Star Metallics Power English ExeSummery

GREEN CIRCLE CONSULTANTS (I) PVT. LTD. REPORT NO.
: GC/Bell/2007-08/SMPL_EIA/Jan 078
GREEN CIRCLE CONSULTANTS (I) PVT. LTD.

EHS, Risk & Quality, Consulting Engineers & Trainers
Project Proponent: Project:
M/s. Star Metallics & Power Pvt. Ltd: 32 MW Captive Power Plant
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GREEN CIRCLE CONSULTANTS (I) PVT. LTD. REPORT NO.: GC/Bell/2007-08/SMPL_EIA/Jan 078
1. BACKGROUND M/s. Star Metallics and Power Private Limited (SMPPL) is a joint venture company formed as a Special Purposes Vehicle (SPV) by Euro Industrial Enterprises Private Limited, India (EIEL) and Emirate Trading Agency (ETA) for operating existing Ferro Alloy Plant located at Vyasankere, near Hospete, Karnataka. SMPPL proposes to establish a 32 MW Coal based Captive Power Plant within the existing premises to meet the power requirement for its ferro alloy plant. Euro Industrial Enterprises Private Limited, India (EIEL) had acquired the established ferro alloy plant having 95 acres of plot area with all its appurtenances and one 15 MVA submerged arc furnace along with its auxiliary equipments from Sandur Manganese & Iron Ores Limited (SIMORE). Emirate Trading Agency (ETA) had purchased two 20 MVA submerged arc furnaces located in the existing ferro alloy plant at Vyasankere, near Hospete, Karnataka from Sandur Manganese & Iron Ores Limited (SIMORE). It has planned to dismantle and relocate one of the 20 MVA furnaces at Bahrain Ferro Alloys limited, Manama, Bahrain. The other 20 MVA furnace is proposed to be operated at its current location at Vyasankere along with one 15 MVA furnace belonging to EIEL. EIEL and ETA have formed a joint venture company as a Special Purpose vehicle (SPV) by the name Star Metallics and Power Pvt. Ltd. (SMPPL) for operating existing ferro alloy plant. SMPPL proposes to install a 32 MW Captive Power Plant (CPP) within the existing unit premises to meet the power requirement of existing Ferro alloy plant. Power from public utility grid is being utilized for Ferro alloy plant and later it will source the power from the proposed 32 MW CPP. 2. NEED OF THE PROJECT The existing Ferro alloy plant had been stopped since last ten years due to unavailability of power. The capacity of plant for silicomanganese production is 44,700 MT per year. Since the state grid power supply is economically unviable in the long run and every effort to restart the ferro alloy plant using power from other sources were unsuccessful, it was decided to install a 32 MW Captive Power Plant to augment the power requirement. The proposed 32 MW captive power plant is coal based with fluidized bed combustion technology. Power from the CPP will be used to run ferro alloy plant and the surplus power will be exported to consumers. 3. PROJECT DETAILS: 3.1 LOCATION OF THE PROJECT: The ferroalloy complex is situated at Vyasankere, 12 km from Hospet (in Bellary district) on the National Highway 13 connecting Bangalore with New Delhi on a 95 acre plot. SMPPLs proposed 32 MW Captive Power Plant will be located within the existing premises of the ferroalloy plant. Hospete (formerly Hospet) is located at 15.27 N 76.4 E. It has an average elevation of 480 meters (1574 feet).
Project Proponent: Project: M/s. Star Metallics & Power Pvt. Ltd: 32 MW Captive Power Plant Page 2 of 13
3.2 SALIENT FEATURES OF EXISTING PLANT & PROPOSED CPP Introduction: Name of the Company Promoters of company Location Plot area Production activity
: : : : :
Star Metallics and Power Pvt. Ltd. EIEL, India & ETA group, Dubai. Vyasankere, Taluka: Hospete, Bellary District, Karnataka. 95 acres Ferro alloy Plant (Existing) 32 MW Captive Power Plant (Proposed) Proposed CPP shall be located within the existing ferroalloy unit premises to meet power requirement. Ferro alloy plant Silico manganese (SiMn) 44,700 MTPA silico manganese Mn: 60-65% Si : 15-20% C : 1.5-2.0% S : 0.05%, max Fe Balance P : 0.3% max Manganese ore, metallurgical coke, limestone, quartz Submerged Arc Furnace Open type (1x15000 KVA, & 1x20000 KVA)
EXISTING Ferro alloy plant: 1 Production plant 2 Product 3 4
: :
Production Capacity : Specification of products SiMn : (IS No. 1470-1990) (Si17Mn63)
