environmental impact assessment/ environmental...

Final Report

ENVIRONMENTAL IMPACT ASSESSMENT/

ENVIRONMENTAL MANAGEMENT PLAN

of

Expansion of 72,000 TPA Sponge Iron to 1,44,000 TPA by

Installation of additional Two no. Kilns of 100 TPD each, Mild Steel

(Ingots, Billets, TM Bars & Channel/ Angles) from 1,80,000 TPA to

3,60,000 TPA by installation of additional two nos. of Induction

furnaces 20 T capacity each, Rolling & section mill, Captive power

plant from 4MW to 6 MW and Waste Heat Recovery Power Plant

(WHRB) from 6 MW to 10 MW

At Survey No.221, Village: Vadala, Taluka: Mundra, Dist: Kutch,

Gujarat

Project Proponent:

M/s. Nilkanth Concast Private Limited

Prepared By

Pollution & Ecology Control Services Dhantoli, Nagpur.

NABET No. : QCI/NABET/EIA/1720/RA0101

Environmental Impact Assessment & Environment Management Plan M/s. Nilkanth Concast Private Limited

PECS, Nagpur Page | 1



Standards TOR Points and Compliance

Sr.

No.

Condition Compliance Section

No. /

Table

No. /

Figure

No.

Page

No.

1. Executive Summary Attached with EIA report -

2. Introduction

a. i. Details of the EIA

Consultant including

NABET accreditation

PECS Nagpur is accredited with

NABET with NABET No. :

QCI/NABET/EIA/1720/RA0101.

All other Details of the EIA

Consultant are given in chapter 12 of

the EIA report.

Chapter

12

122

b. ii. Information about the

project proponent

Information about Project proponent is

given in Chapter 1 of the EIA report.

Section

1.2

30

c. iii. Importance and benefits

of the project

Given in the chapter 1 of the final EIA

report.

Section

1.3.4

36

3. Project Description

a. i. Cost of project and time

of completion.

Capital Cost of expansion project is

Rs. 60 Crore. Time of Completion is

12 Month after getting EC & CTE.

- -

b. ii. Products with capacities

for the proposed project.

Given in the chapter 2 of the final EIA

report.

Section

2.4 &

Table 2.3

48-49

c. iii. If expansion project,

details of existing

products with capacities

and whether adequate

land is available for

expansion, reference of

earlier EC if any.

EC for existing project is issued vide

letter no. J-11011/85/2008 -IAII(I)

dated 23.12.2008 and details are

given in the chapter 2 of the EIA

report.

The total land requirement for the

project is 35.38 Ha. Entire land is in

possession.

Section

2.4,

Table 2.3

& 2.4

48-49

d. iv. List of raw materials

required and their source

along with mode of

transportation.

List of raw materials required for

sponge iron plant are Iron pellets, coal,

dolomite, sponge Iron, scrap mid steel,

billets are given in Chapter-2 of EIA

Report

Section

2.5

Table 2.5

51

e. v. Other chemicals and

materials required with

quantities and storage

capacities

There are caustic flake, Sulphuric acid

and Hydrochloric acid and it is used

for DM Plant.

Storage capacities of sulphuric acid-1

MT/Week in carboy packing. HCL-

Section

2.5

Table 2.5

51



0.7 MT/week in carboy packing and

Caustic flacer- bag packing 0.5

MT/week in bag Packing.

f. vi. Details of Emission,

effluents, hazardous

waste generation and

their management.

Details of Emission, effluents are

given in the chapter 2. Hazardous

waste will be generated in the

proposed expansion project. ESP and

bag filter will be installed to minimize

the air pollution

Section

2.11 (e)

74

g. vii. Requirement of water,

power, with source of

supply, status of

approval, water balance

diagram, man-power

requirement (regular and

contract)

Given in the chapter 2 of the EIA

report. Water

:Section

2.6 &

Table 2.6

Power: Section

2.7 &

Table 2.7

Man-

power: Section

2.8 &

Table 2.8

Water

Status

approval:

Annexure

VIII

54-57

h. viii. Process description along

with major equipments

and machineries, process

flow sheet(quantative)

from raw material to

products to be provided


report.

Section

2.10 &

Figure

2.8-2.12

59-70

i. ix. Hazard identification and

details of proposed safety

systems.


report.

Section

7.2.2

171-

176

j. x. Expansion/modernization

proposals:

a. Copy of all the

Environmental

Clearance(s)

including

Amendments thereto

obtained for the

Copy of Environmental Clearance is

attached as Annexure I

A certified copy of the latest

Monitoring Report issued by Regional

Office of the Ministry of Environment,

Forest & Climate Change, Bhopal as

per circular dated 30th

May, 2012 is

-



project from

MOEF/SEIAA shall

be attached as an

Annexure. A

certified copy of the

latest Monitoring

Report of the

Regional Office of

the Ministry of

Environment and

Forests as per

circular dated 30th

May, 2012 on the

status of compliance

of conditions

stipulated in all the

existing

environmental

clearances including

Amendments shall

be provided. In

addition, status of

compliance of

Consent to Operate

for the ongoing

existing operation of

the project from

SPCB shall be

attached with the

EIA-EMP report.

b. In case the existing

project has not

obtained

environmental

clearance, reasons

for not taking EC

under the provisions

of the EIA

Notification 1994

and/or EIA

Notification2006

shall be provided.

Copies of Consent to

Establish/No

Objection Certificate

and Consent to

attached as Annexure II

Consent to operate is attached as

Annexure III

Not Applicable



Operate (in case of

units operating prior

to EIA Notification

2006, CTE and CTO

of FY 2005-2006)

obtained from the

SPCB shall be

submitted. Further,

compliance report to

the conditions of

consents from the

SPCB shall be

submitted.

4. Site Details

a. i. Location of the project

site covering village,

Taluka/Tehsil, District

and State, Justification

for selecting the site,

whether other sites were

considered.

Location of the Project:

Survey No. : 221

Village: Vadala

Taluka: Mundra

District: Kutch

The expansion of the project will be

carried out in existing premises.

As it is expansion project so, alternate

site is not considered.

Section

2.3 &

Figure

2.1

44-45

b. ii. A toposheet of the study

area of radius of 10km

and site location on

1:50,000/1:25,000 scale

on an A3/A2 sheet.

(including all eco-

sensitive areas and

environmentally

sensitive places)

10 km study area on Toposheet No. 42

F/13 is given in Chapter 2 of the EIA

Report.

Section

2.3 &

Figure

2.2

45-46

c. iii. Co-ordinates (lat-long) of

all four corners of the

site.

Co-ordinates (lat-long) of all corners

of the site given in the Chapter 2 of the

EIA report.

Section

2.3 &

Table 2.1

44

d. iv. Google map-Earth

downloaded of the

project site.


report

Section

2.3 &

Figure

2.4

48

e. v. Layout maps indicating

existing unit as well as

proposed unit indicating

storage area, plant area,

greenbelt area, utilities

etc. If located within an

Industrial


report and attached with EIA report in

A3 size.

Figure

2.5

50



area/Estate/Complex,

layout of Industrial Area

indicating location of

unit within the Industrial

area/Estate.

f. vi. Photographs of the

proposed and existing (if

applicable) plant site. If

existing, show

photographs of

plantation/greenbelt, in

particular.


report

Section

1.6

39

g. vii. Landuse break-up of

total land of the project

site (identified and

acquired),

government/private -

agricultural, forest,

wasteland, water bodies,

settlements, etc shall be

included. (not required

for industrial area)


report

Section

2.4

Table 2.2

48

h. viii. A list of major industries

with name and type

within study area (10km

radius) shall be

incorporated. Land use

details of the study area


report

Section

3.6

Table

3.14

106

i. ix. Geological features and

Geo-hydrological status

of the study area shall be

included.


report

Section

3.8

111-

116

j. x. Details of Drainage of

the project upto 5km

radius of study area. If

the site is within 1 km

radius of any major river,

peak and lean season

river discharge as well as

flood occurrence

frequency based on peak

rainfall data of the past

30 years. Details of

Flood Level of the

project site and

maximum Flood Level of

Details of Drainage of the project up

to 5 km is given in the chapter 4 of the

EIA report. There is no major river

within 1 km radius of project site.

Figure

4.4

150



the river shall also be

provided. (mega green

field projects)

k. xi. Status of acquisition of

land. If acquisition is not

complete, stage of the

acquisition process and

expected time of

complete possession of

the land.

The company is in possession of

35.38 Ha (35,37,989 sqm) free hold

land at Survey No.221, Vill: Vadala,

Taluka: Mundra, Dist: Kutch,

Gujarat. No additional land is

requested for expansion phase.

- -

l. xii. R&R details in respect of

land in line with state

Government policy

There will be no displacement of

people including home oustees, land

oustees and landless laborers, thus

R&R issue are not applicable.

- -

5. Forest and wildlife related

issues (if applicable)

a. i. Permission and approval

for the use of forest land

(forestry clearance), if

any, and

recommendations of the

State Forest Department.

(if applicable)

NA - -

b. ii. Landuse map based on

High resolution satellite

imagery (GPS) of the

proposed site delineating

the forestland (in case of

projects involving forest

land more than 40 ha)

NA - -

c. iii. Status of Application

submitted for obtaining

the stage I forestry

clearance along with

latest status shall be

submitted.

NA - -

d. iv. The projects to be

located within 10 km of

the National Parks,

Sanctuaries, Biosphere

Reserves, Migratory

Corridors of Wild

Animals, the project

proponent shall submit

NA - -



the map duly

authenticated by Chief

Wildlife Warden

showing these features

vis-à-vis the project

location and the

recommendations or

comments of the Chief

Wildlife Warden-thereon

e. v. Wildlife Conservation

Plan duly authenticated

by the Chief Wildlife

Warden of the State

Government for

conservation of Schedule

I fauna, if any exists in

the study area

NA - -

f. vi. Copy of application

submitted for clearance

under the Wildlife

(Protection) Act, 1972, to

the Standing Committee

of the National Board for

Wildlife

NA - -

6. Environmental Status

a. i. Determination of

atmospheric inversion

level at the project site

and site-specific

micrometeorological data

using temperature,

relative humidity, hourly

wind speed and direction

and rainfall.

Atmospheric inversion has been taken

from nearest IMD Station Kandla on

diurnal basis which is being

incorporated in AAQ Modelling.

Attached as Annexure IX (d) in the

EIA report.

- -

b. ii. AAQ data (except

monsoon) at 8 locations

for PM10, PM2.5, SO2,

NOX, CO and other

parameters relevant to

the project shall be

collected. The

monitoring stations shall

be based CPCB

guidelines and take into

account the pre-dominant

wind direction,

Summary of AAQ data at 8 locations

is given in the chapter 3 of the EIA

report and detailed report is attached

as Annexure IX.

The 12 week data has been

incorporated for the period of

December 2015 to February 2015 and

October 2018 to December 2018 and

on suggestion of EAC (Industry - I)

one month data as per the CPCB

sampling criteria is incorporated.

Section

3.2

Table

3.4

84



population zone and

sensitive receptors

including reserved

forests.

c. iii. Raw data of all AAQ

measurement for 12

weeks of all stations as

per frequency given in

the NAQQM

Notification of Nov.

2009 along with - min.,

max., average and 98%

values for each of the

AAQ parameters from

data of all AAQ stations

should be provided as an

annexure to the EIA

Report.

Raw data of all AAQ measurement for

4 weeks of all stations is attached as

Annexure IX

- -

d. iv. Surface water quality of

nearby River (60m

upstream and

downstream)and other

surface drains at eight

locations as per

CPCB/MoEF&CC.

The graphical representation of

Surface water quality data for one

month ( on suggestion of EAC

(Industry - I)) is given in the chapter 3

of the EIA report. The detailed

analysis report is given in Annexure

IX (a)

Section

3.3

Figure

3.6

95

e. v. Whether the site falls

near to polluted stretch of

river identified by the

CPCB/MoEF&CC, if yes

give details.

The proposed site does not fall near to

polluted stretch of river identified by

the CPCB/MoEF&CC,

- -

f. vi. Ground water monitoring

at minimum at 8

locations shall be

included.

The graphical representation of

Ground water quality data for one

month (on suggestion of EAC

(Industry - I)) is given in the chapter 3

of the EIA report. The detailed

analysis report is given in Annexure

IX (a)

Section

3.3

Figure

3.6

94

g. vii. Noise levels monitoring

at 8 locations within the

study area.

The graphical representation of Noise

levels for one month (on suggestion

of EAC (Industry - I)) is given in the

chapter 3 of the EIA report. The

detailed analysis report is given in

Annexure IX (a)

Section

3.4

Figure

3.8

99

h. viii. Soil Characteristic as per

CPCB guidelines.


report

Section

3.5 and

Table

103



3.12

i. ix. Traffic study of the area,

type of vehicles,

frequency of vehicles for

transportation of

materials, additional

traffic due to proposed

project, parking

arrangement etc.


report

Section

4.7.2.2

147

j. x. Detailed description of

flora and fauna

(terrestrial and aquatic)

existing in the study area

shall be given with

special reference to rare,

endemic and endangered

species. If Schedule-I

fauna are found within

the study area, a Wildlife

Conservation Plan shall

be prepared and

furnished.


report

Section

3.9 &

Table

3.15

119-

123

k. xi. Socio-economic status of

the study area.


report and detailed study is given in

Annexure XVI

Section

3.7

103

7. Impact and Environment

Management Plan

a. i. Assessment of ground

level concentration of

pollutants from the stack

emission based onsite-

specific meteorological

features. In case the

project is located on a

hilly terrain, the AQIP

Modelling shall be done

using inputs of the

specific terrain

characteristics for

determining the potential

impacts of the project on

the AAQ. Cumulative

impact of all sources of

emissions (including

transportation) on the

AAQ of the area shall be

Assessment of ground level

concentration of pollutants has been

done using AERMOD and detailed are

given in the chapter 4 of the EIA

report. The air quality contours has

been plotted and given in the chapter 4

of the EIA report.

Cumulative impact of all sources of

emissions (including transportation)

on the AAQ of the area are assessed

and are given in the chapter 4.

AERMOD model is used for

modeling of data. The input data for

modeling is provided in Chapter 4 and

Annexure IX (d) as met data.The air

quality contours are plotted on a

location map shown in Chapter 4

Section

4.7.1

Figures

4.1 to 4.4

131

141-

144



assessed. Details of the

model used and the input

data used for modelling

shall also be provided.

The air quality contours

shall be plotted on a

location map showing

the location of project

site, habitation nearby,

sensitive receptors, if

any.

b. ii. Water Quality modeling

- in case, If the effluent is

proposed to be

discharged in to the local

drain, then water quality

Modeling study should

be conducted for the

drain water taking into

consideration the

upstream and

downstream quality of

water of the drain.

Plant is based on the zero discharge

system so water modelling is not

required.

- -

c. iii. Impact of the transport of

the raw materials and end

products on the

surrounding environment

shall be assessed and

provided. In this regard,

options for transport of

raw materials and

finished products and

wastes (large quantities)

by rail or rail-cum road

transport or conveyor

cum-rail transport shall

be examined.


report.

Section

4.7.2

145

d. iv. A note on treatment of

wastewater from

different plant

operations, extent

recycled and reused for

different purposes shall

be included. Complete

scheme of effluent

treatment. Characteristics

The source and generation of

wastewater are being identified &

quantified as in the water balance,

process flow and industrial effluent

treated through ETP whereas domestic

wastewater through STP. Industry

observers zero discharge principal.

- -



of untreated and treated

effluent to meet the

prescribed standards of

discharge under

E(P)Rules.

e. v. Details of stack emission

and action plan for

control of emissions to

meet standards.


report

Table 4.1 137

f. vi. Measures for fugitive

emission control

Given in the Chapter 4 of the final EIA

report.

Section

4.7.1

131-

134

g. vii. Details of hazardous

waste generation and

their storage, utilization

and management. Copies

of MOU regarding

utilization of solid and

hazardous waste in

cement plant shall also

be included. EMP shall

include the concept of

waste-minimization,

recycle/reuse/recover

techniques, Energy

conservation, and natural

resource conservation.

Identification and quantification of

Hazardous waste is mentioned in

Chapter 2 of EIA report. The

management of hazardous waste is

mentioned in Chapter 4.

Section

2.11 (e)

And

Section

4.7.4

74

and

152

h. viii. Proper utilization of fly

ash shall be ensured as

per Fly Ash Notification,

2009. A detailed plan of

action shall be provided.

Ash generated is being used in own

brick manufacturing plant and

expansion of project, ash will be

utilized for own brick manufacturing

plant

Section

4.7.4

Table 4.5

151

i. ix. Action plan for the green

belt development plan in

33 % area i.e. land with

not less than1,500 trees

per ha. Giving details of

species, width of

plantation, planning

schedule etc. shall be

included. The green belt

shall be around the

project boundary and a

scheme for greening of

the roads used for the

project shall also be

incorporated.

The plantation and green belt

development will also be taken care in

the plant and the space reserved for

plantation will be more than 33% of

the total plant area. Out of the total

land of 35.38 Ha (35,37,989 sqm) Ha.

Nilkanth Concast Pvt Ltd has

earmarked 11.73 Ha (1,17,334 sq. m)

of land for development of green belt.

Nilkanth Concast Pvt Ltd has already

planted 13,800 trees in its plant area.

- -



j. x. Action plan for rainwater

harvesting measures at

plant site shall be

submitted to harvest rain

water from the roof tops

and storm water drains to

recharge the ground

water and also to use for

the various activities at

the project site to

conserve fresh water and

reduce the water

requirement from other

sources.

Detailed in the chapter 10 of the EIA

report.

Section

10.3.2

and

Figure

10.2

208

k. xi. Total capital cost and

recurring cost/annum for

environmental pollution

control measures shall be

included.


report.

Table 6.2 163

l. xii. Action plan for post-

project environmental

monitoring shall be

submitted.

Action plan for Post-project

environmental monitoring is given in

the chapter 6 of the EIA report

Table 6.1 161-

162

m. xiii. Onsite and Offsite

Disaster (natural and

Man-made) Preparedness

and Emergency

Management Plan

including Risk

Assessment and damage

control. Disaster

management plan should

be linked with District

Disaster Management

Plan.

Given in the chapter7 of the EIA

report.

Section

7.3.1

186-

190

8. Occupational health

a. i. Details of Existing

Occupational & Safety

Hazards. What Are The

Exposure Levels Of

Above Mentioned

Hazards And Whether

They Are Within

Permissible Exposure

level (PEL). If these are

not within PEL, what


report.

Section

7.2.3

177



measures the company

has adopted to keep them

within PEL so that health

of the workers can be

preserved.

b. ii. Details of exposure

specific health status

evaluation of worker. If

the workers' health is

being evaluated by pre

designed format, chest x

rays, Audiometry,

Spirometry, Vision

testing (Far& Near

vision, colour vision and

any other ocular defect)

ECG, during pre-

placement and periodical

examinations give the

details of the same.

Details regarding last

month analyzed data of

above mentioned

parameters as per age,

sex, duration of exposure

and department wise.

Annual Health status of existing

workers for 3 consecutive years is

attached as Annexure XIII

The latest data of health status of

workers are upto Feb 2019 are given

in Annexure XIII

- -

c. iii. Annual report of heath

status of workers with

special reference to

Occupational Health and

Safety.

Annual Health status of existing

workers for 3 consecutive years is

enclosed as Annexure XIII

- -

d. iv. Plan and fund allocation

to ensure the

occupational health &

safety of all contract and

casual workers.

Annual health checkup of all

employees will be carried out by

experienced doctors. Rs. 15.00

Lacs/Annum is reserved for this

activity.

- -

9. Corporate Environment Policy

a. i. Does the company have a

well laid down

Environment Policy

approved by its Board of

Directors? If so, it may

be detailed in the EIA

report.

Copy of Environment Policy approved

by Board of Directors is attached as

Annexure X.

-

b. ii. Does the Environment Given in chapter 10 and 11 Section 214



Policy prescribe for

standard operating

process / procedures to

bring into focus any

infringement / deviation /

violation of the

environmental or forest

norms /conditions? If so,

it may be detailed in the

EIA.

10.3.6

c. iii. What is the hierarchical

system or Administrative

order of the company to

deal with the

environmental issues and

for ensuring compliance

with the environmental

clearance conditions?

Details of this system

may be given.

The hierarchical system is given in

Figure 10.1.

Figure

10.1

215

d. iv. Does the company have

system of reporting of

non compliances /

violations of

environmental norms to

the Board of Directors of

the company and / or

shareholders or

stakeholders at large?

This reporting

mechanism shall be

detailed in the EIA report

The responsibilities of the various

members of the environment cell are

given in Chapter 10 of the EIA report.

Section

10.3.6

214-

215

10. Details regarding

infrastructure such as

sanitation, fuel, restroom etc.

to be provided to the labour

force during construction as

well as to the casual workers

including truck drivers during

operation phase.

Since the Plant is in operation

adequate Facilities such as Sanitation,

canteen, restrooms, parking space are

in place.

- -

11. Enterprise Social

Commitment (ESC)

i Adequate funds (at least

2.5 % of the project cost)

CER fund @1% of project cost i.e. Rs.

67.5 Cr will be spent during execution

Section

8.5

198



shall be earmarked

towards the Enterprise

Social Commitment

based on Public Hearing

issues and item-wise

details along with time

bound action plan shall

be included. Socio-

economic development

activities need to be

elaborated upon

of the project. This fund will be spent

in 12 months on various activities as

mentioned in OM dated 01.05.2018.

Table 8.1

12. Any litigation pending against

the project and/or any

direction/order passed by any

Court of Law against the

project, if so, details thereof

shall also be included. Has the

unit received any notice under

the Section 5 of Environment

(Protection) Act, 1986 or

relevant Sections of Air and

Water Acts? If So, details

thereof and compliance/ATR

to the notice (S) and present

status of the case.

NA -

13. A tabular chat with index for

point wise compliance of

above TORs.

