249 190 3 44 191 134 412 455 435 690 0 12
0.0 10.4 13.7 0.0 4.3 3.6 4.2 5.2 7.8 10.5 11.0 2.2 4.0 1.7 4.7 11.6 12.1 20.1 9.6 0.6 5.7 36.7 11.1 28.3 22.9 24.2 26.3 0.0 2.0
Moranhalli Betgera Katarkigudlanur Neeralgi Mattur Madinur Devlapur Kalkera Hatti Chilwadgi Naregal Yettinhatti Ojanhalli Tankankal Hanmanhalli Kutganhalli Gabbur Ginigera Lingadahalli Shahapur Rudrapura Kanakapur Allanagar Basapur Kidadhal Koppal (Rural)
EIA Report
Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural
218 839 717 327 304 439 46 217 187 302 263 220 375 191 119 138 152 954 124 335 28 370 129 265 103 2,322
1,363 4,397 4,194 1,869 1,764 2,402 342 1,351 1,050 1,797 1,409 1,145 1,986 1,139 883 784 979 4,968 738 1,857 109 1,869 740 1,585 654 12,584
686 2,124 2,080 935 928 1,197 179 682 524 898 699 580 1,009 556 458 402 497 2,567 358 913 66 968 375 818 343 6,383
677 2,273 2,114 934 836 1,205 163 669 526 899 710 565 977 583 425 382 482 2,401 380 944 43 901 365 767 311 6,201
987 1070 1016 999 901 1007 911 981 1004 1001 1016 974 968 1049 928 950 970 935 1061 1034 652 931 973 938 907 971
245 674 706 356 337 395 75 284 262 381 250 162 324 263 210 161 231 886 158 369 23 376 172 414 144 1,950
127 337 346 167 183 195 38 143 148 195 110 86 157 139 105 83 114 439 79 185 13 204 82 224 75 1,009
118 337 360 189 154 200 37 141 114 186 140 76 167 124 105 78 117 447 79 184 10 172 90 190 69 941
0 678 878 241 215 600 0 621 220 239 347 244 260 155 113 57 178 1,349 94 264 10 816 125 321 124 2,065
0.0 15.4 20.9 12.9 12.2 25.0 0.0 46.0 21.0 13.3 24.6 21.3 13.1 13.6 12.8 7.3 18.2 27.2 12.7 14.2 9.2 43.7 16.9 20.3 19.0 16.4
0 502 443 418 167 165 0 107 256 493 11 23 98 10 447 122 0 367 0 7 8 172 25 51 111 404
0.0 11.4 10.6 22.4 9.5 6.9 0.0 7.9 24.4 27.4 0.8 2.0 4.9 0.9 50.6 15.6 0.0 7.4 0.0 0.4 7.3 9.2 3.4 3.2 17.0 3.2
Total
19572
108616
54848
53768
53482
18831
9605
9226
18484
898.4
9635
540.9
EIA Report
LITERACY STATUS (10 km radius)

Name
Gudigera Kawaloor Handral Hanwal Wadganhal Halgera Katrahalli Hiresindogi Chiksindogi Dombarhalli Belur Bisarhalli Bikanhalli Mainahalli Alwandi Murlapur Ghatreddihal Belgatti Hatti Raghunathanhalli Hydernagar Keslapur Halwagali Nilogipur Tigari Hunkuntiakkapur Bochanhalli Bhairapur Kampli Moranhalli
Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural
465 3,305 809 442 880 1,734 382 1,680 536 547 577 1,889 353 971 4,032 238 641 612 565 165 362 309 498 678 1,030 503 544 330 439 594
Total
No. of Literates Male

298 2,084 525 289 606 1,104 252 1,074 343 340 392 1,209 225 609 2,457 153 397 415 386 120 221 205 342 459 674 365 394 236 260 398
Female
167 1,221 284 153 274 630 130 606 193 207 185 680 128 362 1,575 85 244 197 179 45 141 104 156 219 356 138 150 94 179 196 439 3,680 837 330 1,081 1,752 445 1,944 579 384 1,022 2,196 344 912 2,875 358 409 629 1,415 306 406 212 714 778 959 1,291 2,082 604 159 769
Total
No. of Illiterates Male