5 6
Raw materials Main production equipment
: :
7 8
Projected operating load of ferro alloy plant Water requirement
: :
24000 kW 148 m 3 /day
PROPOSED 32 MW Captive Power Plant in existing ferro alloy plant premises 1 2 3 4 5 Proposed plant Location Capacity of Captive Power Plant No. of boilers Capacity of boiler : : : : : Captive Power Plant Within existing ferro alloy unit premises 32 MW One 140 TPH, (Type: Fluidized bed Combustion (FBC) 6 7 8 9 Fuel & consumption rate Water requirement No. of turbo generators proposed to be installed Type of turbo generator : : : : Indonesian coal, 1,30,000 MTPA 516 m 3 /day One Straight condensing machine with Air Cooled Condenser
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4.0 ENVIRONMENTAL IMPACT ASSESSMENT STUDY Scope of the Study: The study is conducted with a focus on assessment of Environmental Impacts on Land, Air, Noise, Water, and Socio-Economic environment and also to plan mitigative measures to overcome and minimize the negative impact. Baseline Status: As part of Environmental Impact Assessment study, baseline environmental monitoring was carried out for Winter season 2007-08, covering the months of November 2007 to January 2008. 4.1 DATA SOURCE: The primary as well as secondary data has been collected on various environmental attributes. The information on existing environmental condition has been gathered from several sources including: Secondary data from IMD & Govt. of Karnataka. Site survey and field experiments to gather the information on Meteorological, Air Environment, Water Environment, Noise Environment and Ecological Environment were conducted. An area of 10 Kms radius was selected for the study.
Key aspects of prevailing baseline environmental qualities are as follows. 4.2 AIR ENVIRONMENT: Five ambient air-monitoring stations were selected within the 10 km radius of the study area, representing the downwind, cross wind and upwind impact scenario of the project site. Air quality monitoring was done at five locations in the study area to measure concentrations of Suspended Particulate Matter (SPM), Respirable Suspended Particulate Matter (RSPM), Oxides of Sulphur (SOx), Oxides of Nitrogen (NOx) & Carbon Monoxide (CO). The Ambient Air Quality monitored in the plant area & study area was found to be well within the limits of NAAQ standards prescribed for Residential, Rural & Other Areas. Air Quality in the study area SL. NO 1 2 3 4 5 POLLUTANTS NAAQ STANDARDS RANGE OF AVERAGE VALUES 129.38 to 162.50 200 49.63 to 78.75 100 8.05 to 14.00 80 24.35 to 31.50 80 147.13 to 239.38 4000 3 (All the values are in g/m )
M/s. Star Metallics & Power Pvt. Ltd: 32 MW Captive Power Plant Page 4 of 13
SPM RPM SO2 NOx CO
4.3 NOISE ENVIRONMENT: Five monitoring locations were selected to asses the noise levels in the study area. The day time noise levels were in the range of 53 to 62 dBA and night time in the range of 40 to 65 dBA. 4.4 WATER ENVIRONMENT: Surface and ground water samples were collected in the stydy area. All the parameters were found to be within the prescribed limits of IS 10500-1991 except Total Dissolved Solids in ground water samples. 4.5 LAND ENVIRONMENT: Soil samples were collected to asses the soil quality in the 10 km study area of plant site and it revealed soil of medium fertile quality. 4.6 METEOROLOGICAL DATA PARAMETERS Temperature Predominant Wind direction Humidity Average Rainfall 4.7 POWER REQUIREMENT: Power requirement of ferroalloy industry i.e. 181 million KW is presently obtained from GESCOM Grid (Until proposed CPP becomes operational). Value Max.: Jan to Mar 43 to 44 0C Min : December: 12 to 13 0C East 96% 800 mm to 900 mm
4.8 ECOLOGY (FLORA/FAUNA): Assessment of existing environmental status, flora, fauna, demographic, Socioeconomic factors and land use pattern within an area of 10 Kms radius from the proposed site was done. i) FLORA IN THE STUDY AREA: Most of the part has scrubs consisting of species such as Carissa fistula, Zizyphus oenophilia, Albizzia lebbeck, Acacia catechu and A. latronum. Apart from these species, trees of Grewia tiliaefolia, Eugenia jombalana and Ficus sp. are also found in this region. ii) FAUNA IN THE STUDY AREA: It includes: Mammals: Cheetha, Wolf, Jackal, Striped Heyena, Wild bear, jungle Cat, Langoor, Sambar, Spotted deer, squirrel, etc. Avi Fauna: Crow, Cuckoo, Sparrow, Nightingale, Pigeon, Peacock etc.
