Executive Summary
1
SUMMARY ON
ENVIRONMENTAL IMPACT ASSESSMENT
REPORT
OF
Expansion of Steel Plant
at
PLOT No.29, APIIC Gollapuram Industrial Park (Phase#3), Gollapuram Village,
Hindupur Mandal, Ananthapur District.
Submitted to
ANDHRA PRADESH POLLUTION CONTROL BOARD VIJAYAWADA
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
1.0 PROJECT DESCRIPTION
HINDUPUR STEEL & ALLOYS PVT. LTD. (HSAPL) is operating an existing Induction Furnace
of 30,000 TPA out of total 1,00,000 TPA capacity, 1,00,000 TPA of Rolling Mill & 6000 m3/hr
capacity of producer Gas plant at Plot No. 29, APIIC Gollapuram Industrial park (Phase - 3),
Gollapuram Village, Hindupur Mandal, Anantapur District, Andhra Pradesh. 4.05 Ha. (10
Acres) of total land has been taken on lease from APIIC and proposed expansion will be
taken up in the existing plant premises.
Now as a part of proposed expansion it is proposed to increase the capacity of the MS
Billets / MS Ingots Production from 1,00,000 to 1,45,000 TPA, TMT Bars / Structural steel
Production from 1,00,000 TPA to 3,00,000 TPA & Producer Gas plant (Gasifier) capacity
from 6000 m3/hr to 18,000 m3/hr in the existing plant premises located at Plot No.29, APIIC
Industrial Park Gollapuaram (Phase-3), Gollapuaram Village, Hindupur Mandal, Ananthapur
District, Andhra Pradesh State.
As per the Ministry of Environment, Forests & Climate Change, New Delhi notification,
dated 14th September, 2006 and its subsequent amendments, all Secondary metallurgical
processing industries are classified under Category ‘B’. However due to presence of Inter-
state boundary at a distance of 0.5 Kms., the plant, this project becomes Category ‘A’
project. The Ministry of Environment, Forests & Climate Change, New Delhi has accorded
Terms of Reference (TOR) for the proposed expansion project vide letter no. J-11011 / 250
/ 2011- IA II (I), dated 17th August 2017. The EIA Report has been prepared by
incorporating the TOR stipulated by the Hon’ble EAC.
Pioneer Enviro Laboratories & Consultants Private Limited, Hyderabad, which is
accredited by NABET, Quality Council of India, vide certificate No. NABET/ EIA/ 1619/ RA
026, for preparing EIA report for Metallurgical Unit, have prepared Draft Environmental
Impact Assessment (EIA) report for the proposed expansion project by incorporating the
TOR approved by Ministry of Environment, Forests & Climate Change, New Delhi. The
report contains detailed description of the following:
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
Characterization of status of environment with in an area of 10 km radius from the
plant for major environmental components including air, water, noise, soil, flora,
fauna and socio-economic environment.
Assessment of air emissions, liquid waste and solid waste from the proposed project
along with the noise level assessment.
Environmental Management Plan comprising of emission control measures proposed
to be adopted in the proposed project, solid waste management, Greenbelt
development.
Post Project Environmental Monitoring & Budget for Environmental Protection
Measures.
ENVIRONMENTAL SETTING WITHIN 10 Km. RADIUS OF THE PLANT SITE
The following is the environmental setting within the 10 Km. radius of the project site:
1. The plant is situated in APIIC Industrial Park
2. Proposed expansion will be taken up in the Existing plant premises only. No
additional land is proposed.
3. The plant area does not fall under the industrial areas / cluster, which are listed in
MoEF&CC Office Memorandum dated 13th January 2010 & its subsequent
amendments.
4. Nearest village is Gollapuram and is at a distance of 1.5 Kms. from the plant site.
5. There are no National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors
of Wild Animals within 10 Km. radius of the plant.