Given As above -

14. The TORs prescribed shall be

valid for a period of three

years for submission of the

EIA-EMP reports along with

Public Hearing Proceedings

(wherever stipulated).

- - -

Integrated Steel Plant

1) Iron pellet/coal linkage

documents along with the

status of environmental

clearance of iron ore and coal

mines.

NA - -

2) Quantum of production of

coal and iron ore from coal &

iron ore mines and the

projects they cater to. Mode of

transportation to the plant and

its impact.

- - -



3) For large ISPs, a 3-D view i.e.

DEM (Digital Elevation

Model) for the area in 10 km

radius from the proposal site.

MRL details of project site

and RL of nearby source of

water shall be indicated.

- - -

4) Recent land-use map based on

satellite imagery. High-

resolution satellite image data

having 1m-5m spatial

resolution like quickbird,

IKonos, IRS P-6 pan

sharpened etc. for the 10 Km

radius area from proposed

site. The same shall be used

for land used/land-cover

mapping of the area.

- - -

5) PM(PM10 and PM2.5) present

in the ambient air must be

analysed for source analysis-

natural dust/RSPM generated

from plant operations ( trace

elements) of PM10 to be

carried over.

- - -

6) All stock piles will have to be

on top of a stable liner to

avoid leaching of materials to

ground water

- - -

7) Plan for the implementation of

the recommendation made for

the steel plants in the CREP

guidelines.

- - -

8) Plan for slag utilization - - -

9) Plan for utilization of energy

in off gases (coke, over, blast

furnace)

- - -

10) System of coke quenching

adopted with justification.

- - -

11) Trace metals Mercury, arsenic

and fluoride emissions in the

raw material.

- - -

12) Trace metals in waste material

especially slag.

- - -

13) Trace metals in water - - -



CONTENTS

Sr. No. Particulars Page No.

Executive Summary i-xxiv

CHAPTER 1: INTRODUCTION 27-39

1.0 Introduction 27

1.1 Purpose of the Project 28

1.2 Identification of Project & Project Proponent 29

1.2.1 The Company 29

1.2.2 Project Proponent 30

1.3 Brief Description of Nature, Size, Location of the Project and its

Importance to the Country, Region

30

1.3.1 Nature of the Project 30

1.3.2 Size of the Project 32

1.3.3 Location of the Project 32

1.3.4 Project‟s Importance to the Country/ Region 35

1.4 Scope of the EIA Study 35

1.5 Content of the Report 35

1.6 Site Photographs 38

CHAPTER2: PROJECT DESCRIPTION 40-75

2.1 Type of Project 40

2.2 Need of Project 42

2.3 Location 43

2.4 Size or Magnitude of Operation 47

2.5 Raw Material Requirement 51

2.5.1 Material Balance 52

2.6 Raw Material Requirement 54

2.7 Power Requirement& Supply / Source 55

2.8 Manpower Requirement 56

2.9 Project Implementation Schedule 57

2.10 Process Description 59



2.10.1 Sponge Iron 59

2.10.2 Mild Steel 62

2.10.3 Captive Power Plant 68

2.11 Mitigation Measures 71

2.12 Assessment of New & untested technology for the risk of technological

failure

75

CHAPTER 3: DESCRIPTION OF ENVIRONMENT 76-123

3.0 Introduction 76

3.1 Description of Environment 76

3.1.1 Environmental Monitoring Program 78

3.1.2 Micro Meteorology 79

3.2 Air Environment 80

3.3 Water Environment 87

3.4 Noise Environment 96

3.5 Soil Environment 99

3.6 Land Environment 105

3.7 Socio-economic aspects 107

3.7.1 Human Settlement and Demography 107

3.7.2 Socio Economic Characteristics of the Area 108

3.8 Geology 109

3.8.1 Hydro Geological Studies 109

3.9 Flora & Fauna 118

CHAPTER 4: ANTICIPATED IMPACTS AND MITIGATION MEASURES 124-157

4.0 Introduction 124

4.1 Identification of Impacts 124

4.2 Assessment of Significance of Impacts 124

4.3 Impacts and Mitigation Measures due to Project Sitting (Location) 125

4.4 Impacts and Mitigation Measures due to Possible Accidents Impact 126

4.5 Impacts and Mitigation Measures due to Project Design 126

4.6 Impacts and Mitigation Measures during Construction Phase 126



4.6.1 Impacts on Air Quality 127

4.6.2 Impacts on Water Environment 128

4.6.3 Impacts on Noise Environment 128

4.6.4 Impacts on Soil and land use 129

4.6.5 Impacts on Socio-Economic Environment 130

4.7 Impacts and Mitigation Measures during Construction Phase 130

4.7.1 Impact on Air Quality 131

4.7.2 Measures for minimizing and / or offsetting adverse impacts

identified

145

4.7.2.1 Impacts due to Vehicle Movement 146

4.7.2.2 Traffic Study 146

4.7.3 Noise Levels 148

4.7.4 Impact on Water 149

4.7.5 Impact on soil 151

4.7.6 Solid Waste Generation 151

4.9 Measures for minimizing and / or offsetting adverse impacts identified 152

4.9.1 Irreversible and Irretrievable Commitments of Environments

Component

154

CHAPTER 5: ANALYSIS OF ALTERNATIVES ( TECHNOLOGY AND SITE) 158

5.1 Analysis of Alternatives (Technology & Site) 158

5.2 1.1.1 Alternate Sites/Site Selection 158

CHAPTER 6: ENVIRONMENTAL MONITORING PROGRAM 159-163

6.1 Post Project Environmental Monitoring 159

6.2 Monitoring and Reporting Procedure 160

6.2.1 Data Analysis 162

6.2.2 Reporting Schedule 162

6.2.3 Emergency Procedures 162

6.3 Detailed Budget & Procurement Schedules 163

CHAPTER 7: ADDITIONAL STUDIES 164-194

7.1 Public Consultation 164



7.2 Risk Assessment 169

7.2.1 Approaches to the Study 170

7.2.2 Hazard Identification 171

7.2.3 Occupational health impacts on the workers 177

7.2.4 Do‟s & Don‟ts of preventive maintenance 180

7.2.5 Fire Protection System 182

7.2.6 Occupational Health and Safety 183

7.2.7 Safety Organization 183

7.2.8 Health and Safety Monitoring Plan 185

7.2.9 Health and Safety Monitoring Plan 185

7.3 Disaster Management Plan 186

7.3.1 Emergency Procedure 186

7.3.2 Maintenance of Site Disaster Management Plan 189

7.4 Off Site Emergency Plan 191

7.5 Social Impact Assessment 193

CHAPTER 8: PROJECT BENEFITS 195-200

8.1 Improvement in the Physical Infrastructure 195

8.2 Improvement in the Social Infrastructure 195

8.3 Employment Potential 195

8.4 Other Tangible Benefits 196

8.5 Corporate Environment Responsibility Plan 197

CHAPTER 9: ENVIRONMENTAL COST BENEFIT ANALYSIS 201

CHAPTER 10: ENVIRONMENT MANAGEMENT PLAN 202-216


10.2 Management During Expansion Phase 203

10.2.1 Site Preparation 203

10.2.2 Water Supply and Sanitation 203

10.2.3 Noise 201

10.2.4 Solid and hazardous 204

10.3 Management Plan During Operation Phase 204



10.3.1 Air Management 204

10.3.2 Water Environment 206

10.3.3 Noise Environment 209

10.3.4 Green Belt Development 209

10.3.5 Solid waste Management 212

10.3.6 Environmental Management Cell 214

10.4 Environment Management Plan Cost 216

CHAPTER 11: SUMMARY AND CONCLUSION 217-221

11.1 Summary 217

11.2 Conclusion 220

CHAPTER 12: DISCLOSURE OF CONSULTANTS 222


12.1 Profile of EIA/EMP Consultant 223

LIST OF TABLES


1.1 Details of the Project Site 34

2.1 Site Characterization and Environment Sensitivity 43

2.2 Land Utilization of Plant Area 47

2.3 Project Configuration 48

2.4 Details of the Major units of the Project 50

2.5 Annual requirement of major raw materials 51

2.6 Water Requirement 54

2.7 Power Requirement 55

2.8 Category-wise break-up of Manpower 57

2.9 Composition of Iron Pellets 61

2.10 Composition Coal 61

2.11 Typical Analysis of Sponge Iron 61

2.12 Air Pollution Control Systems installed and Proposed for the Project 71



2.13 Waste Water Treatment and Disposal 73

2.14 Solid Waste Generation and Utilization Plan 74

3.1 Environmental Attributes & Frequency of Monitoring 78

3.2 Description of Ambient Air Monitoring Stations 81

3.3 Techniques& Instruments Used For Monitoring of Ambient Air Quality 83

3.4 Summarized Report of Ambient Air Quality (June 2019) 84

3.5 National Ambient Air Quality Standards 85

3.6 List of surface and ground water sampling stations 87

3.7 Methodology for Sampling and Analysis of Water & Wastewater 91

3.8 Central Pollution Control Board (CPCB) Surface Water Quality Criteria 92

3.9 Details of Sampling Stations of Noise Level Measurement 96

3.10 Soil Sampling Location Details 100

3.11 Analytical Techniques for Soil Analysis 102

3.12 Physico-Chemical Characteristics of Soil 103

3.13 Standard Soil Classification 104

3.14 List of Major Industries in 10 Km Radius 106

3.15 List of Plant Species Recorded From the Study Area 119

3.16 List of Fauna in the Study Area 121

4.1 Stacks Details 137

4.2 The Resultant Concentrations of PM10 due to incremental GLCs for

Plant (Proposed + Existing)

138

4.3 The Resultant Concentrations of SOx due to incremental GLCs for

Proposed Plant (Proposed + Existing)

138

4.4 Transportation Details 147

4.5 Solid Waste Generation & Mitigation Measures 151

4.6 Potential impacts verses Mitigation Measures Adopted 153

4.7 Quantitative Impact Evaluations during Construction & Operation Phase 156

6.1 Monitoring Schedule for Environmental Parameters 161

6.2 Environment Monitoring Cost 163

7.1 Onsite Emergency Chart 188



8.1 CER Budget Plan (Rs. In Lakhs) 198

8.2 Year- wise CER activities (Rs. In Lakhs) 199

10.1 Air Pollution control System for existing & proposed expansion 205

10.2 EMP Budget 216

12.1 Details of sectors accorded to PECS under the QCI-NABET scheme for

accreditation of EIA consultant organization

222

LIST OF FIGURE


1.1 Location of the Project Site 33

2.1 General Location of the Project Site 44

2.2 Topographical Map (10 Km Radius) 45

2.3 Topographical Map (Digital) (10 Km Radius) 46

2.4 The Google Image of the Project Site 47

2.5 Project Site layout Plan 49

2.6 Material Balance 53

2.7 Water Balance Flow sheet 55

2.8 The Process Flow Diagram: Sponge Iron Plant 62

2.9 The Process Flow Diagram: Mild Steel 65

2.10 The Process Flow Diagram: TMT Bar & Section Mill 67

2.11 Process Flow Diagram: Power Plant 69

2.12 Process Flow Diagram: WHRB 70

2.13 ESP installed at Plant 72

3.1 Key Plan 77

3.2 Wind Rose Diagram 80

3.3 Location of AAQ Monitoring Station 82

3.4 Surface and Ground water sampling stations 90

3.5 Ground Water analysis comparative Graph 94

3.6 Surface Water analysis comparative Graph 95



3.7 Locations of Noise Level Monitoring 97

3.8 Noise Monitoring Results 99

3.9 Locations of Soil Sampling Locations 101

3.10 Satellite Image 105

3.11 Land Use / Land Cover Map of 10Km Radius 106

4.1 Predicted GLC of PM10 due to Proposed Plant (AERMOD ) 141

4.2 Predicted GLC of PM10 due to Existing + Proposed Plant (AERMOD 142

4.3 Predicted GLC of SO2 due to Proposed Plant (AERMOD) 143

4.4 Predicted GLC of SO2 due to Existing + Proposed Plant (AERMOD) 144

4.5 Drainage Map 150

10.1 Typical rainwater harvesting structure 208

10.2 Environment Management Cell 215

12.1 NABET Accreditation Certificate 225

12.2 Declaration of Experts 226



ANNEXURES

Sr. No ANNEXURE

I. Environmental Clearance Letter of Existing Unit

II. Certified Compliance of Environmental clearance

III. Consent to Operate letter (GPCB)

IV. TOR letter

V. Amendment in TOR

VI. Extension of TOR

VII. Land possession Document

VIII. Water sales Agreement

IX. (a) Baseline data (Air , Water and Noise) and comparison between 2018 and 2019

data set

IX (b) Baseline data (Air , Water and Noise) -2018

IX (c) Baseline data (Air , Water and Noise) -2016

IX (d) Met Data June 2019

X. Environment Policy

XI. Project Implementation Schedule-Bar chart

XII. Online stack monitoring data ( AFBC) and ETP data

XIII. Occupational Health Register Records

XIV. Details of CER amount spent to different Villages

XV. Public hearing proceeding and minutes

XVI. Social Impact Assessment Report

M/s Nilkanth Concast Pvt Ltd Executive Summary

PECS, Nagpur, Page | i

EXECUTIVE SUMMARY

1. Project Name and Location

M/s. Nilkanth Concast Private Limited (NCPL) is operating mini-steel plant at village Vadala in

Mundra Taluk, Kutch District in the state of Gujarat. At present, the steel plant is producing

1,80,000 Tonnes per Annum (TPA) of TMT Bars /Channels/ Angels. The steel plant has the

facilities Sponge Iron Plant (2x100 TPD), Induction Furnace (2x20T), Rolling and Section mill,

Captive power plant (10 MW) which include power generation based on Waste Heat Recovery

Boiler (WHRB) (6 MW) and AFBC (4 MW) in an area of 35.38 ha.

Map showing the location of the project site is given in the Figure below,

Specific Location of the Project Site


PECS, Nagpur, Page | ii

2. Products and Capacities

The existing plant was accorded Environmental Clearance (EC) by Ministry of Environment,

Forest and Climate Change (MoEF&CC) vide letter No. J-11011/85/2008 –IAII (I) dated

23.12.2008 (Annexure-I). The Project Proponent complied the conditions stipulated in the EC. In

this regard, six monthly compliance report has been submitted to Regional Office of MoEF&CC

at Bhopal. The recent certified compliance report was issued by Regional Office on 17.08.2018

and subsequent closure of non-compliances observed in the same was on 15.03.2019.

Further, the Consent to Operate was renewed by Gujarat State Pollution Control Board vide order

No.AWH-68553 dated 26.02.2015 and is valid up to 08.12.2019.

Now, the industry intends to expand the production capacity up to 3,60,000 TPA of TMT Bars

/Channels/ Angels. In view of this, all the corresponding facilities shall be increased accordingly

in the existing premises.

The land earmarked for the proposed expansion is 12.34 ha which is within the existing premises

of total land of 35.38 ha.

The proposed expansion activities attract the provisions of EIA Notification, 2006 and falling

under Category A of Schedule, 3 (a) Metallurgical Industries (Ferrous and Non-ferrous). Thus,

proposed expansion requires prior Environmental Clearance from MoEF&CC as per the

procedure laid down in the Notification.

The proponent made online application on 23.06.2015 along with Form-1, copy of pre-feasibility

report and other documents for proposing Terms of Reference (TORs) for undertaking detailed

EIA study. The proposal was appraised in the EAC (Industry-1) meeting held during 11th -12th

August 2015 and the committee recommended for prescribing ToRs for undertaking EIA study

for proposed expansion project. Accordingly, the Ministry prescribed ToRs vide letter J-

11011/85/2008 – IAII (I) dated 14.09.2015.

Subsequently, Project Proponent submitted a revised proposal vide online application on 3rd

March 2016 for seeking amendment in ToR letter dated 14.09.2015. The revised proposal was

considered in the EAC (Industry–1) meeting held during 30th -31st March 2016 and the

committee recommended to amend the ToRs for revised configuration as proposed with respect

to expansion of billet/ingots, TMT Bars/Channel /Angels and Power generation capacity.

Accordingly, the MoEF&CC issued an amendment to the ToRs vide letter dated 27th

May

2016.

M/s. Nilkanth Concast Private Limited has proposed to expand manufacturing of Sponge Iron

from 72000 TPA (2 Nos. of Kiln 100 MT/Day each) to 144,000 TPA (4 Nos. of Kiln 100

MT/Day each), Mild Steel, Ingots, Billets, MS Rolled Products, TMT Bars, Channel/Angle from


PECS, Nagpur, Page | iii

1,80,000 TPA (2X20T of Furnace & Rolling Mill) to 3,60,000 TPA (4X 20 T Induction Furnace,

Rolling & Section Mill), Captive Power Plant from 4 MW to 6 MW and Waste heat recovery

boiler based Power Plant from 6 MW to 10 MW.

Although, the application is been made on 365 days of operation, the actual operable days

for sponge iron and induction furnace can be only 330 days, keeping in mind the days for

scheduled outage and maintenance. Based on the actual operability the existing

production of 66000 TPA from two DRI kilns (2X100TPD) will enhance to 1,32,000

TPA with 4 DRI kilns (4X100TPD) after expansion. Similarly the rolled product

production will enhance to 3,00,000 TPA from 4X20T IF (12 H) and 2 stands of CCM.

The captive power generation will enhance from 4 to 6 MW by complete usage of

dolchar and coal (AFBC boiler) and 6 MW to 10 MW by WHRB.

However all environmental parameter used for assessment and evaluation of impacts

are based on TOR quantities rather than actual quantifications.

Raw Material Quantity (TPA)

Source Mode of

Transport

Distance

from

Project site Existing Proposed Total

1.) Sponge Iron

Iron Pellets 102240 102240 204480

Local ( Jindal

Limited,

Rajasthan)

Road 625 Km

Coal 64,800 64,800 129600 Imported/ kandla

port Sea / Road 35 Km

Dolomite 2160 2160 4320

Local (Dhreeeji

Dolomite,

Ahmedabad)

Road 275 Km

2) Mild Steel, Ingots, Billets, MS Rolled Products, TMT Bars, Section

Mild Steel, Ingots/Billets

Sponge Iron

Pellets 72,000 72,000 1,44,000 Inhouse Conveyor

00 Km

(Captive

Production)

Scrap Mild Steel 77430 77430 154860 Imported(Kandla

port) Road 35 Km

MS Rolled Products, TMT Bars, Section

Billets 1,80,000 1,80,000 3,60,000 -- --

00 Km

(Captive

Production)

3) Captive Power Plant

Coal 46,800 23,400 70,200 Imported

(Kandla Port) Road 35 Km


PECS, Nagpur, Page | iv

3. Requirement of Land, raw material, water, power, with source of supply

Requirement of Land

The Project of M/s. Nilkanth Concast Pvt. Ltd. is situated on the 35.38 Ha

(35,37,989 sq.m) free hold land at Survey No.221, Vill: Vadala, Taluka: Mundra,

Dist: Kutch, Gujarat.

Raw Material

The gross annual requirements of various raw materials of the plant with probable

source are given as follows:

Water Requirement

The total water requirement for the Plant along with proposed expansion including

domestic purpose is 1450 (1293 KLD fresh water and 157 KLD recycled water.)

Requirement of water shall be met from the Gujarat Water Infrastructure Limited

(GWIL). No ground water source is tapped.

Water is required in the plant mainly for the purpose of cooling and in boiler. Water is

also required for gardening, domestic and dust suppression. In order to minimize the

fresh water requirement, it is proposed to adopt recirculating system after proper

treatment. Waste water from boiler and cooling will be reused for coal dump cooling,

after proper treatment in ETP. So, the fresh water requirement will be minimized to

1293 KLD. By virtue of flow chart the optimization of water cycle is done to minimize

the water requirement.

Dolchar 5040 5040 10080 Imported

(Kandla Port) Road 35 km

4). DM Plant

Caustic Flake 24 TPA -- 24 TPA Local Road 20 Km

Sulphuric Acid 60 TPA -- 60 TPA Local Road 20 Km

Hydrochloric

Acid 36 TPA -- 36 TPA Local

Road 20 Km


PECS, Nagpur, Page | v

Water Requirement

Sr.

No.

Particular Daily Water

Requirement

Consumption/

System Loss

Wastewater

Generation

Mode of

utilization /

Disposal

1. Process

a Recycled 132 - - Recycle

b Fresh Make

up

1193

1104 221

Sub Total 1 1325 1104 221

2. Dust Suppression & Plantation

a Dust

Suppression

15 15

-

-

b Green belt &

Plantation

65 65 - -

Sub Total 2 80 80 --

-

a

Domestic 45 9 36 Packaged type

STP.

Sub Total 3 45 9 36

Grand Total

(1+2+3)

1450 1193 257* Zero Discharge

Power Requirement

Existing total Power requirement is 31.37 MW. The power requirement is met from CPP

& WHRB and from GETCO. For emergency power supply 1 x 500 kVA D.G. Set is

installed. After proposed expansion the power requirement shall be 60.13 MW.


PECS, Nagpur, Page | vi

Sr.

No. Plants Existing

Existing

Power

Consu

mption

Proposed Final

Configuration

Propose

d Total

Power

Consu

mption

1 DRI Unit 2x100TPD 1.18 4 x 100 TPD 2.36

2

Induction Furnace with

CCM 2 x 25 T 22.38 4x25T 44.76

3 Rolling Mill 2 x 20 T 4.36 4 x20 T 8.73

4

CPP (WHRB) Internal

Consumption 22MWH 2.07 29MWH 2.73

5

CPP (CFBC/AFBC)

Internal Consumption 4 MWH 0.35 6 MWH 0.52

6 Raw Material Handling

Through

Automated

process 1.03

1.03

Total 31.37 60.13

4. Process Description

Process Description: Sponge Iron

Coal based Direct Reduction Rotary Kiln Process:

The coal based direct reduction rotary kiln process was developed for converting iron

pellets directly into metallic iron without the melting of the materials. The process has

the advantage of low capital expenditure and no requirement of coking coal. The

metallic iron in this process is produced by the reduction of iron oxide below the fusion

temperature of iron ore (1535 0C) by utilizing carbonaceous material present in the non-

coking coal. As the iron ore is in direct contact with the reducing agent throughout the

reduction process, it is often termed as direct reduced iron (DRI). The reduced product

having high degree of metallization shows a „honeycomb structure‟, due to which it is

often called sponge iron.