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Reptiles: The reptiles commonly observed are Pythons Cobra Rat-Snake Green Snakes, common garden lizard, saw scaled viper chameleon. 4.9 SOCIO ECONOMIC DATA As per the census the population of the district stood at 16.53 lakhs. The geographical area is 8447 sq.km. It has two revenue sub divisions viz., Bellary Sub-Division and Hospet Sub-Division which have in all seven taluks. The Bellary Sub- Division has 3 taluks while there are five taluks in Hospet SubDivision. There are 27 hoblies, two CMCs one Town Municipality, seven Town Panchayat 542 Revenue villages, 436 and as/habitations. The rural populations constitute 70%. The density of population is 196 per sq.km which is much lower than the State average of 235 per sq.km. However the decimal growth rate for 1981-91 was 26.92 % which is higher than the State growth rate of 21.12 %. The SC/ST population constitutes 28 % of the total population. The sex-ratio was 965 which are slightly higher than the state average of 960. 4.10 LITERACY LEVELS: Literacy rate in study area is given below: LITERACY Year Literacy % Male Literacy % Female Literacy % HOSPETE 1991 Census 2001Census 42.00 60.64 51.00 74.95 31.00 52.92
The study area (Hospete) experiences a considerably very moderate literacy rate of 60.64% (2001). 5.0 ENVIRONMENTAL IMPACTS AND MANAGEMENT PLAN The following is the new unit proposed under expansion of the ferro alloy Plant (a) Coal Based Captive Power Plant of 32 MW. The proposed coal based captive power plant may influence the environment in two distinct phases: a) During construction phase which is temporary and of short term b) During operation phase which may have long term effects 5.1 Impacts during Construction Phase and control measures The construction of proposed captive power plant would result in increase of SPM concentrations due to fugitive dust. Frequent water sprinkling in the vicinity of the construction sites would be undertaken and will be continued after the completion of plant construction as there is scope for heavy truck mobility. It will be ensured that both gasoline and diesel powered vehicles are properly maintained to comply with exhaust emission requirements.
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There will be marginal increase in noise levels during construction phase which is temporary. Certain activities like welding will be undertaken during night time. However, this phenomena is temporary in nature. During construction, provision for infrastructural services including water supply, sewage, drainage facilities and electrification will be made. The construction site would be provided with suitable toilet facilities for the workers to allow proper standards of hygiene and ensure minimum impact on the environment. SMPPL will optimize the layout design to restrict the cutting of plantation in the existing plant site. Any construction activity will benefit the local population in a number of ways. Management of M/s SMPPL will give preference to local people through both direct and indirect employment.
5.2 Impacts during Operation Phase and control measures 5.2.1 Air Environment: 5.2.1.1 WASTE GASES FROM EXISTING FERRO ALLOY PLANT Smelting Furnace: Hot Submerged Arc Furnace off gas and tap hole secondary emissions are the main gaseous emission from existing plant. The gas emissions contain dust particulates, Sulphur dioxide, and oxides of nitrogen, carbon monoxide and traces of oxides of silica. Hot SAF off gas and tap hole secondary emissions would be cooled to 150-250 o C by air dilution prior to passing to the fume extraction system. The exit gases are cleaned by dry gas de-dusting system which is already in place. In the existing bag house fine particulate matter will settle in the settling chamber. Resultant clean gas is vented out to atmosphere at appropriate height. Finished Product Sizing & Preparation: The cast product is cooled, ground and screened for final bagging. These operations generate fugitive dust. Industry has already provided Dust Extraction system and bag filter to capture & separate out the fugitive dust. The clean air is finally vented through a stack. 5.2.1.2 Boiler Emissions from the proposed CPP: The flue gases from the proposed coal fired boiler of 140 TPH carry pollutants such as SPM, SO2, NOx. Following measures are provided to control flue gas emissions: Boiler of Circulating Fluidised bed combustion type of firing is proposed to reap the inherent advantages of very low liberation of NOx in the furnace.
