1. introduction - welcome to...
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1. INTRODUCTION
M/s Rasik Industries (Prop. Indian Securities Limited) is already
manufacturing TMT Bars, Angles, flats etc., at Behind Uttam
Steel Mills Talwara Road, Mandi Gobindgarh, District Fatehgarh
Sahib Punjab. They now want to increase the capacity of their
unit by adding four numbers Induction Furnace of 8 TPH
capacity each. The existing capacity of the unit is 100,000 MTA
of TMT Bars, Angles, round etc. The capacity of the unit after
expansion will be 1,20,000 MTA of Billets, Steel Ingots &
Blooms and 100,000 MTA of TMT Bars, Angles, round. As per
G.O.I Notification dated 14/09/2006 they have to submit Form
No- I along with Pre-Feasibility Report and other relevant
documents for getting Environmental Clearance. Further, the
project site falls within the “Critically Polluted Areas” of Mandi
Gobindgarh as notified by the Central Pollution Control Board,
as such the project is to be treated as Category ‘A’ and thus the
Environmental Clearance will be given by the Ministry of
Environment and Forest, GOI, New Delhi. This Prefeasibility
report has, therefore, been prepared to assess the likely impact of
the proposed expansion on various factors which may be affected
with the implementation of the programme and to suggest
remedial / precautionary measures, if any. Key plan of the site is
attached as Fig 1.1.
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FIGURE – 1.1
KEY - PLAN
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2. PROFILE OF THE PROMOTORS & COMPANY
M/s Rasik Industries (Prop. Indian Security Ltd.) is a Limited
Company. The Director of the company are as under:
1. Sh. Ramesh Kumar Goyal
2. Sh. Rasik Goyal
3. Sh. Murli Dhar Mittal
4. Sh. Piyush Sharma
5. Sh. Naveen Mittal
All the promoters are well versed with the process involved &
can handle the project efficiently.
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3.0 DETAILS OF THE PROJECT
This is an existing unit for manufacturing of TMT Bars, Angles
& Flats. Now it is proposed to increase the capacity of the unit
by installing four numbers Induction furnace of capacity 08TPH
each for manufacturing of Steel Ingots, Billets, Blooms at
behind Uttam Steel Mill, Talwara Road, Mandi Gobindgarh,
Dist- Fatehgarh Sahib, Punjab. It is about 5 Kms from Mandi
Gobindgarh bus stand and about 50 km from Chandigarh and 45
km from Ludhiana on NH-44 highway. The existing area of the
plot is about 7.5 Acres and about 5.5 Acres land will be acquired
for expansion purpose. The capacity of the unit after expansion
will be Billets, Steel Ingots & Blooms will be 400MTD and
TMT bars, rounds, flats & angles will be 335MTD.
3.1 Raw Materials
-The raw materials used in the manufacturing of steel Ingots /
Billets are as under:
i) MS/CI Scrap, Sponge / Pig Iron, Ferro Alloys:-
These will be sourced from Domestic as well as
International Markets.
-The raw materials used in the manufacturing of structural
sections are as under:
ii) Steel Ingots and Billets: -
These will be sourced from own unit.
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3.2 Power
The existing power of the unit is 2500KW. The proposed power
requirement of the unit will be 14000KW. After expansion
power demand will be 16500KW. This demand will be met by
sourcing the power from Punjab State Power Corporation limited
from nearby Sub-station.
3.3 Water
Water consumption for the unit will be small as the requirements
are only for cooling system where water will be re-circulated in a
closed circuit. The existing requirement of the fresh water is
about 15 KLD which include 10 KLD for makeup water is
required for meeting the evaporation losses in the cooling circuit
and 5 KLD for domestic purpose. After expansion total fresh
water required will be 37 KLD which would be met from ground
water through a tube-well already existing within the premises.