Coal based DRI plants are flexible with respect to plant location since non-coking coal

is widely distributed in large deposits and is easy to transport. Most plants employ

reduction process which is carried out in rotary kilns. These plants use wide variety of

raw materials and non-coking coal. The quality of these materials has direct bearing on

the process as well as the product. Some plants do not use iron ore directly. These

plants use iron ore pellets in the rotary kiln. Raw material mix consisting of iron ore/


PECS, Nagpur, Page | vii

iron ore pellets, dolomite and non-coking coal is fed at the one end of the rotary kiln

and is heated by coal burners to produce DRI. The product DRI along with char

(dolchar) is taken out from the other end of the kiln. Apart from this, primary air and

secondary air are supplied to the kiln to initiate the combustion and sustain the reaction

process in the kiln.

The main raw materials for the production of DRI by the rotary kiln process are (i) Iron

pellets, (ii) non-coking coal, and (iii) dolomite in adequate proportion to scavenge the

sulphur.

Process:

This process utilizes non-coking coal as reducing agent along with lumpy grade iron ore/

iron ore pellets.

The reduction is carried out in an inclined horizontal rotary kiln, which rotates at a

predetermined speed. A temperature profile ranging from 8000

C to 10500

C is maintained

along the length of the kiln at different zones and as the material flows down due to

gravity the ore is reduced.

The hot reduced sponge iron along with semi-burnt coal, discharged from kiln is cooled in

water – cooled cylindrical rotary cooler to a temperature of 100 to 200 0

C.

The discharge from cooler consisting of sponge iron, char other contaminations are passed

on through magnetic separators so that sponge iron can be separated from other impurities.

Later the sponge iron is screened into two size fractions i.e. -3 mm & +3 mm, for further

utilization.

The Chemical Reactions involved during the process are as under.

CO2 + C= 2CO 3Fe2 O3 + CO= 2Fe3 O4 + CO2 Fe3 O4 + CO = 3 Fe O +CO2 Fe O +CO = Fe +CO2 C + H2O = CO+ H2 3Fe2 O3 + H2 = 2Fe3 O4+H2O Fe3 O4 + H2 = 3FeO +H2O Fe O+ H2 = Fe+H2O


PECS, Nagpur, Page | viii

Process Flow Diagram: Sponge Iron Plant

Mild Steel (Ingots, Billets, TM Bars & Channel/ Angles)

Induction Furnace:

Induction furnace is a type of electric melting furnace which uses electric current to

melt metal. The principle of induction melting is that a high voltage electrical source

from a primary coil induces a low voltage, high current in the metal (secondary coil).

Induction heating is simply a method of transfer of the heat energy.

Medium frequency induction furnaces which are commonly used for steelmaking use

the heat produced by eddy currents generated by a high frequency alternating field. The


PECS, Nagpur, Page | ix

inductor is usually made of copper in order to limit the electric losses. The inductor is

water cooled. The furnace consists of a crucible made of a suitable refractory material

surrounded by a water cooled copper coil. In this furnace type, the charge is melted by

heat generated from an electric arc. The coil carries the high frequency current. The

alternating magnetic field produced by the high frequency current induces powerful

eddy currents in the charge resulting in very fast heating.

Electrical energy needed for heating one ton of iron to 1500 0

C is 396 kWh. In furnace

several losses takes place which increases the specific energy consumption. The losses

consists of (i) thermal losses, (ii) furnace coil losses, (iii) capacitor bank losses, (iv)

convertor losses, and (v) losses on main side transformer. The higher the losses lower is

the furnace efficiency. Thermal losses contributes maximum towards loss of energy.

The major thermal losses are (i) radiation loss from furnace top, (ii) conduction losses

from refractory lining, (iii) heat losses in cooling water of the coil, and (iv) heat carried

by the removed slag.

During the making of a heat, the furnace is constantly losing heat both to the cooling

water and by radiation from the shell and the exposed metal surface. Electrical energy is

required to be spent to substitute this heat loss. Hence longer the heat time the greater is

the furnace inefficiency.

Process:

Scrap and sponge Iron charged to Induction furnace, which slowly melts above 15300C.

After melting the material and as required for the specific type of Mild steel

composition an addition of Silico manganese, Ferro Silicon, Aluminium, Carbon and

other chemicals shall be made. After chemical analysis of the product , the final metal

will be tapped to the ladle.

Casting Process CCM:


PECS, Nagpur, Page | x

Continuous casting (CC) is a method of producing an infinite solid strand from liquid

steel by continuously solidifying it as it moves through a CC machine. It is the

predominant process route in a modern steel plant which links steelmaking and hot

rolling.

The CC machines are normally named according to the strand dimensions such as billet,

bloom, and slab CC machines etc. There are also CC machines to cast rounds and other

shapes like beam blanks.

The main equipment of a CC machine constitute (i) ladle turret along with turret

weighing system and ladle cover manipulator, (ii) tundish and tundish car along with

tundish weighing system, tundish preheater and dryer, (iii) mould and mould oscillation

along with mould level control and electromagnetic stirrer, (iv) secondary cooling

consisting of strand cooling, strand containment and guiding, (v) withdrawal and

straightener, (vi) dummy bar, dummy bar parking and dummy bar disconnect roll unit,

(vii) pinch roll and torch cut off unit, (viii) Product identification system, and (ix)

Roller table and product discharge system.

Process:

Ladle liquid metal temperature adjustment done minimum (1620 to 1630°C) through

purging by Nitrogen gas to liquid metal. The Ladle goes to CCM then casting start same

time after made billets.


PECS, Nagpur, Page | xi

Process Flow Diagram: Mild Steel

TMT Bar & Section Mill (Channel/Angle)

Rolling Mill:

Steel rolling consists of passing the material, usually termed as rolling stock, between two

rolls driven at the same peripheral speed in opposite directions (i.e. one clockwise and the

second anti-clockwise) and so spaced that the distance between them is somewhat less than

the thickness of the section entering them. In these conditions, the rolls grip the material

and deliver it reduced in thickness, increased in length and probably somewhat increased in

width. This is one of the most widely used processes among all the metal working

processes, because of its higher productivity and lower operating cost. Rolling is able to

produce a product which is having constant cross section throughout its length. Many

shapes and sections are possible to roll by the steel rolling process.

Scrap, Sponge iron

Melting in Furnace at 1550 0C + Addition of Ferro Alloys + Maintaining of Temp. 1650 0C

Slag Removing

Tapping in Ladle at 1620 0C

Casting at CCM


PECS, Nagpur, Page | xii

Steel sections are generally rolled in several passes, whose number is determined by the

ratio of initial input material and final cross section of finished product. The cross section

area is reduced in each pass and form and the size of the stock gradually approach to the

desired profile. Rolling accounts for about 90 % of all materials produced by metal working

process.

When manufacturing long products, it is common to use a series of rolling stands in tandem

to obtain high production rates. The stands are grouped into roughing, intermediate and

finishing stages. Typical temperature, speed, inter-stand time (time between each stand),

true strain and strain rate ranges at each stage are shown in Tab 1. Since cross-sectional area

is reduced progressively at each set of rolls, the stock moves at different speeds at each

stage of the rolling mill. A wire rod rolling mill, for example, gradually reduces the cross-

sectional area of a starting billet (e.g., 150 mm square, 10-12 meters long) down to a

finished rod (as small as 5.0 mm in diameter, 1.93 km long) at high finishing speeds (up to

120 m/sec).

Process:

The Ingots obtained are then transferred to the Rolling/Section Mill section where there is

facility for charging of Hot Ingots incorporated in the process, gives rise to a significant

saving of fuel rating in reheating furnace as well as cutting down the total retention time,

thereby making an overall savings in the fuel rate per ton of ingots/billets.

The Mild Steel Rolled Products are then cut into required length and transferred to the

cooling bed.

From cooling bed these M.S. Rolled Products, if required are transferred to the

straightening machine and ultimately for Sorting, Packing and Dispatch. No gasifier will be

used in this process


PECS, Nagpur, Page | xiii

The Process Flow Diagram: TMT Bar & Section Mill

Captive Power Plant

Total 6 MW Electricity (Existing 4 MW + Proposed 2 MW) shall be produced from the

Captive Power Plant.

AFBC Boiler:

Process:

Coal is collected in coal bunker and insert in boiler through closed conveyor belt where

water is added through Deareator and economiser. The steam generated at Boiler is

passed through the Turbine attached to it. In turbine Generator, the steam is used to rotate

the coil in magnetic field to produce electricity. And exhaust gas is passed through ESP

and then go to atmosphere through stack. Fly ash is collected from dust collector and sell

to brick manufacturer.

Molten Metal from Induction Furnace & CCM

Rolling & Section Mill Process

TMT Bars, Channels/ Angles

Sorting, packing & Dispatch


PECS, Nagpur, Page | xiv

Process Flow Diagram: Power Plant

Waste Heat Recovery Boiler

Waste Heat Recovery boilers are designed to recover heat from waste flue gases from

Furnace exhaust, Kiln exhaust, incinerator exhaust etc. to produce steam or hot water

based on the application requirements of the plant. The amount of steam generators or

Steam Boilers of heat transfer is controlled by the quantity of heat available in the flue

gases.

Waste Heat Recovery Boilers (WHRB) Benefits:

Highly Reliable in operation and robust in construction.

Quick Payback Returns are achieved.

Dolchar


PECS, Nagpur, Page | xv

One time investment with lifetime returns.

No combustion, No emission hence Eco-friendly.

Energy being put to use, which was getting wasted anyway.

Process:

Waste heat from kiln is utilized for heating the iron pellets in pre heater kiln. Thus

temperature of Iron pellets will go up to 600oC prior to entering the kiln, which leads to

decrease in coal consumption and further reduction into coal char generation. The waste

heat generated in the rotary kiln is coming to burning chamber and then pass to waste

heat recovery boiler and power is generated. Hence heat is utilized for the power

generation in the existing unit and exhuast gases is passed through ESP and then go to

atmosphere through stack.

Process Flow Diagram: WHRB

5. Mitigation Measures

Air Pollution

There will be two major source of air pollution in the plant, fugitive emission from

various dry material handling & transfer points and from flue gases generated from the


PECS, Nagpur, Page | xvi

Sponge Iron and Induction Furnaces. The main process includes raw materials storage,

Grinding & screening, Transfer of material and product storage and transportation.

All the pollution control equipment installed and commissioned for Existing facilities and

Pollution Control Equipment proposed for Expansion Project

Proper Dust Suppression is proposed in stock yard of Iron pellets, coal yard etc.,

sprinkling on internal roads, regular checkup & maintenance of vehicles,

It will be ensured that all trucks/dumper caring raw material covered by Tarpaulin.

Water Pollution

Water is required in the plant mainly for the purpose of equipment cooling, steam

generation and Dust suppuration, Water is also required for drinking, sanitary, Green Belt

Development and fire-fighting purpose.

In order to conserve water and minimize the makeup water requirement, it is proposed to

adopt re-circulating systems for equipment cooling. In re-circulating system same water

re-circulates again and again and some make up water is added for evaporation losses.

The outflow from toilets of the plant buildings shall be led to various septic tanks in

respective areas through separate drains and the run-off from them will be connected to

packed type STP.

Out of the Fresh water requirement of 1450 KLD for the existing as well as proposed

plants only 257 KLD waste water will be generated and 157 KLD will be recirculated.

Thus there shall be “Zero” discharge of the untreated effluent.

Waste Water Treatment and Disposal

Sl.

No

Type of Waste

Water

Quantity

(In KLD) Treatment / Disposal Methodology

1 Domestic 36.0 25 KLD wastewater will be treated in STP.

2 Cooling Tower

Blow Down 170 132 KLD wastewater will be re-circulated

in process 3 Boiler 51.0

Total 257.0



PECS, Nagpur, Page | xvii

Noise Pollution

Many operations in the Sponge Iron Plant, CPP, Induction Furnaces & Rolling

Mill produce objectionable level of noise which may not be practicable to

eliminate entirely.

Noise from compressor, fans, centrifugal pumps, electrical motors etc. will be

kept in control so that the ambient noise level shall not exceed 75 dB (A) during

day time & 70 dB (A) during night time. Noise pollution control measures will

be provided in respective departments by way of providing silencers, soundproof

cubicle / covers & proper selection of less noise prone machinery and by

development of green belt.

In some areas where due to technological process, it is not feasible to bring

down the noise level within acceptable limits, personnel working in these

areas are provided with noise reduction aid such as ear muffler and also

the duration of exposure of the personnel are limited as per the norms.

Green Belt Development

The plantation and green belt development will also be taken care in the plant

and the space reserved for plantation will be more than 33% of the total plant

area. Out of the total land of 35.38 Ha (35,37,989 sqm) Ha. Nilkanth Concast

Pvt Ltd has earmarked 11.73 Ha (1,17,334 sqm) of land for development of

green belt.

Every year tree plantation is undertaken in a planned manner on a massive scale.

Most of them including species having capability of pollution control and some

of them are capable to survive in high saline conditions & low fertile soil. Soil

management is also the part of us for better use of soil within the plant premises

and out-sides as well. Extensive Plantation & grassing has been carried out to

check the erosion from various plant activities. Concast Pvt Ltd has already

planted 13,800 trees in its plant area. The detailed layout of the plant has been

prepared with indicative area of plantation for the whole plant.


PECS, Nagpur, Page | xviii

Solid waste Management

The major solid wastes for existing as well as Proposed Project are ESP and Bag

filter collected dust, Slag from steel making, Ash from CPP and Coal Char /

Dolochar from Sponge Iron Production. The details are given below

Solid Waste Utilization Plan

S. No. Solid Waste Source Quantity

TPA Utilization

1. ESP and Bag

filter dust

Sponge Iron

Plant,Material

handling plant , IF

14,400

Shall be used in Brick

Manufacturing and Briquette

Manufacturing.

2. Ash CPP 4,914 Shall be used in Brick

Manufacturing.

3. Slag Induction Furnaces 26,460 Shall be used in Road

embankment.

4. Coal Char/

Dolo Char Sponge Iron Plant 10,080

Shall be used in CPP (AFBC)

along with fresh coal

5. Mill Scale Rolling Mill 1260 Re-Utilized in Induction Furnace

6. Metal Scrap Billet Caster 18000 Re-Utilized in Induction Furnace

Hazardous Waste Inventory

S. No. Hazardous

Waste Quantity Utilization

1. Used oil 36 KL/annum Store separately and will be sold to

authorized vendors/recyclers

2. Used Cotton 24 Kg/annum Store separately and will be sold to


3. DM spent resins 7.2 Kg/ annum Store separately and will be sold to


6. Capital Cost

Total Project cost for proposed up-gradation is Rs. 60 Cr.

7. Site Selected for the Project


PECS, Nagpur, Page | xix

The total land is 35.38 Ha (35, 37,989 sqm) free hold land at Survey No.221,

Vill: Vadala, Taluka: Mundra, Dist: Kutch, Gujarat .

8. Baseline Environmental Data

The proposal was earlier considered by the EAC in 36th meeting held during 9-10th October,

2018. The EAC opined that the EIA report was not as per the generic structure prescribed and

hence needed to modified, with fresh baseline data collected during the period Oct-Dec 2018.

Further the Proposal was considered by the EAC in 7th meeting of the Re-constituted EAC

(Industry-I) held during 29-31st May, 2019. Project Proponent withdrew the proposal and

requested the Ministry to consider the proposal after submission of the revised EIA report with

additional one-month baseline data by them. In view of this, Baseline monitoring for additional

one months has been carried out in the month of June 2019.

Air Environment

The baseline environmental quality for the June 2019 was assessed in an area of 10 km radius

around the proposed project site.

The ambient air quality monitored at 8 locations selected based on predominant wind

direction, indicated the following ranges;

PM10 - 59 μg/m3 – 90.0 μg/m

3

PM2.5 - 22.0 μg/m3 – 42 μg/m

3

SO2 - 11 μg/m3

– 25 μg/m3

NOx - 13 μg/m3

– 28 μg/m3

The concentrations of PM10, PM2.5, SO2 and NOx were found within the National

Ambient Air Quality Standards (NAAQ).

Water Environment

A total 8 samples including two surface & eight ground water samples were collected and

analyzed. The water samples were analyzed as per Standard Methods for Analysis of Water and

Wastewater, American Public Health Association (APHA) Publication.

The data indicates that the ground water as well as the surface water quality are below the

stipulated standard for drinking water (IS 10500 – 2012).


PECS, Nagpur, Page | xx

Noise Environment

Noise levels measured nine stations are within limit of 55.0 dB (A) for Residential Area or 75.0

dB (A) for Industrial Area as given in MoEF Gazette notification for National Ambient Noise

Level Standard.

Land Environment

The characteristics of the soil sample were compared with different depths for respective

parameters in three stations. The soil analysis report indicates that the soil in the area are

capable of supporting plant growth.

9. Impact of the Project

The impacts of the projects are tabulated below:-

S.N. Impact Topics Impact On Impact Due to Adopted Measures

1. Physical Resources

Air Environment

Release of air pollutants

Incorporation & installation of air pollution control systems and ensuring their effective functioning.

Water Environment

Use of water and release of polluted waste water

Maximum recirculation of water and Incorporation & installation of water pollution control systems and ensuring their effective functioning.

Soil Release of polluted waste water, Deposition of PM released & Dumping of solid waste

Incorporation & installation of water and air pollution control systems, Handling & disposal of solid waste including hazardous waste in accordance with statutory norms.

2 Biological Resources

Vegetation Release of polluted wastewater, Deposition of pollutants released.

Incorporation & installation of water and air pollution control systems

3. Land Acquisition Land environment,

Conversion of existing

The total land requirement for the


PECS, Nagpur, Page | xxi

Aesthetics land use pattern project is 35.38 Ha in possession and in industrial use

4. Noise Habitats Use of equipment having operating sound level more than the statutory level.

Noise Control measures as required have been envisaged. All noise levels will be maintained within the permissible statutory limits.

5. Solid Waste Habitats and Surrounding environment

Release of toxic chemicals

Reuse and minimization of solid waste

6. Transportation Habitats and Surrounding environment

Release of pollutant, Improper traffic management.

Use of vehicles meeting the statutory norms related to emission, transport by railway, proper traffic management

7. Social & Economic

Human, livelihood, Education etc

Influx of people, Settlement, Stress on existing infrastructure etc.

No negative impact envisaged. Moreover additional social improvement activities have also been planned by the project management in the region.

8. Cultural resources

Human Influx of people, Settlement

No negative impact envisaged

10. Issue Raised During Public Hearing

11. The public hearing for the expansion project of M/s Nilkanth Concast Pvt Ltd was

conducted in the existing premises of the project on 20th December 2016 as per EIA

Notification 2006 for proposed expansion of Sponge Iron (2 no.of kilns), Billet /Ingots (2

no.of Furnace), TMT Bars /Channels/Angels (Rolling Mill and Section Mill), CPP (2

MW) and Waste Heat Recovery Boiler (4 MW). Public Hearing meeting was presided

by Resident Additional Collector and Additional District Magistrate, Bhuj – Kutch,

Gujarat. The Regional Officer of Gujarat Pollution Control Board stated that there were

two written representations received before Public Hearing. The issue raised at the time

of public hearing is associted with the employment and greenbelt development in nearby

villages. All the issues were considered and will be taken care off by NCPL. Details are

given in the final EIA report.


PECS, Nagpur, Page | xxii

12. CER Plan

As per the Notification dated 1.05.2018 issued by MOEF&CC, it is mandatory to prepare

Corporate Environment Responsibility Plan (CER) to spend 1 % (project cost ≤ 100 crore) of

total capital cost of the project on social, economical and peripheral development activities. As

per the above mentioned new office memorandum CER dated 1.05.2018. Rs. 67.5 lacs will be

allocated for CER based on public hearing issues and requirement of the local people. Various

activities such as construction of toilets, Grass Distribution, Drinking Water Pipeline

construction, construction of Modern Class Room for the youth of Village Vovar, Tree Plantation

etc. are carried out under CSR. Details are given in the final EIA report.

13. Occupational Health Measures

M/s. Nilkanth Concast Private Limited is being provided all necessary provisions under

Factory Act. All personal protect equipment like Safety shoes, helmet & uniform are

issued to each employee based on the nature of job involved. The regular health check-up

are being carried out Details are given in the EIA report.

14. Post Project Environment Monitoring Plan

Regular monitoring of important and crucial environmental parameters is of immense

importance to assess the status of environment during plant operation. With the

knowledge of baseline conditions, the monitoring programme can serve as an indicator

for any deterioration in environmental quality due to operation of the plant so as suitable

mitigation steps could be taken in time to safeguard the environment. Monitoring is as

important as that of control of pollution since the efficiency of control measures can only

be determined by monitoring. The following routine monitoring programme would

therefore be implemented by M/s. Nilkanth Concast Private Limited. The monitoring

schedule for the environmental parameters is suggested in following Table

Sr.

No.

Particulars Monitoring

Frequency

Method of

Sampling

Parameter

I Air Pollution & Meteorology

A Stack Monitoring

1 Stacks Continuous Online PM10 , PM2.5, SO2,


PECS, Nagpur, Page | xxiii

Sr.

No.


Frequency

Method of

Sampling

Parameter

CEMS NOx

B Air Quality Monitoring

1 Locations in and

around the plant

Continuous 24 hr

continuously

PM10, PM2.5 ,

SO2, NOx

2 Work zone monitoring Twice in a month High volume

sampler

PM10, PM2.5 ,

SO2, NOx

C Fugitive Emissions

Raw material handling,

feed area, and other

areas specified by SPCB

Twice in a month 8-hour basis with

High Volume

Sampler

PM10 , PM2.5

II Water and Wastewater Quality

Water Quality

1

Ground water

Once in a season Grab (Class C) and

IS:10500, 1986

2 Surface water Once in a season Grab Parameters

specified in

IS:2296

III Ambient Noise Levels

1

On the Plant Boundary

at three locations

Once in three months

for the various Units of

the plant

24 hr continuous

with one hr

interval

Noise levels in

dB(A)

2. Surrounding Area Once in each season

for ambient noise

levels

24 hr continuous

with one hr

interval

Noise levels in

dB(A)

IV Soil Quality


PECS, Nagpur, Page | xxiv

Sr.