The proposed CPP shall use low ash content (1% ash) imported Indonesian Coal to reduce the generation of SPM and hence the fly ash. The industry shall provide special high efficiency Electrostatic precipitator at boiler outlet for extracting the dust pollutant from flue gas for achieving a dust concentration at the outlet of chimney as low as 100 mg/Nm 3 . An adequate chimney of 60 m AGL shall be provided to disperse the flue gases over a wide area to keep the ambient air quality well within the permissible limits. 5.2.1.3 DG sets: Two DG sets of adequate capacity shall be used as power back up. The industry shall operate the same using low sulphur diesel. Industry shall provide adequate chimneys and necessary noise control measures for the same. The dispersion of pollutants in the atmosphere for the proposed CPP is determined using Gaussian plume dispersion model. For the present study, this model is used for the prediction of maximum ground level concentration (GLC). Predicted ground level concentrations were superimposed on existing ambient air quality to obtain the overall GLCs once the CPP becomes operational. It is found that, there will not be any significant adverse impact on ambient air quality. 5.2.1.4 Fugitive Emissions from Material handling from proposed CPP: Raw material handling process is one of the main sources of dust generation. Coal while being drawn from stockyard and ground in hoppers leads to generation of dust. Proper sprinkling & dust extraction shall be adopted to reduce the same.
5.2.2 NOISE ENVIRONMENT The plant and equipment will be specified and designed with a view to minimize noise pollution. The major noise producing equipment such as turbo-generator & DG sets shall be provided with acoustic enclosures. Pumps, fans, compressors etc., shall be run at speeds less than 1500 rpm. Equipment shall be statically and dynamically balanced. Safety blow off valves, discharge pipes, relief valves etc. shall be equipped with silencers. Pipe lines shall be liberally sized for low velocities. Proper encasement of noise generating sources will be done to control the noise levels below 75 dB(A) at plant boundary. A scientifically designed thick greenbelt shall be grown. 5.2.3 WATER ENVIRONMENT The total water consumption of the ferro alloy plant at present is about 136 m3/day. With the installation of CPP of 32 MW, the water consumption of the complex shall increase to 652 (136 + 516 ) m3/day.
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The following table gives the water requirement. Water Requirement (m3/ day) Existing Proposed TOTAL 36 Nil Nil Nil 100 Nil 136 24 Nil Nil 120 264 108 516 60 Nil Nil 120 364 108 652
Usage (1) Domestic (2) Industrial - Process - Washing - Boiler - Cooling tower - Dm plant back wash TOTAL
The total wastewater generation from the existing ferroalloy plant is 136 m3/day. This is segregated as non process wastewater and domestic sewage. The non process wastewater (Cooling tower blow down) is neutralized and the residual chlorine levels are maintained. This treated wastewater is currently used for gardening & dust suppression in the premises. The total wastewater generation from the proposed CPP is estimated to be about 260 m3/day. This also will be segregated as non process wastewater and domestic sewage to adopt separate treatment schemes. The following table gives the wastewater generation from the existing ferroalloy plant and for the proposed CPP. Effluent Generation (m3/ day) Existing Proposed TOTAL 31 Nil Nil Nil Nil 15 Nil 46 20 Nil Nil Nil 114 40 86 260 51 Nil Nil Nil 114 55 86 306