Water balance of the project has been shown in Fig. 3.1
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Figure: 3.1
WATER BALANCE FLOW DIAGRAM
(KLD)
Supply Water over
head Tank
Domestic Water
Supply
(12)
Cooling Tower
Tank (1200)
STP
(10)
Cooling for
furnace
For Irrigation
purpose for
Plantation
Clear Water Tank
(1175)
Evaporation
(25)
Consumption
(2)
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3.4 Manpower
The requirement of personnel for the proposed plant has been
made keeping in view of the following:
Technical concept of plant, including process control and
instrumentation.
Smooth and efficient operation of the plant.
Effective co-ordination between the various departments
within the plant.
Optimum organization will well defined and judicious job
distribution
Optimum utilization of different grades of workmen and
supervisory staff and
Maximum capacity of the facilities.
In all there are about 100 persons working in the unit out
of which no persons will stay in the factory except
watchman. After expansion about 250 persons will be
working in the unit.
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3.5 Manufacturing Process
Steel Ingots/Billets:
1) By Induction furnace
MS Scrap is put into the Electric furnace pot through
magnetic conveying system, where it is heated to 1700 0C.
Scrap is melted and is heated for about 90-100 minute. In
the molten steel some Ferro alloys are added according to
the carbon contents in the scrap. The molten steel is then
put in moulds with the help of hydraulic crucible where,
after cooling, the steel Ingots are taken out from the
moulds and the same is ready for dispatch. In order to
keep the temperature of the furnace within the desired
limits, water is circulated around the furnace coils and
make-up water is added daily.
TMT Bars and other Structural Steel Section:
These are produced by heating the Ingots & Billets
received from the manufacturing process to about 1150–
12000C so that they can be converted into the desired
sections through rolling. They are then cooled and cut into
proper sizes for dispatch.
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3.6 OTHER FEATURES:
The plant would incorporate the most modern control
system using the latest microprocessor based Dust Control
System.
Cooling water circuit is close circuited, thereby ensuring
no generation of waste water.
The process, selected envisages re-cycling all the material
collected in the pollution control equipment whereby
ensuring no generation of solid waste.
The plant lay out is so arranged that the major production
units are laid in a straight line whereby minimizing/
avoiding the various transfer points.
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4. BASELINE ENVIRONMENTAL SETTINGS
4.1 The State
Punjab is one of the progressive States in the Northern part
of India. It derives its name from five rivers which used to
flow through the State before partition of the Country in
1947 viz Satluj, Beas, Ravi, Chenab, and Jehlam. After
partition two of the rivers i.e. Chenab and Jehlam went to
Pakistan Punjab and the other three remained in Indian
Punjab. The economy of the State is dependent mainly on
Agriculture. Punjab has over 2.04 lakh small and medium
industries and about 600 large scale industries. It leads in
the manufacture of machine and hand tools; printing and
paper cutting machinery; auto parts and electrical switch
gear. The State also provides more than 75% of the
country's requirement for bicycles, sewing machines,
hosiery and sports goods. It has also made big strides
towards industrialization. A number of Industrial areas
have been developed by the State. Ludhiana, Jallandhar,
Amritsar and Mohali are famous for Large and Medium
scale industrial units.
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4.2 Fatehgarh Sahib District
The historic and pious district of Fatehgarh Sahib came
into existence with effect from 13th
April, 1992, Baisakhi
Day deriving its name from Sahibzada Fateh Singh, the
youngest son of Guru Gobind Singh. It is bounded by Distt
of Ropar in the North, Patiala in the South, Mohali and
Part of Patiala in the East Ludhiana in the West it is about
20 Kms towards the west of Chandigarh, the capital of
Punjab.
The economy of the district depends mainly on agriculture
and allied activities. The main towns are Sirhind, Bassi
Pathana, Amloh, Khamano & Mandi Gobindgarh. The last
is also known as the 'Steel Town of India' having a good
number of steel rolling mills. Besides, numerous industrial
units are engaged in the manufacturing of sewing machine
parts, centrifugal pumps, bus/truck body building and
mining machinery.