6. No forest land is involved in the plant site.
7. There are no Reserve/Protected Forests within 10 Km. raidus of the plant site.
8. Penneru River (3.2 Kms.), Nearest Pond (1.2 Kms.) & Few ponds exists with in 10
Km. radius of the plant site.
9. There are many industries are situated within APIIC Industrial Park & APIIC
Industrial Park Tumkunta.
1.1 Plant Configuration and Production Capacity
The following are details of the existing,proposed products & production capacities
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
Units Permitted capacities as per the EC issued on
22nd June, 2015
Present proposed Expansion capacities
Production capacities After Present Proposed
Expansion
MS Billets / MS Ingots (through Induction furnace)
1,00,000 TPA (1x8 MT & 2x12 MT)
45,000 TPA (1x15 MT)
1,45,000 TPA (1x8 MT, 2x12 MT
& 1x15 MT)
TMT Bars / Rolled Products / Structural Steel (through Re-heating Furnace / Hot Charging)
1,00,000 TPA Upgradation of existing unit capacity from 1,00,000 TPA to
1,50,000 TPA +
Establishment of Additional 1,50,000 TPA unit
= Total 2,00,000 TPA
3,00,000 TPA
Producer Gas 6,000 m3/hr 12,000 m3/hr 18,000 m3/hr
1.2 Raw Materials
The following will be the raw material requirement for the proposed expansion project:
Raw Material Quantity (TPA) Sources Mode of Transport
For Steel Melting Shop (MS Billets) – 45,000 TPA
Sponge Iron 42,000 Bellary, Karnataka By road (through covered trucks)
Scrap & Mill scales 8,200 Hindupur By road (through covered trucks)
Ferro alloys 2,000 Gollapuram, Hindupur By road (through covered trucks)
For Rolling Mill (TMT bars & Structural Steel) – 2,00,000 TPA
Steel billets 2,10,000 Proposed SMS & Purchased from nearby plants in Industrial Park & out side Industrial Park.
By road (through covered trucks)
Furnace Oil 32 KLD Hindupur Town (or) near by Depot.
By road
For Producer Gas plant *
Coal Indian 36,000 Open Market By road (through covered trucks)
Imported 23,100 Indonesia / South Africa / Australia
Through sea route / rail route / by road
* Producer gas is not required if Rolled products manufactured through Direct rolling / Hot charging
1.3 MANUFACTURING PROCESS
1.3.1 STEEL MELTING SHOP
In Steel Melting Shop (SMS), Sponge Iron will be melted along with melting scrap and
fluxes to make pure liquid steel and then to mould it in required size billets. As part of
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
expansion project it is proposed to install 15 T capacity of Induction Furnace of to produce
MS Billets / MS Ingots in the SMS plant.
1.3.2 ROLLING MILL
1.3.2.1 Upgradation Of Existing Rolling Mill:
Regarding increase of production of existing Rolling Mill from 1,00,000 TPA to 1,50,000
TPA following upgradations will be taken up:
1. Inter Mill stand will get separated.
2. One (1) more DC Motor will be installed.
3. Speed of the mill will be increased from 10 m/sec to 15 m/sec
1.3.2.2 Additional Proposed Rolling Mill
In the proposed expansion project, Rolled products are manufactured either using
reheating furnace OR through Hot Charging / Direct hot Rolling technology.
Furnace oil / Producer gas will be used as fuel if manufactured through Re-heating furnace.
The cooled Ingots / Billets generated from Induction Furnace /CCM will be re-heated in
furnace and then sent to Rolling Mill.
If manufactured thorugh Hot Charging / Direct Hot Rolling method no fuel is required. The
hot billets generated from Induction Furnace /CCM will be directly sent to Rolling mill. A
bar and round mill will be installed in the plant to produce additional 1,50,000 TPA of
Rolled Products (TMT Bars / Rolled Products / Structural Steel etc.).