156 1,448 283 91 397 630 172 740 196 141 432 823 135 314 1,075 135 146 227 615 118 153 64 318 287 346 550 914 232 51 288
Female
283 2,232 554 239 684 1,122 273 1,204 383 243 590 1,373 209 598 1,800 223 263 402 800 188 253 148 396 491 613 741 1,168 372 108 481
Betgera Katarkigudlanur Neeralgi Mattur Madinur Devlapur Kalkera Hatti Chilwadgi Naregal Yettinhatti Ojanhalli Tankankal Hanmanhalli Kutganhalli Gabbur Ginigera Lingadahalli Shahapur Rudrapura Kanakapur Allanagar Basapur Kidadhal Koppal (Rural)
EIA Report
Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural
2,262 1,999 776 806 1,084 121 482 262 621 536 520 1,011 477 231 318 502 2,585 245 572 70 987 333 455 267 7,390
1,380 1,199 528 533 675 73 331 187 438 355 350 676 284 159 212 312 1,643 163 372 46 642 204 323 169 4,337
882 800 248 273 409 48 151 75 183 181 170 335 193 72 106 190 942 82 200 24 345 129 132 98 3,053
2,135 2,195 1,093 958 1,318 221 869 788 1,176 873 625 975 662 652 466 477 2,383 493 1,285 39 882 407 1,130 387 5,194
744 881 407 395 522 106 351 337 460 344 230 333 272 299 190 185 924 195 541 20 326 171 495 174 2,046
1,391 1,314 686 563 796 115 518 451 716 529 395 642 390 353 276 292 1,459 298 744 19 556 236 635 213 3,148
Total
51022
32423
18599
57594
22425
35169
EIA Report
OCCUPATIONAL STRUCTURE OF THE STUDY AREA (10 km radius)
Total working population Name Rural Total

Gudigera Kawaloor Handral Hanwal Wadganhal Halgera Katrahalli Hiresindogi Chiksindogi Dombarhalli Belur Bisarhalli Bikanhalli Mainahalli Alwandi Murlapur Ghatreddihal Belgatti Hatti Raghunathanhalli Hydernagar Keslapur Halwagali Nilogipur Tigari Hunkuntiakkapur Bochanhalli Bhairapur
Male
272 2,023 456 232 575 982 247 1,024 288 285 465 1,124 197 499 1,831 159 317 391 542 131 199 151 404 396 504 526 719 242
Female
269 1,767 457 249 527 723 242 776 265 220 430 1,016 137 470 1,485 186 296 336 396 137 182 89 331 382 471 472 599 185
Total non-working population Total Male Female

363 3,195 733 291 859 1,781 338 1,824 562 426 704 1,945 363 914 3,591 251 437 514 1,042 203 387 281 477 678 1,014 796 1,308 507 182 1,509 352 148 428 752 177 790 251 196 359 908 163 424 1,701 129 226 251 459 107 175 118 256 350 516 389 589 226 181 1,686 381 143 431 1,029 161 1,034 311 230 345 1,037 200 490 1,890 122 211 263 583 96 212 163 221 328 498 407 719 281
Total main workers Total

432 2,873 483 374 923 993 486 1,211 543 493 887 1,502 282 723 1,995 184 457 506 539 65 381 156 513 405 815 606 957 425
Total marginal workers Female