4.3 Project Site
The project is located at behind Uttam Steel Mill, Talwara
Road, Mandi Gobindgarh of Fatehgarh Sahib Dist of
Punjab on Delhi-Ludhiana Highway, NH-44, It lies near
Long 76o-19’ and Lat: 30
o-39’ and is at an Altitude of
about 266m above mean sea level. All the places are
connected with Mandi Gobindgarh and Fatehgarh Sahib
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through well maintained metalled road. It is about 07
K.M. from Fatehgarh Sahib, and about 5 K.M from Mandi
Gobindgarh Bus Stand. Chandigarh is at a distance of
about 50 K.M. by road The nearest rail head is Mandi
Gobindgarh on Delhi - Ludhiana railway line, which is at a
distance of about 02 K.M. Location plan showing other
features is given in Fig. 4.1 & 4.2 and Layout Plan of the
unit is given in Fig. 4.3
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Fig 4.1 LOCATION PLAN
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Fig 4.2
Location on Google Image
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Fig 4.3
SITE PLAN
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4.4 Climate:
There is a meteorological observatory at Chandigarh which
is at a distance of about 50 km from the site. Its data is
fairly representative of the conditions in the District in
general. The climate of the district is generally dry except
in the brief monsoon season and is very hot in summer and
cold in winter. The cold season is from middle of
November to early part of March. Succeeding period up-to
the end of June is hot season. July, August and September
are the South West monsoon season.
4.5 Temperatures
The area is fairly plain. December and January are the
coldest months whereas in May and June the heat is quite
intense. The temperature varies from 5oC minimum to
41oC maximum during the year.
4.6 Rainfall
The rainfall in the Zone is caused by the South-West
monsoon. It starts in the month of July and extends up-to
the end of September. During this period the monsoon
rain-fall contributes about 70 to 80% of the total annual
rainfall. The average annual rain fall is in the range of 660
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mm. The annual numbers of rainy days on an average are
about 34 in a year, out of which about 20 falls in the
monsoon period of July to September.
4.7 Humidity
In summer months of April, May and June, which is the
driest part of the year, the afternoon humidity comes down
to 22% while the relative humidity during monsoon
months goes upto about 80%.
4.8 Cloudiness
During monsoon season skies are over cast with moderate
to heavy clouds. During rest of the year, the sky is mostly
clear. It is lightly clouded occasionally during winter
season.
4.9 Winds
The Wind direction in the area is mostly from North-West
to South-East. During January to May the winds are quite
strong while July to October is calm months. The general
trends of various meteorological data from meteorological
observatory at Chandigarh and field observations are used
to draw Wind Rose Diagram. The Wind rose diagram is
shown in Figure-4.4
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FIGURE-4.4
WIND-ROSE DIAGRAM
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4.10 Drainage
The area is generally plain and has good slope from North-
East to South-West. The area is well drained and takes the
entire rain water flows to Sirhind Choe which ultimately
joins river Ghaggar near Haryana boundary.
4.11 Land Use
The total area of the District is 1180 sq km. 89% is net
sown area and 11% is under non-agricultural use.
Agriculture is mostly dependent on tube-wells. Rice and
wheat are the main crops in the area.
4.12 Forest
There is no reserved forest near the project site. The area
under forest is hardly about 2000 Ha. The company also
proposes to plant about 200 trees and shrubs within the
project area.
4.13 Flora And Fauna
Ecological system consists of varieties of interrelationship
between both biotic and abiotic components. Biotic
components comprise of both plant and animal
communities, which interact not only within and between
them but also within the abiotic physical. Animal plant
communities in their natural habitat exist in a well
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organized manner. The project does not disturb any natural
setting and is coming up in an already existing Industrial
area. Flora in the area generally consists of Dalbergia,
Prosopis, Albizzia, Ficus, Azolla, Hydrilla, Nelumbo,
Typha, Phragmites, Zizyphus Mauritiana, Syzgium cumini,
Ipomoea aquatica, Cyprus and Grasses. Animals like
Smooth Indian Otter, Hog Deer, Wild Boar, Flying
Fox, Wildcat, Squirrel, Fruit bat, and Common
Mongoose are found in the area.