No.


Frequency

Method of

Sampling

Parameter

In and around the plant

Area

Once in Pre-Monsoon

and Post Monsoon

season

Grab Physico-chemical

parameters and

heavy metals



CHAPTER 1

INTRODUCTION

1.0 INTRODUCTION

M/s. Nilkanth Concast Private Limited (NCPL) is operating mini-steel plant at

village Vadala in Mundra Taluk, Kutch District in the state of Gujarat. At present,

the steel plant is producing 1,80,000 Tonnes per Annum (TPA) of TMT Bars

/Channels/ Angels.

The steel plant has the facilities Sponge Iron Plant (2x100 TPD), Induction Furnace

(2x20T), Rolling and Section mill, Captive power plant (10 MW) which include

power generation based on Waste Heat Recovery Boiler (WHRB) (6 MW) and

AFBC (4 MW) in an area of 35.38 ha.

The existing plant was accorded Environmental Clearance (EC) by Ministry of

Environment, Forest and Climate Change (MoEF&CC) vide letter No.

J-11011/85/2008 –IAII (I) dated 23.12.2008 (Annexure-I). The Project Proponent

complied the conditions stipulated in the EC. In this regard, six monthly

compliance report has been submitted to Regional Office of MoEF&CC at Bhopal.

The recent certified compliance report was issued by Regional Office on

17.08.2018 and subsequent closure of non-compliances observed in the same was

on 15.03.2019. (Annexure-II).

Further, the Consent to Operate was renewed by Gujarat State Pollution Control

Board vide order No.AWH-68553 dated 26.02.2015 and is valid up to 08.12.2019.

(Annexure-III).

Now, the industry intends to expand the production capacity up to 3,60,000 TPA of

TMT Bars /Channels/ Angels. In view of this, all the corresponding facilities shall

be increased accordingly in the existing premises.

The land earmarked for the proposed expansion is 12.34 ha which is within the

existing premises out of total land of 35.38 ha.



1.1 PURPOSE OF THE REPORT

The proposed expansion activities attract the provisions of EIA Notification, 2006

and falling under Category A of Schedule, 3 (a) Metallurgical Industries (Ferrous

and Non-ferrous). Thus, proposed expansion requires prior Environmental

Clearance from MoEF&CC as per the procedure laid down in the Notification.

The proponent made online application on 23.06.2015 along with Form-1, copy of

pre-feasibility report and other documents for proposing Terms of Reference

(TORs) for undertaking detailed EIA study. The proposal was appraised in the

EAC (Industry-1) meeting held during 11th

-12th

August 2015 and the committee

recommended for prescribing ToRs for undertaking EIA study for proposed

expansion project. Accordingly, the Ministry prescribed ToRs vide letter J -

11011/85/2008 – IAII (I) dated 14.09.2015. (Annexure-IV)

Subsequently, Project Proponent submitted a revised proposal vide online

application on 3rd

March 2016 for seeking amendment in ToR letter dated

14.09.2015. The revised proposal was considered in the EAC (Industry–1)

meeting held during 30th

-31st

March 2016 and the committee recommended to

amend the ToRs for revised configuration as proposed with respect to expansion

of billet/ingots, TMT Bars/Channel /Angels and Power generation capacity.

Accordingly, the MoEF&CC issued an amendment to the ToRs vide letter dated

27th

May 2016. (Annexure-V).

Public Hearing for the project was conducted on 20th

December, 2016. The Project

Proponent made online application for EC vide proposal

No.IA/GJ/IND/28721/2015 dated 7th

September 2018 along with Form -2, EIA

report, and other documents. The proposal was considered in the EAC (Industry-

1) meeting held during 9th

-10th

October 2018. The committee returned the

proposal in the present form as the EIA report was not in generic structure and

some non-compliances reported in the report of Regional Officer. Further, the

committee informed the Project Proponent to revised EIA report as per generic

structure specified in the EIA Notification, 2006 interalia including addressing

the Terms of Reference prescribed for project and closure of non-compliances of

earlier EC conditions duly certified by Regional Officer.



In the meanwhile, validity of the prescribed ToRs was expired on 13.09.2019.

Therefore, the Project Proponent made online application vide proposal No.

IA/GJ/IND/28721/2015 dated 30th

January 2019 for seeking extension of validity

of ToRs. The proposal was considered in the EAC (Industry-1) meeting held

during 20th

-22nd

February 2019 and was recommended to extend the ToRs for a

period of one year. Thus, the validity of ToRs was extended up to 13th

September,

2019 vide letter dated 01.05.2019. (Annexure-VI)

The revised EIA report was prepared using the baseline data generated during

October -December 2018. The Project Proponent made online application vide

proposal No. IA/GJ/IND/28721/2015 on 15th

May 2019. The proposal was

considered in the EAC (Industry-1) meeting held during 29th

-31st

May 2019.

However, the proposal was withdrawn by the Project Proponent and informed that

the proposal shall be resubmitted after including additional one-month baseline

data in the EIA report for further validation.

The Project Proponent changed the consultant, M/s Aqua Air Environmental

Engineers Pvt Ltd, Surat and now, appointed M/s Pollution and Ecology Control

Services (PECS), Nagpur to take up the EC process further.

Thus, this EIA report was prepared by PECS based on the one season baseline

data generated during October- December 2018 and validating the same with on-

month data generated during 1st

June – 30th

June 2019.

1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT [TOR 2.2]

1.2.1 The Company

Nilkanth Group is one of the largest manufacturers of international quality steel bars in

India as per IS: 1786-1985. Nilkanth ConcastPvt Ltd, the flagship company of the

group has the prestigious ISO 9001:2000 certification, manufacturing “Nilkanth TMT”.

Nilkanth ConcastPvt Ltd. is the first steel plant set up in Gujarat to start production of

TMT Bars from Billets. Their hard working and dedicated approach have helped them

to emerge as one of the major manufacturers in the industry. The Company is lead by

energetic Director with vast knowledge of steel industry and is well supported by their

qualified staff and experienced labor. The production plant is equipped with modern



production equipment, testing and quality assurance facilities and employs a dedicated

team to ensure quality products to the discerning buyer.

1.2.2 Project Proponent

Name and Address of project proponent:

Name of the Unit Nilkanth ConcastPvt Ltd,

Date of Incorporation 21.08.2003

Regd. Office Plot. No. 403, Ward 6/C, Opposite Om Cineplex,

Adipur, Kutch, Gujarat – 370205.

Plant Location At Survey No.221, Vill: Vadala, Taluka: Mundra,


Address and

correspondence:

At Survey No.221, Vill: Vadala, Taluka: Mundra,


Contact Person Mr. Suresh Sarbhaliya, Vice President

E-mail [email protected]

Tel No. 02838-283494

Fax No. 02838-283488

Board of Directors:

Presently following are the directors of the company: -

Mr. Chandrashekhar N Ayachi

Mrs. Girija C Ayachi

1.3 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE PROJECT AND ITS

IMPORTANCE TO THE COUNTRY, REGION

1.3.1 Nature of the Project

The Existing and proposed project is manufacturing of Sponge Iron, Mild Steel (Ingots,

Billets, Rolled Products: TM Bars, Channel, Angles), Captive Power Plant & WHRB –

Power Plant at Survey No. 221, Village: Vadala, Taluka: Mundra, District: Kutch,

Gujarat. As per the Environmental Impact Assessment (EIA) Notification dated



14th

September, 2006, Metallurgical Industries (Ferrous & Non-Ferrous) falls under

category „A‟ which requires Environmental Clearance (EC) to be obtained from

MoEF&CC before the commencement of ground activity.

M/s. Nilkanth Concast Private Limited now has proposed to expand manufacturing of

Sponge Iron from 72,000 TPA (2 Nos. of Kiln -100 MT/Day each) to 1,44,000 TPA (4

Nos. of Kiln -100 MT/Day each), Mild Steel, Ingots, Billets, MS Rolled Products, TMT

Bars, Channel/Angle from 1,80,000 TPA (2 Nos. of 20 T capacity of induction

Furnaces, Rolling & Section Mill) to 3,60,000 TPA (4 Nos. of 20 T capacity induction

Furnaces, Rolling & Section Mill), Captive Power Plant from 4 MW to 6 MW and

Waste heat recovery boiler- Power Plant from 6 MW to 10 MW.

Although, the application is been made on 365 days of operation, the actual operable

days for sponge iron and induction furnace can be only 330 days, keeping in mind the

days for scheduled outage and maintenance. Based on the actual operability the

existing production of 66000 TPA from two DRI kilns (2X100TPD) will enhance to

1,32,000 TPA with 4 DRI kilns (4X100TPD) after expansion. Similarly the rolled

product production will enhance to 3,00,000 TPA from 4X20T IF (12 H) and 2 stands

of CCM. The captive power generation will enhance from 4 to 6 MW by complete usage

of dolchar and coal (AFBC boiler) and 6 MW to 10 MW by WHRB.



1.3.2 Size of the Project

The Existing and the proposed activities are as under:

Sr.No. Product Existing

Capacity

(TPA)

ToR obtained

for additional

capacity

(TPA) (14th

September

2015)

ToR

Amendment

requested for

additional

capacity

(TPA) (27th

may 2016)

Total

Capacity after

Proposed

Expansion

(TPA)

1 Sponge Iron 72,000 (2kiln:

100 TPD each)

72,000 (2kiln:

100 TPD each --

1,44,000 (4

kiln: 100 TPD

each

2

Mild Steel

(Ingots, Billets,

TM Bars &

Channel/

Angles)

1,80,000

(2 Induction

Furnaces 20 T

capacity each

& Rolling

mill)

--

1,80,000

(2 Induction

Furnaces 20 T

capacity each,

Rolling &

section mill)

3,60,000

(4 Induction

Furnaces 20 T

capacity each,

Rolling &

section mill)

3

Captive Power

Plant 4 MW -- 2MW 6 MW

4

Waste Heat

Recovery

Boiler

(WHRB)-

Power Plant

6 MW -- 4 MW 10 MW

1.3.3 Location of the Project

The Existing and proposed project activities are at Survey No. 221, Village: Vadala,

Taluka: Mundra, District: Kutch, Gujarat.



The General Location of the project is shown in Figure 1.1, and details of the Project site

are presented in Table 1.1.

Source: mapsofindia.com

Figure 1.1: Location of the Project Site



TABLE 1.1: DETAILS OF THE PROJECT SITE

Sr. No. Particulars Details

1 Project Site Survey No.221, Vill: Vadala, Taluka: Mundra,


2 Latitude & Longitude

A- 22°54'12.72"N, 69°52'13.91"E

B- 22°54'27.66"N, 69°52'11.59"E

C- 22°54'29.54"N, 69°52'25.79"E

D- 22°54'32.58"N, 69°52'25.18"E

E- 22°54'36.73"N, 69°52'42.48"E

F- 22°54'33.34"N, 69°52'44.40"E

G- 22°54'23.89"N, 69°52'36.90"E

H- 22°54'16.98"N, 69°52'38.73"E

I- 22°54'16.55"N, 69°52'36.03"E

J- 22°54'18.67"N, 69°52'34.80"E

K- 22°54'16.16"N, 69°52'17.77"E

L- 22°54'10.33"N, 69°52'18.33"E

3 Elevation above MSL 15 m

4 Toposheet 42 F/13

5 Present land use Industrial Use

6 Nearest National Highway/State

Highway

NH 41 : 7.5 km NW

7 Nearest Airport/ Air Strip Kandla Airport: 32.0 Kms NE

8 Nearest Village/ Town Vadala : 1.5 Kms

9 Forest Bhadreshwar Reserved Forest – 2.5 km S

Luna Reserved Forest – 4.0 km SSW

10 Ecologically Sensitive Zones like wild life

sanctuaries, national parks and

biospheres

No National Parks, Sanctuaries within 10 km

Area

11 Water Bodies

Mitti Nadi – 0.5 km NE

Sakra Nadi – 1.5 km E

Chhela Nadi – 6.5 km E

Ruparel Nadi – 6.5 km NE

Bay of Kutch – 4.0 km S



1.3.4 Project’s Importance to the Country/ Region. [TOR 2.3]

Their products are major strength of their customers. Each stage of their product will be

monitored / checked for their quality to ensure quality product reaches their customer. It

is planned to launch new products every year to satisfy the need of their customers as per

the market demand. Proposed expansion in production of sponge Iron has got good

potential in the market. The proposed expansion project is forward and backward

integration project. Sponge iron will be used as raw material for production of billets

whereas billets will be used as raw material for production of TMT bars. Captive Power

plant will be installed to meet the demand of electricity. In order to meet the inhouse

demand of raw material for billets and TMT bars and also to meet the market requirement

in timely manner, the proposed expansion project is undertaken.

Iron, Steel, alloy, is widely used for industrial purpose, infrastructure purpose, domestic

purpose and agricultural purpose, Per capita steel, iron, alloy consumption is a major

indicator of economic status of country. Hence, Strategy of the company is necessary in

planning the development of the still industry in the country to improve the level of per

capita still consumption.

Proposed expansion project will generate 150 Nos. of employment. And priority will be

given to local employment. The infrastructural and social amenities grow in the region

leading to development of the region.

1.4 SCOPE OF THE EIA STUDY

The study area covers the area around the project site, which is falling 10 km distance

from the boundary of the project. Literature review and collection of relevant data and

Terms of Reference (ToR) issued by EAC.

Establishing the baseline environmental status of the study area of 10 km radius for

Meteorology, Ambient Air, Water (Surface & Ground), Noise, Traffic, Soil, Socio-

economic, Ecology etc.;

The project activity through modeling and establishing the Incremental Ground Level

Concentrations (GLC);



Preparation of EMP outlining the measures for mitigating the impacts for various

attributes like air, water, noise, soil, etc. and scope for future expansions for

environmentally sustainable development; and

Identification of critical environmental attributes required to be monitored during the

operations. Designing the post-monitoring plan for the project.

The TOR was prescribed for undertaking detailed EIA-EMP study in addition to generic

TOR vide Letter No. J-11011/85/2008-IA.II(I) Dated: 14th

September, 2015. And the

Amendment for additional capacities vide letter of even No dated 27/05/ 2016.

The Public Hearing was conducted on 20.12.2016 at 11:00 am at Project Site of

M/s. Nilkanth Concast Private Ltd. at Survey N0. 221, Village: Vadala, Taluka: Mundra,

Distt: Kutch, Gujarat.

Further the validity of ToR was extended by the Ministry vide letter No.

J-11011/85/2008-IA.II(I) Dated: 01.05.2019 valid up to 13.09.2019.

Specific TOR issued by the EAC and the generic TOR annexed is followed for

formulating EIA

The current site conditions are taken as the baseline conditions for the completion of the

EIA and Base Line data monitoring carried out during Oct-Dec 2018 and One Month

data carried out during from 1st June 2019 to 30

th June 2019, is considered in this

revised EIA report.

Earlier the report was prepared and presented by M/s. Aqua-Air Environmental

Engineers P. Ltd., Surat – 395002. Now, M/s. Nilkanth Concast Private Limited

appointed M/s. Pollution and Ecology Control Services, Nagpur to revise the EIA report

along with one-month fresh baseline data and to present the case to Honorable EAC

(Industry -I), MoEF&CC, New Delhi, for further consideration.

1.5 CONTENTS OF THE REPORT

This EIA/EMP report is completed as per the Environmental Code and includes the

following chapters:



Chapter 1: Introduction- Provides a background to the proposed project, the project

proponent, and the process of environmental impact assessment.

Chapter 2: The Project Description- Describes the characteristics of the proposed plant,

the processes, location details and operations associated with the construction of the

proposed project.

Chapter 3: Baseline Environmental Status- Describes the background environmental

characteristics and the other economic activities in the area.

Chapter 4: Anticipated Environmental Impacts and Mitigation Measures- The major

impacts both adverse and positive are predicted and the consequent mitigation measures

are provided in this chapter. The impacts are identified with respect to the present

environmental baseline conditions.

Chapter 5: Analysis of Alternatives for Technology and Site - The technology and

project site alternatives are discussed in the chapter five.

Chapter 6: Environmental Monitoring Program- The monitoring to be carried out in

the construction and operation phases will be described in detail along with the frequency

and sampling locations.

Chapter 7: Additional studies - Chapter seven describes various additional studies

carried out for the project. Various risks associated during operational stage of the project

are assessed in this chapter. A disaster management plan to minimize the risks or to

combat the associated risks is also presented.

Chapter 8: Project Benefits - Chapter eight describes various benefits of the project to

the community in the vicinity and as well as to the region on the whole. Activities for

Corporate Environment Responsibility (CER) are delineatedin depth.

Chapter 9: Environmental Cost Benefit Analysis- This chapter includes Project cost,

Cost of Pollution Control facilities and Project Implementation Schedule.



Chapter 10: Environment Management Plan - Chapter ten describes the institutional

arrangements for environmental protection and Conservation during the operational stage

of the Project and the management strategy for the project.

Chapter 11: Summary and Conclusion - The summary of the EIA report has been given

in this chapter along with conclusions. It is an effort to present the EIA report in the form

of a chapter. It will be easy for a reader to cover the whole report by studying this chapter.

Chapter 12: Disclosure of Consultants -Brief introduction of the consultancy

organization involved in EIA report is given in this chapter.

1.6 SITE PHOTOGRAPHS [TOR 4.6]



@@@@



CHAPTER 2

PROJECT DESCRIPTION

2.1 TYPE OF PROJECT

The Existing and Proposed Expansion Project is manufacturing of Sponge Iron,

Mild Steel (Ingots, Billets, Rolled Products: TM Bars, Channel, Angles), Captive

Power Plant & WHRB – Power Plant at Survey No. 221, Village: Vadala, Taluka:

Mundra, District: Kutch, Gujarat. As per the Environmental Impact Assessment

(EIA) Notification dated 14th

September, 2006, Metallurgical Industries (Ferrous

& Non Ferrous) falls under category „A‟ which requires Environmental Clearance

(EC) to be obtained from MoEF&CC before the commencement of ground activity.

The Environmental Clearance for the existing facility was obtained from

MoEF&CCvide Letter No. J-1101/85/2008- IA II (I) dated 23.12.2008.

Initially GPCB has granted Consent to Establish (CTE) vide letter No.

PC/NOC/CCA-KUTCH-446(2)/GPCB ID No.17970/23706 dated 26-10-2009.

Consent to Operate (CTO) was obtained vide order No-AWH-36653 vide letter No.

PC/CCA-KUTCH-446/GPCB ID:17970/47743 dated 30-03-2010 was valid up to

06-12-2014. Renewal of Consent to Operate (CTO) is obtained vide order No-

AWH-68553 issued on 26-02-2015 and is valid up to 08-12-2019.

M/s. Nilkanth Concast Private Limited has proposed to expand manufacturing of

Sponge Iron from 72000 TPA (2 Nos. of Kiln 100 MT/Day each) to 144,000 TPA

(4 Nos. of Kiln 100 MT/Day each), Mild Steel, Ingots, Billets, MS Rolled

Products, TMT Bars, Channel/Angle from 1,80,000 TPA (2X20T of Furnace &

Rolling Mill) to 3,60,000 TPA (4X 20 T Induction Furnace, Rolling & Section

Mill), Captive Power Plant from 4 MW to 6 MW and Waste heat recovery boiler

based Power Plant from 6 MW to 10 MW.

Although, the application is been made on 365 days of operation, the actual operable

days for sponge iron and induction furnace can be only 330 days, keeping in mind the

days for scheduled outage and maintenance. Based on the actual operability the



existing production of 66000 TPA from two DRI kilns (2X100TPD) will enhance to

1,32,000 TPA with 4 DRI kilns (4X100TPD) after expansion. Similarly the rolled

product production will enhance to 3,00,000 TPA from 4X20T IF (12 H) and 2 stands

of CCM. The captive power generation will enhance from 4 to 6 MW by complete usage

of dolchar and coal (AFBC boiler) and 6 MW to 10 MW by WHRB.

However all environmental parameter used for assessment and evaluation of

impacts are based on TOR quantities rather than actual quantifications.

The Existing and the proposed configuration with production capacities are as

under:

Sr.No Product Existing

Capacity

(TPA)

ToR obtained

for additional

capacity (TPA)

(14th

September

2015)

ToR

Amendment

requested for

additional

capacity

(TPA)

(27th

may

2016)

Total Capacity

after Proposed

Expansion

(TPA)

1 Sponge Iron

72,000

(2 kiln: 100

TPD each)

72,000

(2 kiln: 100

TPD each

--

1,44,000

(4 kiln: 100

TPD each

2

Mild Steel

(Ingot,

Billets, TM

Bars &

Channel/

Angles)

1,80,000

(2 Nos of

Induction

Furnaces of

20 T

capacity

each &

Rolling mill)

--

1,80,000

(2 Nos of

Induction

Furnaces of

20 T capacity

each, Rolling

& section mill)

3,60,000

(4 Nos of

Induction

Furnaces of

20 T capacity

each, Rolling

& section mill)

3 Captive

Power Plant 4 MW -- 2MW 6 MW

4

Waste Heat

Recovery

Boiler

(WHRB)

based -

Power Plant

6 MW -- 4 MW 10 MW



2.2 NEED OF PROJECT

In 2018-19, India‟s crude steel capacity was 137.9 MT and production was 106.56 MT

(Provisional) as against a production of 103.13 MT in 2017-18. In 2018-19, with an

increase of 3.3% over the previous year, India has attained the position of 2nd largest

steel producer in the world, after China. The Per Capita steel consumption in India as per

2017-18 data was around 69 kg as against the world average of around 208 kg.