1.3.3 PRODUCER GAS PLANT (GASIFIER)
Producer gas plant is proposed to be established for supply fuel to Pelletization Plant &
Rolling Mill units. Coal is lifted to the coal storage bin by lifting system; the coal is added in
the carbonation stage of two-stage coal gasifier by a programmable control feeding
system. Air is blown in the bottom of furnace by air blower, at the same time, low pressure
steam goes through the blending bin and blends with air, becomes the gasification agent,
which will carry on the gasification reaction with 1200 Celsius degree semi coke in the
gasification stage.
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
1.4 WATER REQUIREMENT
The water requirement for expansion project will be 152 KLD. This includes water for
cooling purpose in Induction Furnace & Rolling Mill, Process water Producer Gas plant,
Dust suppression and for domestic.
APIIC will supply water from Penna Ahobilam balancing reservoir & Neelakantapuram
Srirami Reddy drinking water supply scheme. Water Clearance is already obtained for
water allocation of 10 MLD from the Penna Ahobilam balancing reservoir. The following is
the break-up of the water requirement for proposed project.
WATER REQUIREMENT FOR EXISTIING & FOR EXPANSION PROJECTS
S. No. Unit Quantity in KLD
Existing Permissions
Proposed Expansion
Total after Expansion
1 Cooling water make-up for SMS 46 20 66
2 Cooling water make-up for Rolling mill 66 130 196
3 Domestic requirement 9 2 11
4 For Greenbelt 10 --- 10
TOTAL 131 152 283
1.4 WASTE WATER GENERATION
There will be no effluent generation in the process & cooling in the IF, Rolling Mill & from
Producer gas plant as closed circuit cooling system will be adopted. Sanitary waste water of
1.6 KLD will be treated in septic tank followed by sub-surface dispersion trench.
1.5 WASTEWATER CHARACTERISTICS
The following are the Characteristics of Sanitary waste water
PARAMETER
CONCENTRATION
Sanitary waste water
pH 7.0 – 8.5
BOD (mg/l) 200 – 250
COD (mg/l) 300 – 400
TDS (mg/l) 800 – 900
Oil & Grease (mg/l) --
SS (mg/l) --
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
2.0 DESCRIPTION OF ENVIRONMENT
Base line data has been collected on ambient air quality, water quality, noise levels, flora
and fauna and socio economic details of people within 10 km radius of the plant.
2.1 Ambient air quality
Ambient air quality was monitored for PM2.5, PM10, SO2, NOx & CO at 8 stations including
project site during 1st October 2017 to 31st December 2017. The following are the
concentrations of various parameters at the monitoring stations:
Parameter Concentration
PM2.5 : 17.2 to 44.6 g/m3
PM10 * : 30.6 to 78.2 g/m3
SO2 : 7.3 to 19.4 g/m3
NOX : 8.0 to 25.1 g/m3
CO : 678 to 1225 g/m3
2.2 Water Quality
2.2.1 Surface Water Quality
2 no. of samples have been collected from Penneru River which is flowing at a distance of
3.2 kms from the plant to assess surface water quality. The analysis of samples shows that
all the parameters are in accordance with BIS-2296 specifications.
2.2.2 Ground Water Quality
8 No. of ground water samples from open wells / bore wells were collected from the
nearby villages to assess ground water quality impacts and analyzed for various Physico-
Chemical parameters. The analysis of samples shows that all the parameters are in
accordance with BIS: 10500 specifications.
2.3 Noise Levels
Noise levels were measured at 8 locations during day time & Night time. The noise levels at
the monitoring stations are ranging from 43.86 dBA to 67.40 dBA.
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
3.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES
3.1 Prediction of impacts on air quality
The likely emissions from the proposed project are PM10, SO2, NOx & CO. The predictions
of Ground level concentrations have been carried out using Industrial Source Complex (ISC-
3) model. Meteorological data such as wind direction, wind speed, max. and min.
temperatures collected at the site have been used as input data to run the model.