169 1,108 52 150 400 222 241 378 258 208 422 499 94 273 501 50 148 145 137 3 182 15 144 85 373 185 334 183
Male
263 1,765 431 224 523 771 245 833 285 285 465 1,003 188 450 1,494 134 309 361 402 62 199 141 369 320 442 421 623 242
Total
109 917 430 107 179 712 3 589 10 12 8 638 52 246 1,321 161 156 221 399 203 0 84 222 373 160 392 361 2
Male
9 258 25 8 52 211 2 191 3 0 0 121 9 49 337 25 8 30 140 69 0 10 35 76 62 105 96 0
Female
100 659 405 99 127 501 1 398 7 12 8 517 43 197 984 136 148 191 259 134 0 74 187 297 98 287 265 2
Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural
541 3,790 913 481 1,102 1,705 489 1,800 553 505 895 2,140 334 969 3,316 345 613 727 938 268 381 240 735 778 975 998 1,318 427
Kampli Moranhalli Betgera Katarkigudlanur Neeralgi Mattur Madinur Devlapur Kalkera Hatti Chilwadgi Naregal Yettinhatti Ojanhalli Tankankal Hanmanhalli Kutganhalli Gabbur Ginigera Lingadahalli Shahapur Rudrapura Kanakapur Allanagar Basapur Kidadhal Koppal (Rural)
EIA Report
Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural
293 697 2,288 1,978 812 951 1,233 120 661 588 1,007 816 653 1,042 611 497 397 466 1,866 261 1,043 66 801 308 808 358 5,233
166 362 1,195 1,108 467 523 667 76 352 284 504 417 333 529 317 265 226 248 1,299 181 518 43 510 201 441 190 3,395
127 335 1,093 870 345 428 566 44 309 304 503 399 320 513 294 232 171 218 567 80 525 23 291 107 367 168 1,838
305 666 2,109 2,216 1,057 813 1,169 222 690 462 790 593 492 944 528 386 387 513 3,102 477 814 43 1,068 432 777 296 7,351
145 324 929 972 468 405 530 103 330 240 394 282 247 480 239 193 176 249 1,268 177 395 23 458 174 377 153 2,988
160 342 1,180 1,244 589 408 639 119 360 222 396 311 245 464 289 193 211 264 1,834 300 419 20 610 258 400 143 4,363
206 523 2,101 1,621 739 551 1,177 117 453 473 982 767 649 601 517 496 384 365 1,458 261 980 66 729 286 724 260 5,163
149 317 1,119 1,071 451 417 651 76 332 245 501 416 331 459 311 265 226 236 1,105 181 501 43 484 191 423 154 3,362
57 206 982 550 288 134 526 41 121 228 481 351 318 142 206 231 158 129 353 80 479 23 245 95 301 106 1,801
87 174 187 357 73 400 56 3 208 115 25 49 4 441 94 1 13 101 408 0 63 0 72 22 84 98 70
17 45 76 37 16 106 16 0 20 39 3 1 2 70 6 0 0 12 194 0 17 0 26 10 18 36 33
70 129 111 320 57 294 40 3 188 76 22 48 2 371 88 1 13 89 214 0 46 0 46 12 66 62 37
Total
54130
29998
24132
54486
24850
29636
42858
27267
15591
11272
2731
8541
EIA Report
CATEGORY OF WORKERS IN THE STUDY ARA (10 km radius)

Cultivators Name
Gudigera Kawaloor Handral Hanwal Wadganhal Halgera Katrahalli Hiresindogi Chiksindogi Dombarhalli Belur Bisarhalli Bikanhalli Mainahalli Alwandi Murlapur Ghatreddihal Belgatti Hatti Raghunathanhalli Hydernagar Keslapur Halwagali Nilogipur Tigari Hunkuntiakkapur Bochanhalli Bhairapur Kampli
Agricultural Labors Female

7 244 349 4 24 167 20 142 14 3 132 227 29 78 187 22 116 234 35 0 13 1 8 8 117 147 50 13 26
Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural
Total
244 1,226 669 21 327 613 49 591 148 194 288 803 113 297 772 78 258 519 260 50 139 132 205 238 377 460 520 205 32
Male
237 982 320 17 303 446 29 449 134 191 156 576 84 219 585 56 142 285 225 50 126 131 197 230 260 313 470 192 6
Total
274 2,173 158 401 611 733 408 869 332 278 568 1,015 186 595 1,609 239 317 152 569 192 218 83 470 469 536 446 745 202 59
Male
19 710 56 162 133 282 195 316 104 70 275 308 81 211 591 83 146 69 221 61 60 9 153 105 196 152 202 30 28
Female
255 1,463 102 239 478 451 213 553 228 208 293 707 105 384 1,018 156 171 83 348 131 158 74 317 364 340 294 543 172 31
House hold industry workers Total Male Female