4.14 Ambient Air Quality
The Status of Ambient Air Quality in the study area will be
determined by monitoring air quality in the Area at
different locations after issuing Terms of Reference. The
study area is a mix of rural, urban and industrial area and
the various sources of pollution are dust arising from
agricultural activities, vehicular traffic and industries.
4.15 Water Quality
Water quality of ground as well as surface resources in the
study area will be studied for assessing the water
environment and to evaluate the anticipated impact of the
project on environment after issuing of Terms of
Reference.
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4.16 Ambient Noise Quality
Noise is defined as unwanted sound due to any operation.
Presently there are no noise creating machinery nor any
such has been added, except DG Sets which will be noise
less.
4.17 Soil
Soil is generally sandy loam almost all over the District
and soil depth is generally shallow except in areas having
good vegetative cover. It is generally dry, shallow and
deficient in organic matters. The study area comprises
mostly of alluvial deposits of Quaternary age. The
geological formations in the area comprise of sandstone
largely micacous and form major features. The top zone of
this stage consists of maroon clays and buff clays
alternating one by one.
4.18 Demography And Socio-Economic Scenario
Large scale Industrial development has taken place in and
around Mandi Gobindgarh. The socio-economic profile
has been studied through random sample primary surveys
and secondary data. The significant demographic and socio
economic statistics of the district are summarized and
given in Table- 4.1
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TABLE-4.1
Summary of Key Demographic Statistics
PUNJAB
DIST. FATEHGARH SAHIB
Particulars 2011 2011
Male Population 1,46,34,819 3,20,603
Female Population 1,30,69,417 2,79,211
Total Population 2,77,04,236 5,99,814
Sex Ratio 893/1000 886
Density of
Population/Km2
550 508
Literacy Rate: Total 76.68 % 80.30%
Male 81.48% 84.50%
Female 71.34% 75.50%
Source: Google
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5.0 ENVIRONMENTAL IMPACT ASSESSMENT:
5.1 Present Environment:
Various Environment factors as existing in the project area
which possibly are liable to be affected by the activities
have been assessed & identified as below:
(i) Ambient Air
(ii) Water Quality
(iii) Noise
(iv) Land use pattern
(v) Demography and socio-economic pattern.
5.2 Probable Impact on Environment:
The above factors will be checked after the implementation
of the project to cross check the probable impact discussed
hereunder and remedial measures taken wherever
necessary. Broadly the impacts may be classified in two
categories as under:-
i) Short term -during construction/development stage
ii) Long term -during operational stage.
Both these categories have been considered while
predicting and evaluating the impacts as under:-
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5.3 Development Stage: - (Short Term)
This is a construction phase of the project and the impacts
are temporary due to construction related activities are as
under:-
i) Air Environment:
There is no point source of air pollution. The only
source will be the dust generation due to excavation,
construction and plying of vehicles within unit.
Some emission may be expected from vehicles
plying in the area for transportation of material etc.
Kerosene oil shall be provided to the labour so that
they do not burn wood for cooking etc. Since the
plant is an existing one and very few additions are to
be made there is no likely hood of any significant
effect on the overall air environment of the area.
ii) Water Environment :
Requirement of water during construction (Making
foundation & Platform of furnace) will be about 1.0
m3/day and there will be no discharge as the same
will be used completely. Labour during construction
is not very large. Hardly about 10-15 persons may
be working on an average that may be using water
for drinking and bathing etc. Toilet facilities already
exist at site which will be used by the labour.
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In view of this there is no likely hood of any
significant impact on the general environment of
water in the area.
iii) Noise Environment:
Some noise may be expected from the working of
the machinery for construction purposes and
movement of vehicles. Steps will be taken to reduce
its effect by resorting to staggering of various
operations Even otherwise since there will not be
any large scale machinery, the activity is not likely
to have any significant effect on the over all noise
environment.
iv) Land Environment:
The land at site is fairly level as such no leveling is
required. Natural drainage will not be disturbed.
Solid waste from construction activities will be used
within the premises under roads & refilling. There
will not be any significant impact on land in general.