The following are the predicted max. incremental rise in PM10, SO2, NOx & CO
concentrations (24 hourly) at a distance of 800 m from the origin stack in the down wind
direction over the baseline concentrations and due the vehicular emission are given below.
Net Resultant maximum concentrations due to the Proposed Expansion Project
Item PM10
(g/m3)
SO2
(g/m3)
NOX
(g/m3)
CO
(g/m3)
Maximum baseline conc. in the study area 78.2 19.4 25.1 1225
Maximum predicted incremental rise in
concentration due to the Proposed Expansion
1.1 4.9 4.2 --
Maximum predicted incremental rise in
concentration due to Vehicular emissions
0.5 -- 3.1 1.7
Net resultant concentrations during operation of the
plant 79.8 24.3 32.4 1226.7
National Ambient Air Quality Standards 100 80 80 2000
The predicted results show that the net resultant concentration (max. baseline conc. +
max. incremental rise in conc.) of PM10, SO2, and NOx will be well within the National
Ambient Air Quality Standards after commissioning of proposed expansion project. Hence
there will not be any adverse impact on air environment due to the proposed expansion
project.
3.2 Prediction of impacts on noise quality
The major sources of noise generation in the proposed project will be Furnaces &
machinery. The ambient noise levels will be within the standards prescribed by MoEF vide
notification dated 14-02-2000 under the Noise Pollution (Regulation & Control), Rules 2000
i.e. the noise levels will be less than 75 dBA during day time and less than 70 dBA during
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
night time. 3.3 acres of extensive greenbelt has already been developed to further
attenuate the noise levels. Hence there will not be any adverse impact due to noise on
population in surrounding areas due to the proposed expansion project.
3.3 Prediction of impacts on Water Environment
There will be no effluent generation in the SMS (IF), Rolling Mill & Producer gas plant as
closed circuit cooling system will be followed. Sanitary waste water will be treated in septic
tank followed by sub-surface dispersion trench. Hence there will not be any adverse impact
on environment due to the proposed expansion project.
3.4 Prediction of Impacts on Land Environment
Zero effluent discharge will be adopted. All the required air pollution control systems will
be provided to comply with CPCB / SPCB norms. All solid wastes will be disposed / utilized
as per CPCB / SPCB norms. 3.3 Acres of greenbelt has already been developed in the plant
premises as per guidelines. Hence there will not be any adverse impact on land
environment due to the proposed expansion project.
3.5 Socio - Economic Environment
There will be lot of opportunities in employment to local people during construction as
well as in operation phase. Priority will be given to locals for Semi-Skilled and Unskilled
jobs. There will be further upliftment in Socio Economic status of the people in the area.
Hence there will be further development of the area due to the proposed expansion
project.
4.0 ENVIRONMENTAL MONITORING PROGRAMME
Post project monitoring will be conducted as per the guidelines of CECB and MoEF&CC are
tabulated below:
MONITORING SCHEDULE FOR ENVIRONMENTAL PARAMETERS
S.No. Particulars Frequency of Monitoring
Duration of sampling
Parameters required to be monitored
1. Water & Waste water quality
A. Water quality in the area
Once in a month except for heavy metals which
Composite sampling (24 hourly)
As per IS: 10500
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
will be monitored on quarterly basis.
B. Sanitary waste water Twice in a month Grab sampling (24 hourly)
As per EPA Rules1996
2. Air Quality
A. Stack Monitoring Once in a month Once in a month
PM PM, SO2 & NOx
B. Ambient Air quality Twice a week 24 hours continuously
PM2.5, PM10, SO2 & NOx
C. Fugitive emissions Once in a Month 8 hours PM
3. Meteorological Data
Meteorological data to be monitored at the plant.
Daily Continuous monitoring
Temperature, Relative Humidity, rainfall, wind direction & wind speed.
4. Noise level monitoring
Ambient Noise levels Twice in a year Continuous for 24 hours with 1 hour
interval
Noise levels
5.0 ADDITIONAL STUDIES
No Rehabilitation and Resettlement is involved in the proposed expansion project. Hence
no R & R study has been carried out.