India is the world‟s largest producer of Direct Reduced Iron (DRI) or Sponge Iron.

During 2017-18, total production of sponge iron is reported at around 30.511 million

tonnes of which 85% are coal based plants and 15% are gas based plants.

Post-liberalization, technological profile of the Indian Steel Industry has undergone

substantial change. With setting up of new large modern steel plants based on state-of-

the-art technologies and modernization/ expansion of existing steel plants, there is a

upward trend in efficiency parameters of operation viz. productivity, energy efficiency,

environment friendliness etc.

India‟s finished steel consumption is anticipated to increase to 230 MT by 2030-31 from

90.68 MT in 2017-18. Demand would be supported by the growth in the domestic

market. The industry is witnessing consolidation of players which has led to investments

by entities from other sectors. National steel policy 2017 implemented to encourage the

industry to reach global benchmarks.

Source: http://steel.gov.in/overview.htm. Ministry of Steel, Government of India

In view of the increasing rapid economic growth in the country, M/s. Nilkanth Concast

Private Limited, proposed the expansion of their manufacturing facility. Further,

Proposed expansion in production of sponge Iron has got good potential in the market.

The proposed expansion project is forward integration project. Sponge iron will be used

as raw material for production of billets whereas billets will be used as raw material for

production of TMT bars. Captive Power plant will be installed to meet the demand of

electricity. In order to meet the in-house demand of raw material for billets and TMT bars

and also to meet the market requirement in timely manner, the proposed expansion

project is undertaken.

http://steel.gov.in/overview.htm



2.3 LOCATION: [TOR 4.1 TO 4.4]

The Existing and proposed expansion will be carried out at Survey No.221, Vill: Vadala,

Taluka: Mundra, Dist: Kutchh, Gujarat. The details of the project site are presented in

Table 2.1 and location map is shown in the Figure 2.1. The Topographical Map and

Google image are given in Figure 2.2 & 2.3.

Table 2.1: Site Characterization and Environment Sensitivity

Sr.

No. Particulars Details

1 Project Site Survey No.221, Vill: Vadala, Taluka: Mundra,


2 Site Co-ordinates

A- 22°54'12.72"N, 69°52'13.91"E

B- 22°54'27.66"N, 69°52'11.59"E

C- 22°54'29.54"N, 69°52'25.79"E

D- 22°54'32.58"N, 69°52'25.18"E

E- 22°54'36.73"N, 69°52'42.48"E

F- 22°54'33.34"N, 69°52'44.40"E

G- 22°54'23.89"N, 69°52'36.90"E

H- 22°54'16.98"N, 69°52'38.73"E

I- 22°54'16.55"N, 69°52'36.03"E

J- 22°54'18.67"N, 69°52'34.80"E

K- 22°54'16.16"N, 69°52'17.77"E

L- 22°54'10.33"N, 69°52'18.33"E

3 Topo sheet No. 42 F/13

4

Areas protected under

international

conventions, national or local

legislation for their

ecological, landscape,

cultural or other related value

No protected area within 10 km from the proposed expansion project site.

5

Area used by protected,

important or

sensitive Species of flora or

fauna for breeding,

nesting, foraging, resting,

over wintering,

migration

No protected area or sensitive species within 10 km from the proposed

expansion project site.

6 Inland, coastal, marine or underground waters

Coastal water is 5 Km away from the project site.

7 State, National boundaries N.A.

8 Routes or facilities used by the public for access to recreation or other

tourist, pilgrim areas

N.A.

9 Defense installations N.A.



Densely populated or built-up area

Vadala is around 3 km from the

proposed expansion project site.

10

Area occupied by sensitive

man-made land

Uses Hospitals, schools,

places of worship,

community facilities)

N.A.

11 Areas containing important,

high quality or scarce

resources (ground water

resources,

surface resources, forestry,

agriculture,

fisheries, tourism, minerals)

N.A.

Source: mapsofindia.com

Figure 2.1: General Location of the Project Site



Source: SOI Toposheet

Figure 2.2: Topographical Map (10 Km Radius)



Source: SOI Toposheet

Figure 2.3: Topographical Map (Digital) (10 Km Radius)



Source : Google Earth

Figure 2.4: The Google Image of the Project Site

2.4 SIZE / MAGNITUDE OF OPERATION

The Project of M/s. Nilkanth Concast Pvt. Ltd. is situated on the 35.38 Ha

(35,37,989 sq m) free hold land at Survey No.221, Vill: Vadala, Taluka: Mundra,

Dist: Kutch, Gujarat. The plant layout is given in Figure 2.5.

Table 2.2: Land Utilization of Plant Area

Sr.

no.

Particular Area in M2

1 Weigh Bridge & Office 272.91

2 Sponge Iron Machinery Foundation 4098.04

3 Control Room 185.74

4 DG & Compressor Room 308.10

5 Furnace/Concast/Rolling Mill Shed 10030.00

6 Cooling Tower, Pump Foundation & Sand Bed Filter

473.82

7 Coal Shed 1600.00

8 Tank Farm & Pump House 631.02

9 RO Plant 400.12

10 Toilet Block 40.00



11 Canteen 172.02

12 Rest Room & Dispensary Room 230.91

13 Brick Shed 196.80

14 Thermax (2 Unit) 364.00

15 Cooling Bed (2 Unit) 2080.00

16 Building (2 Unit) 754.00

17 Loading Point 1224.00

18 Weigh Bridge 98.00

19 Iron pellets Storage Area 10000.00

20 Coal Storage area 23840.00

21 Steel scrap Storage area 55100.00

22 Manufacturing plant of Bending/Twisting of

BARS

10000.00

23 TMT Bars Storage area 27194.00

24 Sponge Iron Storage area 10000.00

25 Green Belt Area 117334.00

26 Open Area & Road 77045.12

27 Packaged Type STP (Proposed) 100.00

Total 353798.00

M/s. Nilkanth Concast Pvt. Ltd. has the following Existing and Proposed units.

Table 2.3: Project Configuration [TOR 3.2]

Sr.No. Product Existing Units Proposed Units Total Units after

Proposed

Expansion

1 Sponge Iron 2 kiln of 100

TPD each

2 kiln of 100 TPD

each

4 kiln of 100 TPD

each

2 Mild Steel (Ingots,

Billets, TM Bars &

Channel/ Angles)

2 Induction

Furnaces of 20 T

capacity each &

Rolling mill

2 Induction

Furnaces 20 T

capacity each,

Rolling & section

mill

4 Induction

Furnaces 20 T

capacity each,

Rolling & section

mill)

3 Captive Power Plant 4 MW 2MW 6 MW

4 Waste Heat Recovery

Boiler (WHRB)-

based Power Plant

6 MW 4 MW 10 MW



Figure 2.5: Project Site layout Plan [TOR 4.5]



Table 2.4: Details of the Major units of the Project [TOR 3.3]

AFBC Boiler WHRB Boiler Sponge Iron Plant Induction Furnace

Rolling Mill

24 T Thermax Make Furnace

Primary Superheater Secondary

Superheater

Drum

Mud Drum

Air Pre Heater

Esp

Soot Blower

HP/LD Dosing

Dearater

Boiler Feed Pump

Main Cooling Water Pump

Auxilary Cooling Water Pump

Cooling Tower

Raw Water Tank

Coal Plant

D M Plant

I D Fan

F D Fan

P A Fan

Flow Control Valve

Temperature Control Valve

Level Control Valve

Safety Valve

Chimney

Coal Feeder

Radiation Zone

Superheater

Economiser

Strem Drum

ESP

I D Fan

H P Dosing

Safety Valve

Level Control

Valve

Temperature

control Valve

Flow

Control

Valve

Chimney

Coal Feeder

Kiln Section: Kiln Noose Cooing Fan Kiln Main Drive Shel Air Fan Inlet Nozzle Cooling Fan Wet Scrubbers ABC Fan Stack Cap Cooler Section: Water Spray System Cooler Main Drive Cooler Water Pump Cooler Discharge Valve Feed Conveyor: Sealing Air Fan Dolomite Feed Pump Iron Feed Pump Coal Feeder

Hydraulic Motor D M Water Plant Fume Extractor Vibration Motor Cooling Tower Induction Motor

Motor Fly Wheel Reduction Gear Pinion Gear

Universal Coupling Cooling Belt

Pump House

Cooling Tower

Environmental Impact Assessment & Environment Management Plan M/s. NilkanthConcast Private Limited Description of Environment


2.5 RAW MATERIAL REQUIREMENT [TOR 3.4& 3.5]

The production of every tonne of sponge Iron plant involves consumption of about

1420 Kg of Iron Pellets, 900 kg of Coal and 30 Kg of Dolomite. For AFBC boiler 70,

200 TPA coal will be required. Besides, the raw materials must fulfill the quality

specifications demanded by process, equipment and technology. The major raw

materials required are Iron Pellets, Dolomite and Coal. The gross annual

requirements of various raw materials of the plant with probable source are given in

Table 2.5.

Table 2.5: Annual requirement of major raw materials

Raw Material

Quantity (TPA)

Source Mode of

Transport

Distance

from

Project

site Existing Proposed Total

1.) Sponge Iron

Iron Pellets 102240 102240 204480

Local ( Jindal

Limited,

Rajasthan)

Road 625 Km

Coal 64,800 64,800 129600 Imported/ kandla

port Sea / Road 35 Km

Dolomite 2160 2160 4320

Local ( Dhreeeji

Dolomite,

Ahmedabad)

Road 275 Km

2) Mild Steel, Ingots, Billets, MS Rolled Products, TMT Bars, Section

Mild Steel, Ingots/Billets

Sponge Iron

Pellets 72,000 72,000 1,44,000 Inhouse Conveyor

00 Km

(Captive

Production)

Scrap Mild Steel 77430 77430 154860 Imported(Kandla

port) Road 35 Km

MS Rolled Products, TMT Bars, Section

Billets 1,80,000 1,80,000 3,60,000 -- --

00 Km

(Captive

Production)

3) Captive Power Plant

Coal 46,800 23,400 70,200 Imported

(Kandla Port) Road 35 Km

Dolchar 5040 5040 10080 Imported

(Kandla Port) Road 35 km

4). DM Plant

Caustic Flake 24 TPA -- 24 TPA Local Road 20 Km

Sulphuric Acid 60 TPA -- 60 TPA Local Road 20 Km

Hydrochloric

Acid 36 TPA -- 36 TPA Local

Road 20 Km



2.5.1 Material Balance

DRI(4x100 TPD) Induction Furnace 4x20 T

INPUT OUTPUT INPUT OUTPUT

PELLETE 204480 SPONGE

IRON

144000 SPONGE IRON 144000 HOT

METAL

378000

DOLOMITE 4320 CHAR 10080 SCRAP 154860 SLAG 26460

COAL 129600 GAS &

DUST

253738 PIG IRON 105600

AIR 72000 UNBURNED

COAL

2582 Total 404460 404460

Total 410400 410400

CCM POWER PLANT 10 MW

INPUT OUTPUT INPUT OUTPUT

Hot Metal 378000 Rolled

Products

360000 Coal 70200 Power 16

MWh

Scrap 18000 Dolchar 10080 Total

Ash

4914

Total 378000 378000 Hot Air from DRI

at a temp. of 417 K

25373

Air 168000

cum



Figure 2.6: Material Balance



2.6 WATER REQUIREMENT [TOR 3.7]

The total water requirement for the Plant along with proposed expansion including

domestic purpose is 1450 (1293 KLD fresh water and 157 KLD recycled water.)

Requirement of water shall be met from the Gujarat Water Infrastructure Limited

(GWIL). Water drawl permission for 1.5 MLD (0.800 MLD + 0.700 MLD) is

available with the company and permission letter is attached as Annexure VIII. No

ground water source is tapped.

Water is required in the plant mainly for the purpose of cooling and in boiler. Water

is also required for gardening, domestic and dust suppression. In order to minimize

the fresh water requirement, it is proposed to adopt recirculating system after proper

treatment. Waste water from boiler and cooling will be reused for coal dump

cooling, after proper treatment in ETP. So, the fresh water requirement will be

minimized to 1293 KLD. By virtue of flow chart the optimization of water cycle is

done to minimize the water requirement.

Table 2.6:Water Requirement

Sr.

No.

Particular Daily Water

Requirement

Consumption/

System Loss

Wastewater

Generation

Mode of

utilization /

Disposal

1. Process

a Recycled 132 - - Recycle

b Fresh Make

up

1193

1104 221

Sub Total 1 1325 1104 221

2. Dust Suppression & Plantation

a Dust

Suppression

15 15

-

-

b Green belt &

Plantation

65 65 - -

Sub Total 2 80 80 --

-

a

Domestic 45 9 36 Packaged type

STP.

Sub Total 3 45 9 36

Grand Total

(1+2+3)

1450 1193 257* Zero

Discharge

* Out of 257 KLD generated waste water 157 KLD will be recirculated.



Figure 2.7 Water Balance Flow sheet

2.7 POWER REQUIREMENT& SUPPLY / SOURCE [TOR 3.7]

Existing total Power requirement is 31.37 MW. The power requirement is met from

CPP & WHRB and from GETCO. For emergency power supply 1 x 500 kVA D.G.

Set is installed. After proposed expansion the power requirement shall be 60.13 MW.

The detailed energy balance is given below:-

Table 2.7: Power Requirement

Sr.

No. Plants Existing

Existin

g

Power

Consu

mption

Proposed Final

Configuration

Propose

d Total

Power

Consu

mption

1 DRI Unit 2x100TPD 1.18 4 x 100 TPD 2.36

2

Induction Furnace

with CCM 2 x 25 T 22.38 4x25T 44.76

3 Rolling Mill 2 x 20 T 4.36 4 x20 T 8.73

4

CPP (WHRB)

Internal Consumption 22MWH 2.07 29MWH 2.73

5

CPP (CFBC/AFBC)

Internal Consumption 4 MWH 0.35 6 MWH 0.52

6

Raw Material

Handling

Through

Automated process 1.03 1.03

Total 31.37 60.13



Plant Requirement Existing Proposed

Installed Capacity of CPP

10 16

Actual Expected Generation @85%

8.5 13.6

Actual available Power (MW)

8.5 13.6

Actual Requirement

31.37 60.13

Makeup Power from Source

22.87 ≈ 23 46.53 ≈ 47

Supply Sources

TG Set 16.6 16.6

G.E.B. 12.29 12.29

GETCO 18.1

Total 28.89 46.99

132 kV/ 33 kV switch yard already exists in the company premises for taking

electricity supply from GETCO. We are also having facility to take power supply

from our captive power plant.

Fuel facilities

Only HSD/ LDO is being used for DG Set in emergency.

2.8 MANPOWER REQUIREMENT [TOR 3.7]

The project is providing direct employment to nearly 506 workers. The local persons

have been given preference in employments as per the qualification and technical

competencies. Necessary training has been given to train the unemployed youths of

the nearby villages. Indirect employment opportunities have been created in the

periphery of the project as the project started operation in the region. In order to

operate and maintain the plant facilities, including its technical general administration

needs. About additional 395 Nos. of manpower will be require for expansion.

The above manpower covers the top management, middle and junior level executives

and other supporting staff including workforce. The category wise break-up of

existing and proposed manpower is indicated in the following table.



Table 1.8: Category-wise break-up of Manpower

Sr.

No Category

Existing

Manpower

Additional

Manpower

Total

Man

Power

1 Tech Managerial 22 10 32

2 Tech Executive 68 50 118

3 Supervisory 92 75 167

4 Skilled 229 175 404

5 Unskilled 78 75 153

6 Management 17 10 27

Total 506 395 901

2.9 PROJECT IMPLEMENTATION SCHEDULE

Project Implementation Concept

In order to ensure coordinated implementation within the short construction period

envisaged for the project, it will be necessary to evolve an optimal compromise

between the fully disaggregated mode and the turnkey package implementation

mode.

The proposed model has been adopted in a number of projects with considerable

success and fast ramp up. The construction schedule for the project has been drawn

up accordingly. The implementation of project schedule is given as in Bar chart as

Annexure XI

Construction Schedule

The schedule has been developed considering mostly the supply of plant and

equipment, as well as volume of work for Construction /Erection of the plant and

other local conditions at site. According to the schedule, worked out, the Sponge

Iron Plant, WHRB, Expansion of CPP, Induction Furnaces & Rolling Mill has been

planned, to be commissioned within 12 months from the date of placement of order

for the main plant.

Site Development & Constructions Facilities



Site development activities such as contour survey, soil investigation, site

preparation, site drainage, construction water, construction power, construction

storage yards etc. are already developed. Establishment of construction power, water

site preparation and other activities will be completed in three (3) months from „go-

ahead‟.

Special efforts will have to be made during implementation to keep the earthwork

and the site preparation to the minimum both for cost savings as well as reduction in

construction time.

Civil & Structural Work

The schedule for carrying out the civil work and structural steel work is based on the

volume of work and interlink between the completions of some of these activities to

enable the subsequent activities to proceed. Structural steelwork covers all the

building structures. In order to meet the overall time-frame envisaged in the

schedule, the completion of civil and structural work in a time-bound manner is a

pre-requisite for the project completion for the schedule.

Equipment Manufacture & Delivery

As indicated earlier, as an advance action, enquiries will have to be issued for the

various plant and equipment, on a global basis, tenders evaluated and orders

finalized. Major packages will cover material handling system, Sponge Iron Plant,

WHRB and Induction Furnaces and these will need to be tendered out. Placement of

order for such packages is envisaged within two (2) months to seven (7) months

from the date of go ahead for project construction. It is assumed that advance work

on the preparation of specifications, evaluation of tenders and readiness for

placement of orders will be taken parallel. The duration generally accepted

internationally for manufacture and delivery of various equipment have been taken

into account while evolving the implementation schedule.

Equipment Erection

Erection of equipment will have to commence after availability of fronts on

completion of the civil and structural work as well as delivery of equipment at the

plant site. It is expected that the duration for erection of equipment for the various

plant facilities will vary between Six (6) months to Eight (8) months from the date of

commencement of equipment erection.



External Facilities

The various off site facilities such as external water supply, external power supply

and rail & Road transportation links, Sea links etc are already available.

Trial Runs & commissioning

Commissioning work will be done after completion of Erection work. A period of 6

months has been envisaged for carrying out commissioning work and trial runs.

Project Monitoring

At the project implementation stage, all project activities from design and

engineering to construction, equipment supply, erection, testing and commissioning

of the plant and equipment will be monitored on the basis of a computerized network

monitoring system. Various reports as relevant for different aspects of project

monitoring will be generated through the computerized system.

Action points will be identified agency-wise and actions taken for timely

implementation the milestones to be achieved for meeting this schedule will be

identified and monitored for their achievement. Critical activities of the project as

they arise will also be identified and monitored and followed up to ensure timely

completion.

Estimated project cost:

Total costs of the Proposed Expansion project will be Rs. 60.00 Crore with Rs. 4.0

Crore as a capital cost for Pollution Control Equipment & EMP and Rs. 0.6 Crores

will be spent for CER activities.

2.10 PROCESS DESCRIPTION

2.10.1 Sponge Iron [TOR 3.8]

The Sponge Iron shall be produced from 4 x 100 TPD Rotary Kilns. (Existing 2 x 100

TPD & Proposed 2 x 100 TPD)

Coal based Direct Reduction Rotary Kiln Process:

The coal based direct reduction rotary kiln process was developed for converting

iron pellets directly into metallic iron without the melting of the materials. The

process has the advantage of low capital expenditure and no requirement of coking

coal. The metallic iron in this process is produced by the reduction of iron oxide

below the fusion temperature of iron pellet (1535 0C) by utilizing carbonaceous

material present in the non-coking coal. As the iron pellet is in direct contact with



the reducing agent throughout the reduction process, it is often termed as direct

reduced iron (DRI). The reduced product having high degree of metallization shows

a „honeycomb structure‟, due to which it is often called sponge iron.

Coal based DRI plants are flexible with respect to plant location since non-coking

coal is widely distributed in large deposits and is easy to transport. Most plants

employ reduction process which is carried out in rotary kilns. These plants use wide

variety of raw materials and non-coking coal. The quality of these materials has

direct bearing on the process as well as the product. Some plants do not use iron

pellet directly. These plants use iron pellet pellets in the rotary kiln. Raw material

mix consisting of iron pellet, dolomite and non-coking coal is fed at the one end of

the rotary kiln and is heated by coal burners to produce DRI. The product DRI along

with char (sometimes called dolchar) is taken out from the other end of the kiln.

Apart from this, primary air and secondary air are supplied to the kiln to initiate the

combustion and sustain the reaction process in the kiln.

The main raw materials for the production of DRI by the rotary kiln process are (i)

Iron pellets, (ii) non-coking coal, and (iii) dolomite in adequate proportion to

scavenge the sulphur.

Process:

This process utilizes non-coking coal as reducing agent along with lumpy grade iron

pellets.

The reduction is carried out in an inclined horizontal rotary kiln, which rotates at a

predetermined speed. A temperature profile ranging from 8000

C to 10500

C is

maintained along the length of the kiln at different zones and as the material flows

down due to gravity the ore is reduced.

The hot reduced sponge iron along with semi-burnt coal, discharged from kiln is

cooled in water – cooled cylindrical rotary cooler to a temperature of 100 to 200 0

C.

The discharge from cooler consisting of sponge iron, char other contaminations are

passed on through magnetic separators so that sponge iron can be separated from other

impurities.

Later the sponge iron is screened into two size fractions i.e. -3 mm & +3 mm, for

further utilization. The process flow chart of ferro alloys is given in the Figure 2.6



The Chemical Reactions involved during the process are as under.

CO2 + C= 2CO 3Fe2 O3 + CO= 2Fe3 O4 + CO2 Fe3 O4 + CO = 3 Fe O +CO2 Fe O +CO = Fe +CO2 C + H2O = CO+ H2 3Fe2 O3 + H2 = 2Fe3 O4+H2O Fe3 O4 + H2 = 3FeO +H2O Fe O+ H2 = Fe+H2O

The Typical Physical and Chemical composition of the Iron pellets is as under:

Table 2.9: Composition of Iron Pellets

Chemical Composition Physical Composition

Constituent % Size 5-20 mm.