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v) Socio Economic:
It is an existing project and it does not involve any
displacement of population or rehabilitation of any
kind. Rather it will provide employment to local
people and boost the economy of the area. It will
have some positive impact, although not to a large
extent.
5.4 Operational Stage: - (Long Term)
After completion, when the additions start production, the
operational impacts on the various parameters are
discussed as under:-
i) Ambient Air Environment:
There are only two sources of likely pollution:
a) SPM emission from the Induction furnaces
b) Steel Rolling Mills & Reverbratory Furnace
c) D.G. Sets.
There is one number steel rolling mill of capacity 335
TPD. Now they want to enhance the capacity of unit by
addition 4 numbers Induction furnaces of capacity 8 TPH
each. There will be generation of emission containing
SPM. All these processes are closed circuits as such
emissions to the atmosphere will be minimum. However,
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APCD like Bag filters will be provided at the exit point to
arrest particulate matter for Induction furnace and gassifire
on rolling mill. Whatever solid waste is arrested through
APCD the same will be collected & disposed off at
designated site.
Flue gas from the DG Sets will pass through a chimney of
adequate height and the final gas will be within
permissible limits. Thus air environment is not likely to be
affected significantly.
ii) Water Environment:
The total use of water after expansion will be about
37m3/day. The domestic waste water generated will be
about 10m3/day, which will be treated through STP. The
There will be no generation of industrial waste water after
expansion. The entire cooling water will be recirculated.
Thus water environment is not likely to be affected after
expansion. Further, ground water will be balanced through
recharge by rain water harvesting from the roof top
through recharge wells. Thus pressure on underground
water will be reduced.
iii) Land Environment:
It is an existing steel manufacturing unit. Now they want to
enhance the capacity of unit in additional land. Thus there
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will not be any significant adverse effect on the existing
general land environment with the enhancement of the
project.
iv) Noise Environment:
There is no noise producing machinery or equipment
except ID fans & Blower etc. which is placed in a room
causing least disturbance in the area. There is no likelihood
of any significant change in noise environment. The DG
Sets are of noiseless type.
v) Socio Economic Pattern
The project will provide extra employment to local people
in the field of running plants and maintenance of APCDs
and security etc. Thus it will have some positive effect on
the employment potential in the area.
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6.0 ENVIRONMENTAL MANAGEMENT PLAN:
6.1 General
Environment Management Plan (E.M.P) in a project is
prepared to mitigate the possible adverse effect of
various activities on the existing environmental factors,
during construction as well as in operational stages, to
avoid their deterioration, if any. It is desirable that
necessary steps are taken right from the beginning of the
project to be more effective. E.M.P. for this project has
been prepared keeping in view the existing conditions and
likely changes which may occur due to the proposed
project.
6.2 Air Environment
During construction stage water will be sprinkled on the
soil to avoid dust generation if any. The debris and unused
construction malbas shall be removed immediately for
recycling, if any, or for land fill.
APCDs like Bag filters, shall be provided to arrest SPM
from flue gases to keep it within permissible limits. All
vehicles for service activities at the project site shall be
checked for vehicular emission. The agencies will be asked
to keep them within prescribed limits. They will also be
asked to maintain them properly. A chimney of suitable
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height has been provided for the D.G. Set to control the
G.L.C. of S.P.M., SO2, & Nox levels. Extensive tree
plantation shall be resorted to for further improving the air
environment in general and minimize noise levels.
6.3 Water Environment:
Water shall be drawn from existing tube-well installed in
the factory area. During construction existing toilet
facilities shall be used by the labour. Finally waste water
from the toilets shall be taken to septic tank through
underground delivery system and treated up to tertiary
level. Treated water will be used for irrigation within the
premises. It will not be thrown outside either on land or in
any water body. Roof top Rain Water shall be harvested
and used for ground water recharge to minimize effect of
withdrawal of water from the underground.
6.4 Land Environment:
To avoid erosion of the top soil the development is planned
in the shortest possible time and land-clearing activity shall
be kept to the absolute minimum by working at the specific
sites one by one where construction is to take place so as to
increase detention and infiltration. The construction
activity is within the shed area. Natural
waterways/drainage pattern shall be maintained by
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providing culverts where needed. The requirements of sand
and aggregates for the construction works will be met
through venders. The land use is thus so planned that there
is minimum adverse impact.