0 83 13 4 11 58 3 91 11 11 2 131 1 3 265 1 9 4 8 3 8 2 6 14 7 30 19 1 109 0 71 13 3 11 44 3 55 7 9 1 83 1 3 129 0 9 1 3 3 4 2 5 10 5 9 18 1 60 0 12 0 1 0 14 0 36 4 2 1 48 0 0 136 1 0 3 5 0 4 0 1 4 2 21 1 0 49
Other workers Total

23 308 73 55 153 301 29 249 62 22 37 191 34 74 670 27 29 52 101 23 16 23 54 57 55 62 34 19 93
Male
16 260 67 50 128 210 20 204 43 15 33 157 31 66 526 20 20 36 93 17 9 9 49 51 43 52 29 19 72
Female
7 48 6 5 25 91 9 45 19 7 4 34 3 8 144 7 9 16 8 6 7 14 5 6 12 10 5 0 21
Moranhalli Betgera Katarkigudlanur Neeralgi Mattur Madinur Devlapur Kalkera Hatti Chilwadgi Naregal Yettinhatti Ojanhalli Tankankal Hanmanhalli Kutganhalli Gabbur Ginigera Lingadahalli Shahapur Rudrapura Kanakapur Allanagar Basapur Kidadhal Koppal (Rural)
EIA Report
Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural Rural
236 1,307 726 267 286 308 73 442 189 360 95 72 319 157 323 117 324 371 88 252 6 140 91 355 25 100
190 766 591 222 256 247 56 261 113 226 91 59 230 120 173 97 186 304 83 145 2 117 91 199 24 86
46 541 135 45 30 61 17 181 76 134 4 13 89 37 150 20 138 67 5 107 4 23 0 156 1 14
407 811 971 454 569 722 42 162 300 447 523 307 502 356 140 206 121 562 165 623 3 256 120 246 238 153
133 299 284 176 183 255 16 45 119 144 164 112 147 123 71 71 46 245 92 274 0 93 32 77 123 53
274 512 687 278 386 467 26 117 181 303 359 195 355 233 69 135 75 317 73 349 3 163 88 169 115 100
11 30 33 19 1 20 0 0 5 1 4 7 10 2 5 8 6 100 0 15 0 97 0 9 0 615
9 22 21 9 1 5 0 0 2 1 2 6 8 2 2 4 3 67 0 7 0 55 0 4 0 459
2 8 12 10 0 15 0 0 3 0 2 1 2 0 3 4 3 33 0 8 0 42 0 5 0 156
43 140 248 72 95 183 5 57 94 199 194 267 211 96 29 66 15 833 8 153 57 308 97 198 95 4,365
30 108 212 60 83 160 4 46 50 133 160 156 144 72 19 54 13 683 6 92 41 245 78 161 43 2,797
13 32 36 12 12 23 1 11 44 66 34 111 67 24 10 12 2 150 2 61 16 63 19 37 52 1,568
Total
16857
12346
4511
24313
8405
15908
1906
1252
654
11054
7995
3059
EIA Report
Annexure G MEAN METEOROLOGY (December 2009 February 2010) HOUR WIND DIRECTION NW NW NNW N N NNE NNE N N WWN WWN W W WWN WWN NW NW NW NNE N NNE NNE NNE WWN WIND SPEED (m/sec) 1.5 1.8 1.7 2.5 2.7 2.9 3.1 2.5 0.7 0.8 1.2 1.7 1.9 1.5 0.6 0.9 1.4 1.9 2.5 2.2 2.7 3.1 3.0 2.8 TEMPERATURE (oK) 295.9 297.6 293.2 293.2 291.5 290.4 288.2 294.3 295.3 297.6 301.5 301.5 305.4 304.3 303.7 302.6 300.9 300.4 299.3 297.6 296.5 294.8 293.7 291.5 STABILITY CLASS 7 7 7 6 6 6 5 4 3 2 2 2 2 2 2 2 3 4 5 6 6 6 6 6 MIXING HEIGHT (M) 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101 1101
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

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Proposed Expansion of Sponge Iron Plant from 100 TPD to 175 TPD at M/s.