Total Iron 63.3-63.5 % Shattering Index +95%

SiO2 + Al2O3 5.5-6 % Tumbler Index +88%

CaO + MgO 0.5-1.0 % Abrasion Index +5%

Sulphur 0.02 % Max. Reducibility Index +94%

Phosphorous 0.04 % Max. Thermal Degradation Index 5%

Typical Coal composition is as under :

Table 2.10: Composition Coal

Constituent %

Moisture 10 % max

Ash 6 – 8 %

Fixed Carbon 55 %

Size 0 – 20 mm.

Ash Softening Point 1350 0C

Calorific Value 6500 kCal/mole

Reactivity 2.2 C0/gm.Deg.C.

Typical Analysis of Sponge Iron Produced is as under.

Table 2.11: Typical Analysis of Sponge Iron

Constituent %

Total Iron 91 -93 %

Metallic Iron 80 – 84 %

Metallization 90 -92 %

Gangue 3 – 4 %

Carbon 0.15 %

Sulphur 0.02 – 0.03 %

Phosphorous 0.035 – 0.05 %



Figure2.8: The Process Flow Diagram: Sponge Iron Plant

2.10.2 Mild Steel (Ingots, Billets, TM Bars & Channel/ Angles)

Mild Steel shall be produced from 4 x 20 T Induction Furnaces (Existing 2 x 20 T &

proposed 2 x 20 T).

Induction Furnace:

Induction furnace is a type of electric melting furnace which uses electric current to

melt metal. The principle of induction melting is that a high voltage electrical source

from a primary coil induces a low voltage, high current in the metal (secondary

coil). Induction heating is simply a method of transfer of the heat energy.



Medium frequency induction furnaces which are commonly used for steelmaking

use the heat produced by eddy currents generated by a high frequency alternating

field. The inductor is usually made of copper in order to limit the electric losses. The

inductor is water cooled. The furnace consists of a crucible made of a suitable

refractory material surrounded by a water cooled copper coil. In this furnace type,

the charge is melted by heat generated from an electric arc. The coil carries the high

frequency current. The alternating magnetic field produced by the high frequency

current induces powerful eddy currents in the charge resulting in very fast heating.

Electrical energy needed for heating one ton of iron to 1500 0

C is 396 kWh. In

furnace several losses takes place which increases the specific energy consumption.

The losses consists of (i) thermal losses, (ii) furnace coil losses, (iii) capacitor bank

losses, (iv) convertor losses, and (v) losses on main side transformer. The higher the

losses lower is the furnace efficiency. Thermal losses contributes maximum towards

loss of energy. The major thermal losses are (i) radiation loss from furnace top, (ii)

conduction losses from refractory lining, (iii) heat losses in cooling water of the coil,

and (iv) heat carried by the removed slag.

During the making of a heat, the furnace is constantly losing heat both to the cooling

water and by radiation from the shell and the exposed metal surface. Electrical

energy is required to be spent to substitute this heat loss. Hence longer the heat time

the greater is the furnace inefficiency.

The induction furnace has the following technical advantages over electric arc furnace.

i) Low requirement on the electric grid

ii) Relatively cleaner process and lesser environ related expenditure.

iii) Higher yields

iv) Lower consumption of Ferro-alloys

v) No cost on electrodes

vi) Low operational cost of rolled steel depending on unit costs

vii) Lower space requirement

viii) Induction furnace is suitable for charging addition agents any time due to the

characteristics of the bath agitation.

ix) Has low load and no flicker disturbance

x) Automated application in a simple way



The disadvantages are

i) The requirement of minimal wall thickness of the refractory lining is having risk of

crack formation resulting in stoppage of operations.

ii) Induction furnaces puts more stringent requirement on the quality of scrap

iii) Decarburizing, desulphurizing and dephosphorizing is restricted due to refractory

wear.

iv) The non- metallic component of the charge materials is to be kept under control so

that volume of the slag remains under limit and does not have adverse effect on the

lining.

v) Compared to EAFs, Induction furnaces of very high capacities are not presently

available

Process:

Scrap and sponge Iron charged to Induction furnace, which slowly melts above

15300C. After melting the material and as required for the specific type of Mild steel

composition an addition of Silicomanganese, Ferro Silicon, Aluminium, Carbon and

other chemicals shall be made. After chemical analysis of the product , the final

metal will be tapped to the ladle.

Casting Process CCM:

Continuous casting (CC) is a method of producing an infinite solid strand from

liquid steel by continuously solidifying it as it moves through a CC machine. It is the

predominant process route in a modern steel plant which links steelmaking and hot

rolling.

The CC machines are normally named according to the strand dimensions such as

billet, bloom, and slab CC machines etc. There are also CC machines to cast rounds

and other shapes like beam blanks.

The main equipment of a CC machine constitute (i) ladle turret along with turret

weighing system and ladle cover manipulator, (ii) tundish and tundish car along with

tundish weighing system, tundish preheater and dryer, (iii) mould and mould

oscillation along with mould level control and electromagnetic stirrer, (iv) secondary

cooling consisting of strand cooling, strand containment and guiding, (v) withdrawal

and straightener, (vi) dummy bar, dummy bar parking and dummy bar disconnect



roll unit, (vii) pinch roll and torch cut off unit, (viii) Product identification system,

and (ix) Roller table and product discharge system.

Process:

Ladle liquid metal temperature adjustment done minimum (1620 to 1630°C) through

purging by Nitrogen gas to liquid metal. The Ladle goes to CCM then casting start

same time after made billets.

Figure 2.9: The Process Flow Diagram: Mild Steel

TMT Bar & Section Mill (Channel/Angle)

Rolling Mill:

Steel rolling consists of passing the material, usually termed as rolling stock, between

two rolls driven at the same peripheral speed in opposite directions (i.e. one clockwise

and the second anti-clockwise) and so spaced that the distance between them is

somewhat less than the thickness of the section entering them. In these conditions, the

rolls grip the material and deliver it reduced in thickness, increased in length and

Scrap, Sponge iron

Melting in Furnace at 1550 0C + Addition of Ferro Alloys + Maintaining of Temp. 1650 0C

Slag Removing

Tapping in Ladle at 1620 0C

Casting at CCM



probably somewhat increased in width. This is one of the most widely used processes

among all the metal working processes, because of its higher productivity and lower

operating cost. Rolling is able to produce a product which is having constant cross

section throughout its length. Many shapes and sections are possible to roll by the steel

rolling process.

Steel sections are generally rolled in several passes, whose number is determined by the

ratio of initial input material and final cross section of finished product. The cross

section area is reduced in each pass and form and the size of the stock gradually

approach to the desired profile. Rolling accounts for about 90 % of all materials

produced by metal working process.

When manufacturing long products, it is common to use a series of rolling stands in

tandem to obtain high production rates. The stands are grouped into roughing,

intermediate and finishing stages. Typical temperature, speed, inter-stand time (time

between each stand), true strain and strain rate ranges at each stage are shown in Tab 1.

Since cross-sectional area is reduced progressively at each set of rolls, the stock moves

at different speeds at each stage of the rolling mill. A wire rod rolling mill, for example,

gradually reduces the cross-sectional area of a starting billet (e.g., 150 mm square, 10-12

meters long) down to a finished rod (as small as 5.0 mm in diameter, 1.93 km long) at

high finishing speeds (up to 120 m/sec).

Typical parameters at rolling stages

Unit Roughing Intermediate Finishing

Temperature

range

Deg C 1000-1100 950-1050 850-950

Speed range m/sec 0.1-1 1-10 10-120

Inter-stand time

range

Milli-

second

1600-10300 1000-1300 5-60

True strain

range

- 0.20-0.40 0.30-0.40 0.15-0.50

Strain rate

range

per

second

0.90-10 10-130 190-2000



Process:

The Ingots obtained are then transferred to the Rolling/Section Mill section where there

is facility for charging of Hot Ingots incorporated in the process, gives rise to a

significant saving of fuel rating in hot charge furnace as well as cutting down the total

retention time, thereby making an overall savings in the fuel rate per ton of

ingots/billets.

The Mild Steel Rolled Products are then cut into required length and transferred to the

cooling bed.

From cooling bed these M.S.Rolled Products, if required are transferred to the

straightening machine and ultimately for Sorting, Packing and Dispatch. No gasifier

will be used in this process.

Figure 2.10: The Process Flow Diagram: TMT Bar & Section Mill

Molten Metal from Induction Furnace & CCM

Rolling & Section Mill Process

TMT Bars, Channels/ Angles

Sorting, packing & Dispatch



2.10.3 Captive Power Plant

Total 6 MW Electricity (Existing 4 MW + Proposed 2 MW) shall be produced from

the Captive Power Plant.

AFBC Boiler:

A 24 T AFBC, Bi Drum, Outdoor, water tube, natural circulation , balance draft,

bottom supported boiler is installed.

The Design specification of the AFBC boiler is given in following Table:

1 Design Specification of Steam Generator

Parameters Unit Value

Boiler Rating (MCR) TPH 24

Stream Pressure at main

Steam Stop valve outlet KSCG 66

Steam Temperature at the

Main Steam stop valve Deg C 490±5

Main Steam Temperature

Control Range % MCR 70-100

Efficiency % 83±1

Feed water temperature Deg C

Feed water Inlet temperature

to Deaerator Deg C

Flue Gas Temperature at

APH Outlet Deg C

Relative Humidity %

Fuel Firing Combination

Main Fuel for MCR

Generation - Imported Coal 100 %

Startup fuel for coal - Charcoal Sprayed with

Diesel Fuel

Boiler Performance Testing

Procedure -

As per ASME PTC 4.1

indirect abbreviated heat

loss method on GCV

basis

2 Design Code: Boiler and Economizer/ Pressure parts: IBR 1950 with lasted amendments

Source: Thermax Limited

Process:

Coal is collected in coal bunker and insert in boiler through closed conveyor belt

where water is added through Deareator and economiser. The steam generated at



Boiler is passed through the Turbine attached to it. In turbine Generator, the steam is

used to rotate the coil in magnetic field to produce electricity. And exhaust gas is

passed through ESP and then go to atmosphere through stack. Fly ash is collected

from dust collector and sell to brick manufacturer.

Figure 2.11: Process Flow Diagram: Power Plant

Waste Heat Recovery Boiler

2 X 10 T Waste Head Recovery boilers were installed and 2 X 10 T WHRB are

proposed. Waste Heat Recovery boilers are designed to recover heat from waste flue

gases from Furnace exhaust, Kiln exhaust, incinerator exhaust etc. to produce steam or

Dolchar



hot water based on the application requirements of the plant. The amount of steam

generators or Steam Boilers of heat transfer is controlled by the quantity of heat

available in the flue gases.

Waste Heat Recovery Boilers (WHRB) Benefits:

Highly Reliable in operation and robust in construction.

Quick Payback Returns are achieved.

One time investment with lifetime returns.

No combustion, No emission hence Eco-friendly.

Energy being put to use, which was getting wasted anyway.

Process:

Waste heat from kiln is utilized for heating the iron pellets in pre heater kiln. Thus

temperature of Iron pellets will go up to 600oC prior to entering the kiln, which leads

to decrease in coal consumption and further reduction into coal char generation. The

waste heat generated in the rotary kiln is coming to burning chamber and then pass to

waste heat recovery boiler and power is generated. Hence heat is utilized for the

power generation in the existing unit and exhuast gases is passed through ESP and

then go to atmosphere through stack.

Figure 2.12: Process Flow Diagram: WHRB



2.11 MITIGATION MEASURES [TOR 3.6]

The pollutants in the form of solids, liquids and gases, generated from various

technological units of M/s. Nilkanth Concast Pvt. Ltd. have no hazardous effects on

the environment. Pollution of the environment not only adversely affects all life

forms, but also shortens the life of plant and equipment. This vital aspect,

therefore, has been taken into account while planning the plant and equipment and

adequate measures are being taken to limit the emission of pollutants within the

stipulations of statutory norms. Adoption of technology like recovery of dust/ash for

re-use as raw material fulfills the twin objectives of material conservation and

pollution control.

a) Air pollution


various dry material handling & transfer points and from flue gases generated from

the Sponge Iron and Induction Furnaces. The main process includes raw materials

storage, Grinding & screening, Transfer of material and product storage and

transportation.

All the pollution control equipment installed and commissioned for Existing

facilities and Pollution Control Equipment proposed for Expansion Project are given

in the table:

Table 2.12: Air Pollution Control Systems installed and Proposed for the Project

Sr.

No.

Stack

Attached To

Fuel

Consumption

Stack

Height

APCM Emissions

Existing

1 Rotary Kiln -

1&2

Coal 30 m ESP PM, SO2, NOx

2 AFBC Boiler Mixture of

Coal,

Lignite and

Char

53 m ESP PM, SO2, NOx

3 WHRBBoiler –

1& 2

30 m ESP PM, SO2, NOx

4 Induction

Furnace 1&2

-- 30 m Bag Filter PM

5 Iron pellet

Crusher




6 Coal

Crusher/Screen

House


7 Cooler

Discharge

Building


8 Intermediate Bin -- 12 m Bag Filter PM

9 Product

Separation/

Storage House


Proposed

1 Rotary Kiln -3 &

4

Coal 30 m ESP PM, SO2, NOx

2 WHRB Boiler 3

& 4

--l 30 m ESP PM, SO2, NOx

3 Cooler

Discharge

Building


4 Product

Separation/

Storage House




Figure 2.13: ESP installed at Plant

b) Water pollution


generation and Dust suppuration, Water is also required for drinking, sanitary, Green

Belt Development and fire fighting purpose.

In order to conserve water and minimize the makeup water requirement, it is

proposed to adopt re-circulating systems for equipment cooling. In re-circulating

system same water re-circulates again and again and some make up water is added

for evaporation losses.

Out of the Fresh water requirement of 1450 KLD for the existing as well as

proposed plants only 257 KLD waste water will be generated and 157 KLD will be

recirculated. Thus there shall be “Zero” discharge of the untreated effluent.



Table 2.13: Waste Water Treatment and Disposal

Sl.

No

Type of Waste

Water

Quantity


1 Domestic 36.0 25 KLD wastewater will be treated in STP.

2 Cooling Tower

Blow Down 170 132 KLD wastewater will be re-circulated

in process 3 Boiler 51.0

Total 257.0

c) Noise pollution

Many operations in the Sponge Iron Plant, CPP, Induction Furnaces & Rolling Mill

produce objectionable level of noise which may not be practicable to eliminate

entirely.

Noise from compressor, fans, centrifugal pumps, electrical motors etc. will be kept in

control so that the ambient noise level shall not exceed 75 dB (A) during day time &

70 dB (A) during night time. Noise pollution control measures will be provided in

respective departments by way of providing silencers, soundproof cubicle / covers &

proper selection of less noise prone machinery and by development of green belt.

In some areas where due to technological process, it is not feasible to bring down

the noise level within acceptable limits, personnel working in these areas are

provided with noise reduction aid such as ear muffler and also the duration of

exposure of the personnel are limited as per the norms.

d) Solid Waste Management.

The major solid wastes for existing as well as Proposed Project are ESP and Bag

filter collected dust, Slag from steel making, Ash from CPP and CoalChar /

Dolochar from Sponge Iron Production.

Table 2.14 Solid Waste Generation and Utilization Plan


TPA Utilization

1. ESP and Bag

filter dust

Sponge Iron

Plant& RMH

Units

14,400 Shall be used in Fly Ash brick

Manufacturing.

2. Ash CPP 4914 Shall be used in Fly-Brick



Manufacturing Unit

3. Slag Induction Furnaces 26460 Shall be used in Road

construction and back filling.

4. Coal Char/

DolChar Sponge Iron Plant 10080 Shall be used in CPP

5 Mill Scale Rolling Mill 18000 Re-utilized in Induction

Furnace

e) Hazardous Waste Inventory

S. No. Hazardous

Waste Quantity Utilization







f) Green Belt

The plantation and green belt development will also be taken care in the plant and

the space reserved for plantation will be more than 33% of the total plant area. Out

of the total land of 35.38 Ha (35,37,989sqm) Ha. NilkanthSteel has earmarked 11.73

Ha (1,17,334sqm) of land for development of green belt.

Every year tree plantation is undertaken in a planned manner on a massive scale.

Most of them including species having capability of pollution control and some of

them are capable to survive in high saline conditions & low fertile soil. Soil

management is also the part of us for better use of soil within the plant premises and

out-sides as well. Extensive Plantation & grassing has been carried out to check the

erosion from various plant activities. Nilkanth concast Pvt Ltd has already planted

13,800 trees in its plant area.

The detailed layout of the plant has been prepared with indicative area of plantation

for the whole plant. The greenbelt is shown in the plant layout.

2.12 Assessment of New & untested technology for the risk of technological failure

The project proponent will adopt all tested and proven technology in expansion of the

project. No new and untested technologies will be adopted. However for existing

furnaces and kilns online monitoring system has between implemented and shall



extend to the forthcoming units. Based on the continued efficiency of bag filters, the

type and size of bag filters will be adjusted in order to keep the emission standards

within the limits. As an environmental well-being adequate plantation and appropriate

rain water harvesting plans will be implemented in the plant premises.



CHAPTER 3

DESCRIPTION OF ENVIRONMENT

3.0 Introduction

To assess environmental impacts from proposed project at a specific location, it is

essential to monitor the environmental quality prevailing in the surrounding area prior

to implementation of the proposed project. The environmental status within the impact

zone could be used for identification of significant environmental issues to be

addressed in the impact assessment study.

In order to identify and establish the extent of likely impacts, it is essential to gather

information on existing environmental quality with regard to various components of

the environment. The baseline environmental qualities of various environmental

components like air, noise, water, land, flora and fauna and socioeconomic form

important and integral part of EIA study. The baseline data forms the basis for

predicting/assessing the environmental impacts of the proposed project.

3.1 Description of Environment

Project Proponent requested the Ministry to reconsider the proposal after submission

of the revised EIA report with additional one-month baseline data by them in the 7th

meeting of the Re-constituted EAC (Industry-I) held during 29-31st May, 2019.

Accordingly baseline monitoring for additional one month has been carried out for the

month of June 2019. The base line data collected by NABL approved laboratory.

Previously, baseline data has been used for preparation of this EIA was generated

during October, November & December 2018. Recent data of June 2019 has been

used in the report Study Area:

The study area is 10 km radius from the boundary limits of the Project Site.

A key plan indicating Project Area as core zone and 10 km radius buffer zone is

shown below. The Figure 3.1 provides surface features like villages, habitation,

drainages, roads, railways etc.



Figure 3.1: Key Plan



The current site conditions are taken as the baseline conditions for formulation of

the EIA. Field monitoring for measuring meteorological conditions, ambient air

quality, water, soil and noise had been commenced during December to Feberuary

2016 and October 2018 to December 2018 [attached as Annexure IX ( c & b

respectively] to study the baseline environmental status for one season and one

month monitoring has been carried out for the month of June 2019 ([attached as

Annexure IX (a)] .In addition, data related to land use; socio-economic status has

been analysed based on the secondary information like district census reports and

remote sensing satellite imageries.

3.1.1 ENVIRONMENTAL MONITORING PROGRAM

The location of the air, water, noise and soil sampling stations were selected for

appropriate monitoring. A monitoring station was positioned at core zone (Project

site) for Micro-meteorological data collection.

Table 3.1: Environmental Attributes & Frequency of Monitoring

Sr.

No

Environmental

Component

Sampling

Locations Sampling Parameters

Total

Sampling

Period

Sampling

Frequency

1. Meteorology One Central

location

Wind Speed, Wind

Direction 1 months Hourly

Rainfall, Cloud Cover 1 months Daily

Temperature and

Relative Humidity 1months

Twice &

Thrice

Daily

2. Ambient Air

Quality Eight locations PM10, PM2.5, SO2, NOX

Two days

per week

for one

Month

24 hourly

3. Water Quality

03 Surface &

08 Ground

water locations

As per IS -10500:2012

and IS -2490:1982 for

ground water & surface

water samples

Grab

sampling

Once

during

study

period

4. Noise Eight locations Ld, Ln 24 hourly

composite

Once

during

study

period

5. Soil Three locations

Physical and Chemical

constituents, Suitability

for agricultural growth

Composite

sample

Once

during

study

period



3.1.2 Micro Meteorology

Meteorology

The methodology adopted for monitoring surface observations is as per the standard

norms laid down by Bureau of Indian Standards (IS - 8829) and Indian

Meteorological Department (IMD).

The Central Monitoring Station (CMS) equipped with continuous monitoring

equipment was installed at Plant Site at a height of about 10 m above ground level

to record wind speed, wind direction, temperature, relative humidity & rain fall. The

meteorological monitoring station was located in such a way that it is free from any

obstructions and as per the guidelines specified under IS - 8829.

The observations for Wind speed, Wind direction, Temperature, Relative Humidity

and Rain fall were collected during period i.e. June 2019. The observations for

Wind speed, Wind direction, Temperature, Relative Humidity and Rain fall were

collected during period i.e. June 2019. The meteorological data is attached as

Annexure IX (d)

Wind Speed and Wind Direction

During the sampling period hourly wind speed and wind directions were recorded.

The results of wind speed and wind directions are depicted in the Figure-3.2 as

wind rose. The met data for one month is given in Annexure IX (d)



Source: Baseline Survey

Figure 3.2: Wind Rose Diagram

3.2 AIR ENVIRONMENT

SELECTION OF MONITORING STATIONS

The sources of air pollution in the region are industrial emissions, vehicular traffic,

dust arising from unpaved village roads and domestic fuel burning. The prime

objective of the baseline air quality study was to establish the existing ambient air

quality of the area. This will be useful for assessing the conformity to standards of the

ambient air quality during the operation of the proposed project.