Usage (1) Domestic (2) Industrial - Process - Washing - Boiler blow down - Cooling tower blow down - DM plant discharge TOTAL
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5.2.3.1 Demineralization plant Effluents are generated during regeneration of ion exchangers. Alkaly effluents are generated during the rinsing of anion and mixed bed exchangers. The effluents from the water treatment plant are led to a properly sized neutralisation pit having a holding capacity of two regenerations. 5.2.3.2 Blow down Blow down from the plant consists of cooling tower blow down and boiler blow down. The steam blow down will have a pH of 9.5 10.5 at 100 o C temperature. The steam blow down will be cooled and mixed with cooling tower blow down. The quality of cooling tower blow down will be as per the standards prescribed by Pollution Control Board for discharging into inland. Residual chlorine in cooling tower blow down will be maintained within acceptable levels. The treated waste water consisting of cooling tower blow down, boiler blow down and neutralised effluent will be conforming to the GSR 422 E onland discharge standards. The treated effluent shall be used for dust suppression in fuel handling area (12 m 3 per day), green belt development (12 m 3 per day) and ash handling system (231 m 3 per day). There will be no discharge of effluent from the plant outside the plant site. About 51 m3/ day sewage will be generated from various buildings in the existing and proposed power plant area. The domestic wastewater generated will be subjected to treatment in Septic tanks followed by soak pits. No additional land will be acquired for expansion. SMPPL shall optimize the layout design to restrict the cutting of plantation in the existing plant site. 5.2.4 Solid Waste Generation: The solid waste generation from the existing ferroalloy plant and proposed power plant are mainly from the following five areas. Fines from Raw Material handling Fines from Product Handling Dust collected from cleaning of Flue gas from submerged arc furnace (SAF) Slag from submerged arc furnace (SAF) Fly ash & Bed ash from boiler of the proposed CPP
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Following table gives the quantities of solid wastes in Tons per annum (TPA) and their disposal practices adopted/ proposed to be adopted. Types Of Solid Waste Quantity (TPA) 7800 Disposal Practices adopted /proposed Collected, packed in bags & disposed for commercial usage -do-doReprocessed & used for commercial purposes Shall be sold to Cement Plants Shall be reused within the plant
Fines from Raw Material handling
Fines from Product Handling
2240
Dust collected from cleaning of Flue gas 1700 from submerged arc furnace (SAF) Slag from submerged arc furnace (SAF) 31300
Fly ash from boiler of the proposed CPP Bed ash from boiler of the proposed CPP
1120 180
5.2.5 HAZARDOUS WASTE MANAGEMENT: Around 1000 liters per annum of used oil is expected to be generated from usage of DG sets. This shall be sold to authorized recyclers. 5.2.6 THERMAL POLLUTION: Heat constitutes a form of pollution if it is above acceptable levels. Therefore control measures shall be adopted to minimise thermal pollution. All equipment and pipelines whose surface temperature is 50 0 C and above will be provided with thermal insulation. The plant building shall be designed for adequate air circulation through natural ventilation. In addition, air conditioning systems will be provided for specific areas. Man coolers will be installed at hot work spots. 5.2.7 WORK ZONE POLLUTION: The work zone pollution would be mostly due to fugitive dusts, heat and noise. The work zone noise would be mostly emanating from the rotary equipment and machinery like fans, blowers, compressors and pumps. The fugitive dust emission in open area would be controlled by Dust Extraction and Dust Suppression systems. As far as possible, natural draft ventilation would be enabled in the shop. All the process vessels would be lined with adequately thick refractory bricks to contain the surface heat emission and in some cases they would be indirectly cooled by water. In