6.5 Solid Waste
The other solid wastes from the bag filters shall be stored
in a dumping pit of R.C.C. and disposed off in the
designated land fill places. Slag from the manufacturing
process shall be given to cement plant for further use.
6.6 Green Belt
The main objective of the green belt is to provide a barrier
between the source of pollution and the surrounding areas.
The green belt helps to capture the fugitive emission and
to attenuate the noise generated, apart from improving the
aesthetics. Development of green belt and other forms of
greenery shall also prevent soil erosion and washing away
of topsoil besides helping in stabilizing the functional
ecosystem and further, to make the climate more
conducive and to restore water balance. It is planned that
the selected plants will be grown as per normal
horticultural (or forestry) practice and authorities
responsible for plantation will also make sure that adequate
provision for watering and protection of the saplings exists
at site.
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6.7 Occupational Health and Safety of workers
The only health hazards expected are heat & dust.
Following mitigation measures will be provided:-
1. HEAT:
Workers working near the furnace and
handling moulds manually may be exposed to
heat.
Fans will be provided near such places and hot
air shall be drawn through exhaust fans.
All workers will be provided PPE like gloves,
helmets, gum boots, goggles etc.
Fresh water shall be available near the working
area.
2. DUST:
• Exhaust fans have been provided for collection
of dust laden air within the shed and its
further disposal through bag filters.
• Face masks and side covered glasses have
been provided to all workers.
• Frequent check-up of the workers will be done
which shall include chest X-ray, ECG & vision
testing. Necessary treatment shall be provided
wherever required.
• All check-ups will be documented and
reviewed monthly for Occupational health and
safety of the workers.
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7.0 ENVIRONMENT MONITORING PROGRAMME
Regular monitoring of all significant environmental parameters is
essential to check the compliance status vis-à-vis the
environmental laws and regulation. The objectives of the
monitoring will be as follows:
To verify the results of the impact assessment study
with respect to the proposed projects.
To study the trend of concentrated values of the
parameters, which have been identified as critical and
then planning the mitigating measures.
To check and assess the efficacy of pollution control
equipment.
To ensure that any additional parameters, other than
those identified in the impact, do not turn critical after
the commissioning of proposed project.
To implement the EMP, a structured Environment Management
Cell (EMC) interwoven with the existing management system
will be created. EMC will undertake regular monitoring of the
environment and conduct yearly audit of the environmental
performance during the construction of the project. It will also
check that the stipulated measures are being satisfactorily
implemented and operated. It shall also co-ordinate with local
authorities to see that all environmental measures are well
coordinated.
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A comprehensive environmental monitoring program that has
been prepared for the purpose of implementation in the proposed
residential colony by the EMC is described below:
The ambient Air quality shall be monitored at project
site and two upward and downstream locations once
every quarter for PM2.5, PM10, NOx & SO2 and CO
levels during the Construction Phase and Operational
Phase. The Ambient Noise Levels shall also be
monitored once every six months.
The vehicles shall be checked for PUC once every
quarter during the development period and records shall
be maintained.
Groundwater quality of the Tube-wells in site area will
be regularly monitored preferably once in a quarter
during the development period.
Air Pollution Control System & ETP/STP shall be
provided with a small Laboratory and weekly
monitoring of the parameters shall be undertaken. In
addition monitoring shall be got done from an
independent agency as laid down by State Pollution
Control Board.
All the above observations will be complied and
documented by the EMC to serve the following
purposes.
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Identification of any environmental problems that are
occurring in the area.
Initiating or providing solution to those problems
through designed channels and verification of the
implementation status.
Controlling activities inside the project, until the
environmental problem has been corrected.
Suitably responding to emergency situations.
7.1 Environment Management Cell:
The Environment Management Cell shall include:
Representative of Management (Head of Environment
Cell)
Process Incharge
Incharge Maintenance Department
A representative of Environmental Consultants