Eight (8) numbers of monitoring stations were set up to assess the existing air quality

of the study area. The locations of the monitoring stations were based on the frequent

wind directions in order to site the stations as close as feasible to the anticipated

maximum pollutant deposition areas, topography, human settlement and other

meteorological parameters in core and buffer zone area.

One air sampling station was identified in core zone and the remaining seven in the

buffer zone. Descriptive listing of the ambient air quality monitoring stations is given

in Table-3.2 and shown in Figure 3.3.



TABLE 3.2: DESCRIPTION OF AMBIENT AIR MONITORING STATIONS

Source: Baseline Survey by Cherry Green Environment

Sr.

No.

Description of

monitored stations

Sample

code

Distance from

proposed

plant

expansion

Direction Zone Latitude

/Longitude

1. Project Site A-1 Within - Core 22°54'22.69"N

69°52'21.86"E

2. Vadala A-2 1.5 km NW Buffer 22°55'1.78"N

69°51'24.09"E

3. Bhadreshwar A-3 2.5 km E Buffer 22°54'36.75"N

69°54'4.45"E

4. Pavdiara A-4 1.5 km NE Buffer 22°55'7.90"N

69°52'59.18"E

5. Bharudia A-5 5.0 km NNE Buffer 22°57'17.29"N

69°52'42.19"E

6. Hatadi A-6 7.0 km NE Buffer 22°56'19.59"N

69°56'16.93"E

7. Kukadsar A-7 6.0 km E Buffer 22°54'23.16"N

69°55'32.25"E

8. Luni A-8 7.0 km SW Buffer 22°52'22.35"N

69°48'42.96"E



Figure 3.3: Location of AAQ Monitoring Station

Frequency of Monitoring

Ambient air quality (AAQ) samples were collected on basis of 24-hour sampling

and twice a week at each site. The ambient air quality samples were collected for

continuous 1week beginning from 1st June, 2019 to 30

th June, 2019.



The samples were preserved and analysed as per the standard methods

recommended by Standard Operating Procedure (SOPs) of Central Pollution

Control Board (CPCB 2011).

Method of Analysis

Ambient air samples were analysed with Gravimetric, Colorimetric or Atomic

Absorption Spectrophotometric (AAS) method as per standard methods specified by

Central Pollution Control Board (CPCB 2011).

The Techniques used for ambient air quality monitoring and minimum detectable

levels are presented in Table-3.3.

Table 3.3: Techniques& Instruments Used For Monitoring of Ambient Air

Quality

Sr.

No. Parameter Technique

Technical

Protocol

Minimum

Detectable

Limit

(μg/m3)

1. PM10 APM 550 - Dust Sampler

(Gravimetric Method)

IS-5182

(part-IV) 5.0 μg/m

3

2. PM2.5 APM 550 - Dust Sampler

(Gravimetric Method)

IS-5182

(part-IV) 5.0 μg/m

3

3. Sulphur dioxide

APM 433 - Gaseous

Sampler (Chemical

Absorption)

IS-5182

(Part-II) 3.0 μg/m

3

4. Oxides of

Nitrogen

APM 433 - Gaseous

Sampler (Chemical

Absorption)

IS-5182

(Part-VI) 3.0 μg/m

3

Source: CPCB

Observations

The results of Ambient Air Quality monitoring with regard to the parameters are

given in Annexure IX (a). A summarized report of Ambient Air Quality is given in

Table 3.4. The National Ambient Air Quality Standards are given in Table 3.5.



Table 3.4: Summarized Report of Ambient Air Quality

(June 2019)

A1 A2 A3 A4

PM10 PM2.5 SO2 NOx PM10 PM2.5 SO2 NOx PM10 PM2.5 SO2 NOx PM10 PM2.5 SO2 NOx

Minimum 79.0 30.0 18.0 21.0 68.0 27.5 15.1 19.0 69.0 32.5 11.0 15.0 75.0 28.0 15.0 18.0

Maximum 88.0 42.0 25.0 28.0 76.5 33.0 20.0 25.0 77.0 41.0 23.0 25.0 90.0 40.0 23.0 26.0

Average 83.4 36.6 21.1 25.0 71.6 30.3 18.2 21.8 73.4 36.1 15.3 18.3 81.6 32.3 19.4 24.0

98th

Percentile 87.7 41.9 24.9 27.9 76.3 32.9 20.0 24.7 77.0 40.9 22.4 24.6 89.7 39.3 22.7 26.0


A5 A6 A7 A8

PM10 PM2.5 SO2 NOx PM10 PM2.5 SO2 NOx PM10 PM2.5 SO2 NOx PM10 PM2.5 SO2 NOx

Minimum 65.0 27.0 12.0 14.0 59.0 22.0 11.0 13.0 65.0 28.0 13.0 16.0 66.0 26.5 12.0 15.0

Maximum 72.0 31.0 21.0 25.0 70.0 30.0 17.0 20.0 77.0 36.0 20.0 26.0 73.5 30.5 23.0 26.0

Average 68.9 29.4 16.4 19.9 64.3 27.0 13.5 16.3 71.3 32.4 16.9 21.0 69.5 28.6 18.0 21.8

98th

Percentile 71.9 31.0 20.6 24.7 69.9 29.9 16.7 19.7 76.9 35.9 20.0 25.9 73.2 30.4 22.9 26.0


Environmental Impact Assessment & Environment Management Plan M/s. Nilkanth Concast Private Limited Description of Environment


Table 3.5: National Ambient Air Quality Standards

POLLUTANT UNIT

TIME

WEIGHTED

AVERAGE

CONCENTRATION IN AIR

INDUSTRIAL

AREAS,

RESIDENTIAL

RURAL & OTHER

AREAS

SENSITIV

E AREAS

PM10 µg/m3

Annual Average

24 hours

60.0

100.0

60.0

100.0

PM2.5 µg/m3

Annual Average

24 hours

40.0

60.0

40.0

60.0

Nitrogen Dioxide

(NOx) µg/m

3

Annual Average

24 hours

40.0

80.0

30.0

80.0

Sulphur dioxide

(SO2) µg/m

3

Annual Average

24 hours

50.0

80.0

20.0

80.0

Refer: GSR 826(E) dated 16th

Nov. 2009

RESULTS & DISCUSSIONS

Statistical analysis (minimum, maximum, arithmetic mean and 98 percentile values) of

the ambient air quality in the study area for the entire three months monitoring period

(October- December 2018) and one month data(June 2019) has been done. The

following interpretation can be made on the basis of the obtained results:

Particulate Matter - 10 (PM10)

Arithmetic Mean of the 24-hourly average values of PM10 varied station-wise between

64.3µg/m3 (at Hatdi Village) to 83.4 µg/m3 (Project Site). Arithmetic Mean of the

24-hourly average values of PM10 at all locations is within the limit of 100 µg/m3 as

stipulated in the National Ambient Air Quality Standards, 2009. The value of PM10

ranges from 59.0 to 90 µg/m3. These values represent quite satisfactory condition

regarding PM10 concentration in ambient air.



PM2.5 Particulate Matter (<2.5 μm)

Arithmetic Mean of the 24-hourly average values of PM2.5 varied station-wise between

27.0 µg/m3 (at Hatadi Village) to 36.6 µg/m

3 (Project site). Arithmetic Mean of the 24-

hourly average values of PM2.5 at all locations is within the limit of 60 µg/m3,as

stipulated in the National Ambient Air Quality Standards, 2009. The value of PM2.5

ranges from 22.0 to 42.0 µg/m3. These values represent quite satisfactory condition

regarding PM2.5 concentration in ambient air.

Sulphur dioxide (SO2)

Arithmetic Mean of the 24-hourly average values of SO2 varied station-wise between

13.5µg/m3 (at HatadiVillage) to 21.1 µg/m

3 (Project Site). Arithmetic Mean of the 24-

hourly average values of SO2 at all locations is within the limit of 80 µg/m3as stipulated

in the National Ambient Air Quality Standards, 2009. The value of SO2 ranges from

11µg/m3 (at Hatadi Village) to 25 µg/m

3 (Project Site). These values represent quite

satisfactory condition regarding SO2 concentration in ambient air.

Oxides of Nitrogen (NOx)

Arithmetic Mean of the 24-hourly average values of NOx varied station-wise between

16.3µg/m3 (at Hatadi Village) to 25.0 µg/m3 (at Project Site). Arithmetic Mean of the

24-hourly average values of NOx at all locations is within the limit of 100 µg/m3,as

stipulated in the National Ambient Air Quality Standards, 2009. The value of NOx

ranges from 13.0 µg/m3 to 28.0 µg/m

3.These values represent quite satisfactory

condition regarding NOx concentration in ambient air.

Conclusion

The AAQ results as monitored during the post monsoon season in 2018 is attached as

Annexure IX (b) and AAQ results of one month monitoring during June 2019 is

summarised in Table 3.7 B. and detailed raw data is The result shows that that the values

of PM10, PM2.5, SO2, NOx at all the monitoring stations are below the MoEF& CC

norms for the respective pollutants.



Overall Ambient Air Quality of the plant area and its buffer zone is good and there are

no abnormal values recorded. Concentrations of all monitored parameters are within

stipulated standards from MoEF&CC AAQ Standards. Some higher values of particulate

matters are result of heavy traffic movement over highways.

3.3 WATER ENVIRONMENT

The water quality monitoring stations were selected to represent the surface and ground

water quality of water bodies in and around 10 kilometer Buffer Zone of plant. Sampling

stations for water were selected taking all water sources into account, as per MoEF

norms. The list of surface and ground water sampling stations selected in 10 km buffer

zone of plant is presented in Table 3.6 and in Figure 3.4.

Table 3.6 List of surface and ground water sampling stations

Sr.

No.

Description

of the

sampling

station

Sample

code

Distance

from

plant

Direction Zone

Latitude

/Longitude

Site

Specifications

1. Project site GW-1 Within - Core 22°54'22.69"N

69°52'21.86"E

Bore well within

the project site

2. Vadala GW-2 1.5 km NW Buffer 22°55'1.78"N

69°51'24.09"E

The location is in

the Densely

populated area

adjacent to a

street road.

3. Pavdiyara GW-3 1.0 km NE Buffer 22°54'36.75"N

69°54'4.45"E

The location is in

the Densely

populated area

adjacent to a

street road

4. Bhadreshwar GW-4 2.5 km E Buffer 22°55'7.90"N

69°52'59.18"E

The location is

within the

boundary of an

industrial

complex adjacent

to the SH. There

is no GW

exploitation in the

lower



topographical

areas to the south

of the location.

5. Vovar GW-5 6.0 km N Buffer 22°57'17.29"N

69°52'42.19"E

This is a deep

tube well located

outside the village

boundary meant

to be used both

for domestic and

agricultural

usage.

6. Hatdi GW-6 7.0 km NE Buffer 22°56'19.59"N

69°56'16.93"E

This is located in

a down gradient

topographic

slope. Probably

has a good

availability of

GW due to the

slope factor. This

is the farthest

from the

industrial location

in down slope

direction and can

reflect aresultant

behavior of GW

of the region.

7. Kukadsar GW-7 6.0 km E Buffer 22°54'23.16"N

69°55'32.25"E

This is a location

for agricultural

usage and is an

isolated

installation

adjacent to the

SH.

8. Luni GW-8 7.0 km SW Buffer 22°52'22.35"N

69°48'42.96"E

Locationally this

is about 600 mt

away from the

river stream and

is within the

rivers‟ deltaic

formations.

9.

Gulf of

Kuchch

Upstream

SW-1 3.0 km SE Buffer 22°53'22.59"N

69°54'32.45"E

This is a creek

water sample very

close to the salt

harvesting area,




mostly used for

drinking water

purpose. On taste

of the water, it

seems to be saline

in nature.

10.

Gulf of

Kuchch

Downstream

SW-2 3.5 km SW Buffer 22°52'27.53"N

69°51'9.81"E

This is a creek

water sample very

close to the salt

harvesting area,

mostly used for

drinking water

purpose. On taste

of the water, it

seems to be saline

in nature.

11.

Bharudia

Pond

SW-3 5.0km- NNE Buffer 22°56'55.71"N

69°53'22.55"E

Dried at the time

of sampling



Figure 3.4: Surface and Ground water sampling stations

Samples were collected in June-2019 from all available water sources in the study area.

Grab samples of surface and ground water were collected. On spot analysis was carried

out for the parameters like pH, Temperature, Odour, Taste, DO etc.

Samples for chemical analysis were collected in polyethylene carboys. Samples

collected for metal content were acidified with 1.0 ml HNO3. Bacteriological Samples

were collected in sterilized glass bottles. Selected physico-chemical and bacteriological



parameters have been analyzed for evaluating the existing base line water quality status

in the study area.

Analytical Techniques

The analytical techniques followed for evaluation of water quality were as per the

Standard Methods for the Examination of water and wastewater, 22nd Edition, 2012,

APHA and the methods for a few parameters is given in the Table 3.7

Table 3.7: Methodology for Sampling and Analysis of Water & Wastewater

Sr. No. Parameters Methods

(Indian Standard)

Methods

(APHA)

1. Ph IS 3025 (part 11) : 1983 APHA-4500-H+

2. Colour IS 3025 (part 4) : 1983 APHA-2120 C

3. Odour IS 3025 (part 5) : 1983 IS:3025, part-4

4. Temperature IS 3025 (part 9) : 1984 APHA-2550 B

5. Dissolved Oxygen IS 3025 (part 38) : 1989 APHA-4500 O

6. BOD IS 3025 (part 44) : 1993 APHA-5210 B

7. COD IS 3025 (part 58) : 2006 --

8. Electrical

Conductivity IS 3025 (part 14) : 1984 APHA-2510 B

9. Turbidity IS 3025 (part 10) : 1984 APHA-2130 B

10. Chlorides IS 3025 (part 32) : 1988 APHA-4500 Cl-

11. Fluorides -- APHA-4500 F

12. Total Dissolved

Solids IS 3025 (part 16) : 1984 APHA-2540 C

13. Total Suspended

Solids IS 3025 (part 17) : 1984 APHA-2540 D

14. Total Hardness IS 3025 (part 21) : 1983 APHA-2340 C

15. Alkalinity IS 3025 (part 23) : 1986 APHA-2320 B

16. Sulphates IS 3025 (part 24) : 1986 APHA-4500

SO4-2

17. Calcium IS 3025 (part 40) : 1991 APHA-3120 B/

APHA-3500 Ca

18. Magnesium IS 3025 (part 46) : 1994 APHA-3120 B/

APHA-3500

Mg 19. Boron IS 3025 (part 57) : 2005 APHA-4500 B

20. Coliforms IS 5401 (part 1) : 2002 APHA-9215 D

Source: CPCB



Table 3.8: Central Pollution Control Board (CPCB) Surface Water Quality Criteria

S.N. Parameters Class A Class B Class C Class D Class E

1. pH 6.5-8.5 6.5-8.5 6.5-8.5 6.5-8.5 6.5-8.5

2. Dissolved Oxygen

(as O2), mg/l 6 5 4 4 -

3. BOD, 5 days at

20oC, max

2 3 3 - -

4.

Total coliform

organism,

MPN/100 ml, max

50 500 5000 - -

5. Free Ammonia

mg/l - - - 1.2 -

6.

Electrical

conductivity,

mhos/cm, max

- - - - 2250

7. Sodium absorption

ratio, max. - - - - 26

8. Bornn (as B), mg/l,

max. - - - - 2

Class A : Drinking water source without conventional treatment but after dis-infection

Class B : Outdoor bathing (organised)

Class C : Drinking water source after conventional treatment and after dis-infection

Class D : Propagation of Wild life and Fisheries

Class E : Irrigation, Industrial Cooling, and Controlled Waste Disposal

Below E : Not meeting A, B, C, D & E Criteria

Source: CPCB

Observations

The characteristics of ground and surface water samples are given in Annexure IX (a).

Desirable as well as permissible limits for each parameter prescribed by of Indian

Standard: BIS 10500–2012 is also included in the tables.



Comparison of Data set

The existing data set collected for one month during June 2019 has been compared with

an earlier EIA report of Copper Refinery project of Adani Enterprises limited (EIA report

of Copper refinery proposal number J-11011/113/2016-IA) from the same region with

similar geophysical conditions. The Adani set of data is for post monsoon period,

whereas Nilkanth data set is for pre-monsoon. (Comparison of data set are given in

Annexure IX a). This is also to note that Nilkanth buffer area has been monitored thrice

during Dec –Feb 2015, October to December 2018 and June 2019. The comparison of

surface water and ground water between 2018 data set and one month 2019 data set has

been done. The 2018 data is for post monsoon period, whereas one month 2019 data

set is for pre-monsoon. The graphs showed the variation may be due seasonal difference.

The detailed are reported in Annexure IX (a).

The comparative analysis of one month data set are given as follows.

Ground Water

Particularly the results with higher values has been compared with the secondary data set

for a trend analysis

Based on the pH verses TDS relationship generally it is found when the pH is lower TDS

increases and alkalinity to mostly attributed by hardness parameter. The locations were

with a lower pH the TDS is also comparivetly low is because the respective sample is

away from the euchring environment and had a factor of dilution with fresh water. the

variation in hardness is correlated with alkanity and pH and the trend indicates lower

hardness is due to less impact of saline ingression which is been evident by the presence

of chlorides and sulphates with traces of fluoride and nitrate as well in the ground water

samples

The presence of fluoride as in the ground water samples are absent in the surface water

samples. The existing industry with proposed expansion has almost no release of fluoride

in solid, liquid or gaseous form and cannot attribute to the presence of fluoride in the

existing ground water conditions. Therefore it may be inferred the source of fluoride in



7.94 7.92 7.58 8.04 7.88 7.9 7.72

650 670 410 489.8

810 870

380 Co

nce

ntr

atio

n

Sampling Location

pH Vs Total Dissolved Solids

pH - Total Dissolved Solid mg/l

7.94 7.92 7.58 8.04 7.88 7.9 7.72

330 345 202

376 286

365 276 C

on

cen

trat

ion

Sampling Location

pH Vs Alkalinity

pH Alkalinity mg/l

7.78 7.94 7.92 7.58 8.04 7.88 7.9 7.72

50 55 65

98 79 89

67 78

Co

nce

ntr

atio

n

Sampling location

pH Vs Total Hardness

pH - Total Hardness mg/l

ground water is elsewhere from its recharge area. Further, the industry takes all

precautions not to contaminate the soil with its waste and raw material by storing it under

covered sheds and on the top of concrete basis.

Figure 3.5: Ground Water analysis comparative Graph



7.89 7.98

125

176

Gulf of Kutch SW1 Gulf of Kutch SW2

Co

nce

ntr

atio

n

Sampling Location

pH Vs Alkalinity

pH - Alkalinity mg/l

Gulf ofKutchSW1

Gulf ofKutchSW2

Total Hardness mg/l 5452 5552

Alkalinity mg/l 125 176

0100020003000400050006000

con

cen

trat

ion

Alkanility Vs Hardness

Total Hardnessmg/l

Alkalinity mg/l

1 2

Total DissolvedSolid mg/l

22,210 23,540.00

Alkalinity mg/l 125 176

05,000

10,00015,00020,00025,000

Co

nce

ntr

atio

n

Sampling location

TDS Vs Alkanility

Surface Water

The surface water is highly impacted by the crick and is saline in nature with a pH range

between7.89 to 7.98. It indicates mild alkalinity but significant hardness is marked by

higher dissolved solids and due to the observed presence of fluorides, magnesium and

calcium oxides and sulphates. On lay ground water samples presence of fluoride is not

observed in the surface water samples due to the local stratography and lithology, iron in

dissolve form is accumulated in static water in this region for which pH is an indicator.

The lower the pH higher is concentration of Iron. It is also observed on a reduced

alkalinity the iron concentration shows increasing trend.

Figure 3.6: Surface Water analysis comparative Graph



3.4 Noise Environment

Noise is most often and mostly defined as unwanted sound. In an environment noise

affects the health or interferes with the work zone activities of the people if the noise

levels are more than the permissible levels. Considerable noise gets generated in any

industrial situation due to operation of equipment.

At present, noise at area is produced due to multiple sources of commercial activities,

industrial activities and due to heavy movement of vehicles on the road.

Noise levels have measured at hourly intervals at eight stations N–1 to N-8 are described

at Table 3.9. Noise level measurement stations have shown in Figure – 3.7.

Table – 3.9: Details of Sampling Stations of Noise Level Measurement


Sr.

No.

Description of

monitored stations

Sample

code

Distance

from

plant

Direction Zone Latitude

/Longitude

1. Project Site N-1 Within - Core 22°54'22.69"N 69°52'21.86"E

2. Vadala

N-2 1.5 km

NW Buffer 22°55'1.78"N 69°51'24.09"E

3. Bhadreshwar

N-3 2.5 km

E Buffer 22°54'36.75"N 69°54'4.45"E

4. Pavdiara

N-4 1.5 km

NE Buffer 22°55'7.90"N 69°52'59.18"E

5. Bharudia

N-5 5.0 km

NNE Buffer 22°57'17.29"N 69°52'42.19"E

6. Hatadi

N-6 7.0 km

NE Buffer 22°56'19.59"N 69°56'16.93"E

7. Kukadsar

N-7 6.0 km

E Buffer 22°54'23.16"N 69°55'32.25"E

8. Luni

N-8 7.0 km

SW Buffer 22°52'22.35"N 69°48'42.96"E



Figure 3.7: Locations of Noise Level Monitoring



Parameters Measured During Monitoring

For noise levels measured over a given period of time interval, it is possible to describe

features of noise using statistical quantities. This is calculated using the percent of the

time certain levels exceeds the time interval. The notation for the statistical quantities

of noise levels is described below

i. Hourly Leq values have been computed by integrating sound level meter.

ii. Lday: As per the CPCB guidelines the day time limit is between 0600 to 2200

hours as outlined in the Ministry of Environment and Forest Notification S.O.

123 (E) dated 14/02/2000.

iii. Lnight: As per the CPCB guidelines the night time limit is between 2200 to

0600 hours as outlined in the Ministry of Environment and Forest Notification

S.O. 123 (E) dated 14/02/2000.