addition to this, there would be provision for forced draft cooling and ventilation of closed environment in the work zone. Proper equipment design for control of noise at source, adopting proper protective appliances and administrative control for rotation of manpower in noisy areas would prevent exposure of workmen to high noise levels. 5.2.8 Occupational Safety & Health Management
Plant safety measures would form an integral part of the environmental management plan of the proposed plant. Workers safety would be given highest priority so as to avoid any form of personal injury or lost-time accident. In-built safety features of the plant and machinery would help to avoid hazardous events causing damage to the life and property. SMPPL has provided all necessary provisions under Factory Act. In addition a Safety committee will be formed and manned by equal participants from Management and Workers. Safety shoes, helmet & uniform are issued to each worker. Other safety equipments will be used according to the nature of job involved SMPPL has established its own well equipped occupational health center headed by experienced Doctors with a team of Nurses, /Compounders . 5.2.9 SOCIAL IMPACTS:
Population displacement is main culprit during the establishment of a thermal power plant due to large area requirement. The proposed project shall be located in the existing ferro alloy plant premises in an area of 25 acres (Existing area is 95 acres). Hence, there shall not be additional requirement of land. There shall be no displacement of the population by the proposed project. The land transformation shall be marginal. 5.3 Social Welfare SMPPL shall employ an additional manpower of 45 people in the proposed CPP. plant. A total of about 100 persons will be given indirect employment during construction and installation of the new unit. Preference will be given to the local people. This expansion project would aid in the overall social and economic development of the region.
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SMPPL has also constructed a full-fledged colony consisting of houses for the benefit of employees. Most of the employees shall be from the local area. Hence, the influence of influx on environment is insignificant. It is anticipated that the project would bring following benefits to the people of the surrounding villages Generation of employment and improved standard of living. Establishment of small and medium scale engineering ancillaries, agro - based industries with cascading employment opportunities. Superior communication and transport facilities etc.
5.4 GREEN BELT DEVELOPMENT: More than 2200 trees (more tha 40 years old) are present all around in the existing premises. The industry shall increase the green belt as per KSPCB guidelines.
5.5 POST PROJECT MONITORING PLAN
As a part of the Environmental Management Plan (EMP), monitoring of air and water quality shall be carried out. SMPPL will upgrade its quality control laboratory and also avail third party services for monitoring of environmental parameters as per KSPCB/CPCB guidelines.
Budgetary Provisions For Environmental Monitoring Plan Sl. No 1 2 3 4 5 6 7 Item Electrostatic Precipitator Air Cooled Condenser (Decrease of water consumption for cooling) Cost of Chimney Water Pollution Control Green Belt Laboratory for Monitoring Recurring Cost in Rs. Lakhs 130 1500 60 10 15 20 180
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GREEN CIRCLE CONSULTANTS (I) PVT. LTD. REPORT NO.

GREEN CIRCLE CONSULTANTS (I) PVT. LTD.

Project Proponent: Project:

EXISTING Ferro alloy plant: 1 Production plant 2 Product 3 4

Production Capacity : Specification of products SiMn : (IS No. 1470-1990) (Si17Mn63)

Raw materials Main production equipment

Projected operating load of ferro alloy plant Water requirement

24000 kW 148 m 3 /day

Project Proponent: Project:

SPM RPM SO2 NOx CO

Project Proponent: Project:

Project Proponent: Project:

Project Proponent: Project:

Project Proponent: Project:

Project Proponent: Project:

Project Proponent: Project:

Fines from Raw Material handling

Fines from Product Handling

Project Proponent: Project:

Project Proponent: Project:

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