6.0 PROJECT BENEFITS
With the establishment of the proposed project employment potential will increase. Land
prices in the area will increase. The economic status of the people in the area will improve
due to the proposed project. Periodic medical checkups will be carried out. Top priority will
be given to locals in employment. The project will generate employment opportunities for
about 150 persons during construction stage and for about 50 persons once the plant is
commissioned.
7.0 ENVIRONMENT MANAGEMENT PLAN
7.1 Air Environment
The following air emission control systems proposed in the proposed expansion project:
S. No.
Stack attached to No. of Stacks
Height (in M) Control Equipment
Particulate emission at the
outlet
1. IF (1x15 MT) 1 no. 30 Fume extraction system < 50 mg/Nm3
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
followed by Bag filter
2. Rolling mill with Re-heating Furnace
1 no. 54 -- --
3. Coal Gasifier (coal handling area)
-- -- Cyclone separator < 50 mg/Nm3
The following air pollution control systems/ measures are proposed in the Plant:
All conveyors will be completely covered with G.I. sheets to control fugitive dust.
All bins will be totally packed and covered so that there will not be any chance for dust
leakage.
All the dust prone points material handling systems will be connected with de-dusting
system with bag filters.
All discharge points and feed points, wherever the possibility of dust generation is
there a de-dusting suction point will be provided to collect the dust.
7.2 Water Environment
In the existing plant zero effluent discharge is being maintained and similar pattern will
be maintained after expansion also.
There will not be any effluent generation from SMS (IF), Rolling Mill & Producer Gas
plant as closed circuit cooling system will be followed.
Sanitary wastewater will be treated in septic tank followed by sub-surface dispersion
trench.
7.3 Noise Environment
The major sources of noise generation in the proposed project will be Furnaces and other
machinery. Acoustic enclosure will be provided to existing D.G. Set. All the machinery will
be manufactured in accordance with MoEF&CC norms on Noise levels. The employees
working near the noise generating sources will be provided with earplugs. The extensive
greenbelt developed within the plant premises will help in attenuating the noise levels
further. Noise barriers in the form of trees are recommended to be grown around
administrative block and other utility units.
7.4 Land Environment
SUMMARY ON ENVIRONMENTAL IMPACT ASSESSMENT REPORT
Plot No.29, APIIC Industrial Park Gollapuaram (Phase-3)
There will not be any effluent generation from SMS (IF), Rolling Mill & Producer Gas plant
as closed circuit cooling system will be followed. Sanitary waste water will be treated in
septic tank followed by sub-surface dispersion trench. All the required Air emission control
systems will be installed and operated to comply with CECB norms. Solid wastes will be
disposed off as per norms. Extensive greenbelt has already been developed in the plant
premises. Desirable beautification and landscaping practices will be followed. Hence there
will not be any impact due to the proposed expansion project.
Solid waste generation and disposal
S.No Type of Solid waste
from Expansion (in TPA)
Disposal Proposed
1 Slag from IF 4,500 Presently we are giving slag [from existing SMS] to slag crushing units. The same practice will be followed in proposed expansion also.
2 Mill Scales from reheating furnace
2000 Mill scales will be given to nearby Ferro alloys manufacturing units or casting units.
3 End Cutting from Rolling Mill
8000 Recycled back as raw material in own induction Furnaces
4 Ash / cinders generated from Gasifier (Rolling Mill)
17 Ash will be given to nearby Bricks manufacturing units.
5 Tar 0.25 Will be Given to TAR recyclers or Road making contractors.
7.5 Greenbelt Development
Greenbelt of 3.3 acres of greenbelt has already been developed in the proposed project.
Capital cost for environment protection for the total project is Rs.5.0 Crores.
7.6 Implementation of CREP Recommendations
All the CREP recommendations will be strictly followed.
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