ENVIRONMENTAL IMPACT ASSESSMENT

M/s. BABA AKHILA SAI JYOTHI INDUSTRIES PVT. LIMITED

M/s. GLOBAL ENVIRO LABS

Hence displacement and

5 M/s. Global Enviro Labs, Hyderabad

6 M/s. Global Enviro Labs, Hyderabad

7 M/s. Global Enviro Labs, Hyderabad

2. SCOPE AND METHODOLOGY

11 M/s. Global Enviro Labs, Hyderabad

13 M/s. Global Enviro Labs, Hyderabad

TABLE-2: ENVIRONMENTAL ATTRIBUTES AND FREQUENCY OF MONITORING

Parameters SPM, RSPM SO2, NOx, PAH

Water Quality Biology

Noise Levels Soil Characteristics Land Use

Noise levels in dB(A)

14 M/s. Global Enviro Labs, Hyderabad

16 M/s. Global Enviro Labs, Hyderabad

20 M/s. Global Enviro Labs, Hyderabad

PROCESS FLOW DIAGRAM OF SPONGE IRON PLANT

CRUSHING & STORAGE

FEED TO ROTARY KILN HEAT UP TO 1100 deg.C

COOLING WITH WATER IN COOLER

MAGNETIC SEPARATOR 0-4m

MAGNETIC SEPARATOR 4-18 m

DOLOCHAR CHAR SPONGE LUMPS

21 M/s. Global Enviro Labs, Hyderabad

22 M/s. Global Enviro Labs, Hyderabad

Input Iron Ore Coal Limestone

Quantity in TPD 350 175 07

23 M/s. Global Enviro Labs, Hyderabad

QUANTITY Process After proposed Expansion (KL/day) 90 12 14 116

24 M/s. Global Enviro Labs, Hyderabad

Combustion Efficiency (CE) of after Burner Chamber (ABC)

35 M/s. Global Enviro Labs, Hyderabad

36 M/s. Global Enviro Labs, Hyderabad

38 M/s. Global Enviro Labs, Hyderabad

39 M/s. Global Enviro Labs, Hyderabad

Identifications of various industrial operations in the study area:

40 M/s. Global Enviro Labs, Hyderabad

42 M/s. Global Enviro Labs, Hyderabad

43 M/s. Global Enviro Labs, Hyderabad

44 M/s. Global Enviro Labs, Hyderabad

46 M/s. Global Enviro Labs, Hyderabad

Sample Extraction, Clean-Up, Concentration And Analysis Sequence

Whatman EPM-2000 Filter

Ultrasonic Extraction with Toluene (50ml x 3 times)

Filter and dry with Anhydrous Sodium Sulphate

Concentration with Rotary Vacuum Evaporator

Clean-up with Silica Gel Column Chromatography

Elution with a CycloHexane (5 ml x 3 times)

Concentration with Rotary Vacuum Evaporator

Evaporated to nearly Dryness under Nitrogen

Re-dissolved in 0.5-1.0 ml of Toluene

Redissolved in 2-5 ml Methanol

Capillary GC-FID or GC/MS

49 M/s. Global Enviro Labs, Hyderabad

Air Toxic Pollutants

Ambient Air Quality Standard upto 2005 10 g/m3 5 ng/m3

Ambient Air Quality Standard upto 2010 10 g/m3 5 ng/m3

Benzo(a) Pyrene i.e, B(a)P

50 M/s. Global Enviro Labs, Hyderabad

SEE SW WWN NW NNE SE NNW