A noise rating developed by E P A for specification of community noise from all the

sources, is the Day-Night Sound Level (Ldn).

Ldn: It is similar to a 24 hr equivalent sound level, except that during the night time

period , which extends from 10 p.m. to 6 a.m., a 10 dB(A) weighing penalty is added to

the instantaneous sound level before computing 24 hr average. This night time penalty

is added to account for the fact that noise during night, when people usually sleep is

judged more annoying than the same noise during the day time.

Method of Monitoring

Noise level monitoring was performed March -2019. The noise levels were monitored

on working days only and Sundays and Public holidays were not monitored. During

each hour Leq were directly computed by the instrument based on the sound pressure

levels. Lday (Ld), Ldn values were computed using corresponding hourly Leq of day

and night respectively. The data of the noise monitoring is given in Table 3.9.




Results

Although the noise limits are well within the noise standard for industrial as well as

residential area, the diurinal variation of noise level between day time and night time

have a greater variation in industrial and high density traffic area are in location 6 to 9

and the gap diminishes in more or less residential areas with minimum traffic

3.5 Soil Environment

Soil samples were collected at selected locations in the study area to assess the existing

soil conditions around the plant area. This will establish the baseline characteristics and

will facilitate identifying the incremental concentrations due to the project at a later

stage. The baseline characteristics, which are analyzed now, include the impact on soil

due to all the miscellaneous activities and natural soil quality. The soil quality data

have generated for June -2019

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

1 2 3 4 5 6 7 8 9

dB

Sampling Locations

Average Day Time

Average Night Time

Figure 3.8: Noise Monitoring Results



Overall, three sampling locations have been selected at study area. The locations of

sampling station are given at Table 3.10 and the locations of soil sampling points have

shown in Figure 3.6.

Table 3.10 Soil Sampling Location Details


Sr.

No. Sampling Sites

Station

Code

Distance from

plant Area Direction Zone

Latitude

/Longitude

1.

Project Site S – 1 Within Core

22°54'22.69"N

69°52'21.86"E

2.

Vadala S – 2 1.5 km NW Buffer

22°55'1.78"N

69°51'24.09"E

3.

Bhadreshwar S – 3 2.5 km E Buffer

22°54'36.75"N

69°54'4.45"E



Figure 3.9: Locations of Soil Sampling Locations



Methodology of Sampling & Analysis

Samples were collected of June -2019 from all the sources. Total three samples from

three different locations were monitored.

The samples were analyzed for physical and chemical characteristics. The samples

have been analyzed as per the established scientific methods for physico-chemical

parameters. The parameters and relevant standard methods have described in Table –

3.11.

Table 3.11: Analytical Techniques for Soil Analysis

Parameters Method

(IndianStandard)

Method

(ASTM number)

Particle size

distribution IS 2720 Sieve analysis (D 422 – 63)

Natural Moisture IS 2720 -

Texture Classification IS 2720 Chart developed by Public

Roads Administration

Infiltration rate IS 2720 Infiltrometer

Liquid Limit IS 2720 -

Plastic Limit IS 2720 -

Bulk density IS 2720 Sand replacement, core cutter

Porosity IS 2720 Void ratio

pH IS 2720 pH meter (D 1293 – 84)

Electrical conductivity IS 2720 Conductivity meter

(D 1125 – 82)

Nitrogen IS 2720 Kjeldahl distillation

(D 3590 – 84)

Phosphorous IS 2720 Molybdenum blue, colorimetric

(D 515 – 82)

Potassium IS 2720 Flame Photometer (D 1428 – 82)



Observations:

The physico-chemical characteristics of soil samples have been reported in Table 3.12

Table 3.12:Physico-Chemical Characteristics of Soil

Parameters Unit S1 S2 S3

Project site Vadala Bhadreshwar

Physical Property:

Texture - Sand Clay Slit Clay

Sand % 28 15 23

Silt % 31 14 20

Clay % 25 16 22

Chemical Properties:

pH - 8.07 8.75 8.34

Conductivity ms/cm 5.7 1.473 0.608

Na+ mg/kg 32 21 17

K+ mg/kg 13 11 25

Heavy metal:

Chromium(Cr) ppm N.D N.D N.D

Copper(Cu) ppm 0.490 0.162 0.223

Nickel(Ni) ppm 0.341 0.281 0.281

Lead(Pb) ppm N.D N.D N.D

Zinc(Zn) ppm 0.067 0.556 0.507

Iron(Fe) ppm 140.36 117.24 134.2


Standard Soil Classification

Standard soil classification regarding agriculture, in view of its test parameters, is

detailed below in Table 3.13. The use of soil for agriculture or for other use may be

decided on basis of soil characteristics.



Table 3.13: Standard Soil Classification

Sr. No. Test parameters Classification

1. pH < 4.50 extremely acidic

4.51-5.00 very strongly

acidic

5.01-5.50 strongly acidic

5.51-6.00 moderately

acidic

6.01-6.50 slightly acidic

6.51-7.30 neutral

7.31-7.80 slightly alkaline

7.81-8.50 moderately

alkaline

8.51-9.0 strongly alkaline

> 9.0 very strongly

alkaline

(* tolerable to crops)

2. Salinity or Electrical

Conductivity

(mmhos/cm)

(1mmhos/cm = 640

ppm)

upto 1.00 average

1.01-2.00 harmful to

germination

2.01-3.00 harmful to crops

> 3.00 sensitive to salts

3. Organic Carbon (%) upto 0.30 very less

0.31-0.40 less

0.41-0.50 medium

0.51-0.80 on an average

sufficient

0.81-1.00 sufficient

> 1.0 more than sufficient

4. Nitrogen (kg/ha) upto 50 very less

51-100 less

101-150 good

151-300 better

> 300 sufficient

5. Phosphorous (kg/ha) upto 15 very less

16-30 less

31-50 medium

51-65 on an average

sufficient

65-80 sufficient

> 80 more than sufficient

6. Potassium (kg/ha) 0 very less

120-180 less

181-240 medium

241-300 average

301-360 better

> 360 more than sufficient

Source: Hand book of Agriculture ICAR (Indian Council of Agriculture Research)

Results and Discussion

The observations are as below:

Texture of soil samples from project siteis sand. Rest two Samples are clay and

silt-clay in Texture Classification.

The electrical conductivity in all the soil samples ranged from 0.608ms/cm to

1.473 ms/cm, indicating thereby that all the soil samples are normal in severity of

salt content and are normal for plant growth.

The pH in all soil samples ranges from 8.07 to 8.75.



The soil analysis report indicates that the soil in the area is capable of supporting

plant growth.

3.6 Land Environment

Land use pattern of the study area has been assessed through Remote Sensing

methodology using IRS-P6, LISS-III geocoded images. Figure-3.10 shows the satellite

imagery around the Project

Figure -3.10: Satellite Image

Land use / land cover categories identified in the area are Agriculture, Built-up, Forest,

Industry, Mining, Open Land, Reservoir, River, Wasteland and Waterbody. The land

use pattern of the study area is given below and in detail presented in Figure 3.11 and

Table 3.14.



Table 3.14: List of Major Industries in 10 Km Radius

Figure 3.11: Land Use / Land Cover Map of 10Km Radius.

Sr. No Name of Industries Distance by Road

1. Adani Power Plant 0.5 km

2. Phillips Carbon Black Ltd 5.55 Km

3. BHEL – OPGS Power Plant 2.61 Km

4. Carbon Edge Industries Ltd 7.15 Km



3.7 Socio-economic aspects

The study area covers within a radius of 10 km from the Project site. The 10 km radius

study area around the project site comprises of 10 villages. The socio-economic profile

of the study area is presented based on site visits; discussions with the villagers and the

secondary data available.

3.7.1 Human Settlement and Demography

Demographic characteristics of the study area are represented by a number of criteria,

namely population composition, sex ratio, family structure, and age distribution pattern.

Attempt has been made to compare the demographic features between the census data

whenever corresponding data are available. The area selected for the study constitutes 10

inhabited villages.



52% 48%

Sex Composition In Study Area (%)

Male

Female

88%

10% 2%

SC ST & Other Population Comparision in %

Others

SC

ST

0

50

100

LiteracyMale %

LiteracyFemale %

Gujrat 85.75 69.68

Study Area 61.42 42.99

% Literacy

3.7.2 Socio Economic Characteristics of the Area

Community Profile: The population is

distributed among 3420 households in the study

area. The 10 inhabited villages have a

population of 15995 comprising of 8280 males

and 7715 females. The number of females per

1000 males is 931 when compared with the

figures of the Gujarat State 919 and for the

nation 933 the study area found to be lesser than State and greater than national figures

indicating an equally composite society of male and female.

The scheduled caste population of the study area

on percentage basis is 10% of the total

population and scheduled tribe population is 2%.

Socio-Religious Groups: In the project area, the

predominant community is of Hindus. The

community is divided into several castes and

sub-castes. They are engaged in agriculture, animal husbandry, weaving and craft-

related activities. Some of them sell vegetables and work as labourers. They share

similar kind of interdependency, kinship relation and strong identity with the all

community. There is communal harmony in the region.

Literacy: The overall literacy in the

10 villages of the study area was

52.53%. The male literacy in the

study area was 61.42%as compared

with State was 85.75% in this period,

and the female literacy was 42.99%

while it was 69.68% for the State. The

graphical representation illustrates



25%

4%

5%

0%

16%

1%

49%

Vocational Pattern of the Study Area

Main Worker

Cultivator Worker

Agril Lab

HH industry

Other Worker

Marginal Worker

Non-Worker

comparative literacy of the study area and Gujarat. It may be noted that percentage of

literacy of study area was less than as compared with State in both male and female.

Vocation-wise distribution of the population based on 2011 census data of the study

area is graphically represented below indicate that about 49% non working population is

dependent on 51 % working

population.

As may be seen from these data, the

percentage of main workers in the

study area was 25%, in 2011. The

percentage of cultivators was 4% in

area. On the other hand, percentage of agricultural laborers was 5% and 17% people

were engaged in other activities. The percentage of household industries was lowest 0%

in the study area. The marginal workers in the study area were 1%. The non-workers

were 49% in study area.

3.8 Geology

3.8.1 HYDRO GEOLOGICAL STUDIES

Physiography

The predominant geomorphic units identified in the district are 1) Fluvial, 2)

Physiographically, the Kutch district can be divided into four parts, namely:

a) Central High land and the Upland in the Rann Area;

b) Central Plain in the southern part;

c) Little and Great Rann areas; and

d) Banni plains.

The mainland of Kutch is an undulating country with rugged broken ground and broad

plains and is marked by hill ranges and isolated peaks. There are three hill ranges in the

main land namely Dhinodhar, Jura and Vavar, which rise to 387 m and 274 m amsl.

The other uplands in the main land area are in Wagad area in the east forming part of

Bhachau and RaparTalukas. The Pachham, Khadir and Bela islands in the Great Rann



in the north also form highlands with maximum elevation of 458 m amsl. All the hill

ranges follow a general east-west trend.

Kutch district has about 350 km long coastline and its coastal plain is about 35-45 km

wide and attains the elevation up to 80 m amsl. The coast is generally flat and broken

by small and big creeks, viz., Kori, Boacha and Godia.

The Rann forms a unique and conspicuous landform and has been divided into the

Great Rann in the north and Little Rann in the east. The Rann mainly comprises

marshy land, salt/mud flats and is devoid of vegetation and habitation and has a very

hostile environment. The total area of Rann is about 25000 sq.km.

The extensive low lying area south west of Pachchham Island resembles Rann except

for some patches of scanty vegetation. It is known as Banni plain and covers an area of

about 2000 sq. km. About 777 sq. km of Banni plain is reported to be superior

grassland.

Physiographycally, the study area is fairly flat. Due to gentle gradient towards the sea

(Gulf of Kutch) most of the water flows in the sea within short span of time. Drainage

pattern of the Kutch district is mainly by Bharud, Kali, Suri, Khari, Mithi, Rukmavati

and BhukhiLuni, Rupen, Kankawati and Malwan rivers and its tributaries.

Drainage pattern of the study area is drained by several rivers and small tributaries,

which are of dendritic pattern which remains dry in almost all the season. The seasonal

rivers (rain fed) flowing through study area are MittiNadi (0.5 km, NE), SakraNadi

(1.5 km, E) Gulf of Kutch (4 km, S), ChhelaNadi (6.5 km, E) &RuparelNadi (6.5 km,

NE) from the project site.

Natural drainage passing through the site will be suitably trained and maintained. There

will not be any diversion.

Geology

The Pre-Cambrian granite and Aravalli rocks are reported to be exposed in a tiny hillock

i.e. “MerudaTakkar” in the northern part of great Rann.

The sedimentary rocks of marine and non-marine origin formed under different

environmental conditions during middle Jurassic to Recent period occur in the district



besides volcanic and intrusive rocks (Deccan Trap) of middle Cretaceous to lower

Eocene.

Geologically, the study area is underlain by Quaternary sediments consisting of a

succession of clay, silty clay, sand and sand mixed with gravel.

Hydrogeology

The hydrogeological studies to understand the local geology, geomorphic features,

drainage network, aquifer characteristics and yield of water. Accordingly, various

components controlling the hydrogeological regime.

Occurrence of Ground Water

The formations forming aquifer or hydrogeological units can be grouped as:

a) Mesozoic formations;

b) Deccan trap (Hard rock) as aquifer;

c) Tertiary formations; and

d) Quaternary sediments.

The ground water conditions, its occurrence and movement, hydraulic characteristics

and chemical quality aspects vary considered in each hydrogeologic group. The pre-

cambrian granite and Aravalli rocks are reported be exposed in a tiny hillock i.e.

“MerudaTakkar” in the northern part of great Rann.

Mesozoic Formations

The sediments belonging to Mesozoic period include both marine and non-marine

sedimentary formation and occupy almost 60% of the district. Patcham, Chari and

Katrol series belong to Jurassic period where as Umia or Bhuj represent lower

Cretaceous.

Patcham Series

The rocks of this series consist of yellow and greyish coloured sandstone, shale, and

fossil ferrous. Limestone and represent marine sedimentary sequence. It occupies largely

the island belt of Patcham, Khadir and Bela and small area in northern part in main land

of Kutch. The ground water occurs under water table and confined conditions in the

sandstone/shale sequence belonging to this group. The semi-consolidated sandstone



exposed in the lower reaches forms phreatic aquifer and is being developed locally for

domestic and irrigation purposes. The dug wells tapping this aquifer ranges in depth

from 10 to 24 m bgl, whereas the depth to water level during summer varies from 15 to

20 m. Their yield varies from 50 to 175 m3 /day. The quality of ground water is potable

to slightly brackish and near Rann and lower reaches while the deeper ground water is

saline. In Khadir Island, the springs have been observed at Hadibadang and Kakindiya

bet. They had about ½ lps discharges and quality of ground water was fresh at

Hadibadang and saline at Kakindiya. Exploratory borehole in this formation indicated

presence of alternating layers of shale and sandstone with minor bands of limestone

down to 150 m depths. Ground water at deeper levels is under confined conditions and

quality is saline, EC up to 9000 μs/cm. Only, shallow aquifer down to 30-35 m

constituted by feldspathic sandstone exposed in the mid-reaches hold some promise for

potable ground water in this formation.

Chari Series

The formations belonging to this formation are hard oolitic limestone, sand stone and

shale representing marine facie. This formation occurs mostly as inlier in the core of

anticlines and constitutes hilly topography. There is no ground water development in

formations belonging to Chari series because of marine nature of sediments and its

physiographic settings. Not much information is available about occurrence and

movement of ground water.

Katrol Series

The rocks belonging to this series occupy the Wagad up land and northern and central

parts of main land. It is represented by shale and sand stone sequence with minor bands

of limestone. The sandstone is generally made up of hard indurated blocks, except in

Wagad area where it is feldspathic and soft/friable at places. Ground water development

in these formations is confined to only the Wagad area falling in parts of Bhachau and

RaparTalukas.

Exploratory drilling in Wagad area has revealed presence of alternate bands of sandstone

and shale. The sandstone at shallow depth is generally soft and friable and forms aquifer



locally. The ground water in this formation occurs under phreatic to confined conditions.

The ground water development is generally through dug wells which, range in depth

from less than 10 m to about 25 m. At places, the dug-cum-bored wells are also

observed with depth of bores ranging between 25 and 60 m. Depth to water level ranges

from 10 to 30 m bgl. Yield of dug wells and dug-cum-bored wells range from 60 to 660

m3 /day. Though, the formation is hard and compact at deeper levels, at places the

ground water may occur in fractures in localized areas. Few tube wells, ranging in depth

from 40 to 140 m are observed in Wagad area tapping the fractured part of the aquifer.

The discharge of such tube wells range from 400 to 1000 lpm at drawdowns ranging from

3 to 9 m. In rest of the district, the formations belonging to Katrol Series do not from

aquifer due to hard and compact nature and geomorphological setting.

Bhuj Series

The formations belonging to the Bhuj (Umia) series form the most prolific aquifer

system in the district. This aquifer is extensively developed in central part of the district

in a belt extends from Gadhuli-Dayapar-Lakhpat area in the west to Bhachau in the east.

Lithologically the Bhuj Sandstone comprises of fine to coarse grained sandstone

interbedded with siltstone and shale. The sandstone, which mainly forms the aquifer is

soft, friable and highly porous/permeable.

The quality of ground water in general is fresh with EC 5000 μS/cm. Besides this, the

quality of the formation water is known to deteriorate with depth in underlying lower

Bhuj formations.

Ground water occurs both under phreatic and confined conditions. The unconfined of the

phreatic aquifers system in this formation extends down to a depth ranging from 20 m to

about 100 m depending on the presence of aquitards/ confining layers. The ground water

in central parts occur mainly in unconfined to semiconfined conditions whereas in the

western part, the deeper horizons within this system are under confined conditions and

free flow/auto flow conditions are also observed at places. The ground water in phreatic

system is generally developed through dug wells, dug-cum-bored wells and shallow tube

wells. However, due to excessive development and deepening of water levels, most of

the dug wells have gone dry, particularly in Bhachu-Dudhai, Anjar-Khedoi-Vidi, Kera-



Sisagadh and Deshalpur-Nakhatrana-Netra areas. In these areas, the ground water is

mainly developed through deep and medium depth tube wells ranging in depth from 80

to 250 m. These tube wells tap aquifer zones in the depth range of 40 to 220 m with

aggregate thickness of granular zones ranging from 30 to 100 m. The discharge of tube

wells range between 40 and 360 m3 /hr for drawdowns ranging between 3 and 12 m.

The piezometeric levels/water levels in Bhuj Sandstone ranges from 30 to 70 m bgl.

Deccan Trap

Deccan trap occurs as almost one continuous belt from Anjar to Lakhpat Taluka with a

lateral dislocation near the injunctions of Nakhatrana, Abdasa & Mandvitalukas. It

mainly comprises of light to dark grey basalt & dolerite as moderately extensive flows.

In the areas underlain by Deccan trap, ground water occurs in the weathered mantle and

along the interflow zones, joints and fissures. In this formation, very limited

groundwater development is observed due to poor water bearing characteristics and

highly saline ground water particularly in the central and western part. At places this

formation has limited thickness and acts only as a capping to underlying formations.

Ground water development is meagre in Deccan traps. It occurs in the weathered

portions & joints. Dug wells are 11 to 15 m deep with depth to water 5 to 9 m bgl.

Tertiary Formations

The tertiary sediments belonging to Eocene to Miocene period are of marine origin &

are largely argillaceous and calcareous in nature and do not contain arenaceous members

and thus mostly have inferior quality of formation water. However, the grey and mottled

sandstone and calcareous grits of the Manchhar series (Pliocene) form moderate aquifer

in the coastal areas between Mandvi-Mundra and parts of Abdasatalukas, where ground

water quality is moderate. However, occurrence of fluoride more than permissible limits

in the coastal tracts of Abdasataluka in general is indicative of non-acceptable quality of

ground water. The recent alluvium in the district in the coastal areas contain variable

quality of ground water.

Formations of Ranikot Series occur in parts of Mandvitaluka, fringing the southern

margin of the Deccan traps. They comprise of soft argillaceous, aluminous and

variegated shale, laterite and bauxite. There is very little ground water development in

this formation.



Supra Trappeans occur as about 9 m thick ferruginous laterite (iron cap) and aluminous

ferruginous laterite derived in situ from Deccan Trap flows in Anjar- Khedoi Region.

They locally yield very meager supplies of brackish to saline water to wells. However,

generally this formation occurs above the zone of saturation.

In Bhachau region they are as much as 76 m thick at places and locally yields small

supplies of brackish water to shallow wells.

Supra Trappeans comprising laterite, aluminous shale and lateritic clays also occur as

narrow belts overlying Bhuj Series in central parts of district. There is no ground water

development in the areas underlain by this formation.

Laki Series (Eocene)

Laki Series occurs in parts of Abdasa & Lakhpat Talukas. The formations comprise of

up to 160 m thick red & mottled clays gypsiferous, pyritiferous& carbonaceous shale

with thin seams of lignite & pockets of unconsolidated fine grained sand beds at the

bottom of the series.

The formations of this series yield very little quantities of brackish to saline water to dug

wells. Ground water occurs in confined conditions also. The confined aquifer is capable

of yielding large quantities of highly saline water.

Kirthar Series (Eocene)

Formations of Kirthar Series occur in parts of Abdasa & Lakhpat Talukas. They

comprise about 325 m thick mainly composed of Nummulitic limestone with occasional

thin beds of calcareous shale.

These formations yield very little quantities of poor quality water in wells located in low

grounds.

Nari&Gaj Series (Miocene-Oligocene)

The formations of these series occur in parts of Abdasa & Lakhpat Talukas. They

comprise of up to 640 m thick, mostly argillaceous formations composed of mottled

clays and variegated shale with thin beds of fine grained clayey sandstone and Shelly

limestone.



These formations yield very little quantities of brackish to saline water to wells. Quality

is potable in wells located near the stream courses or in the vicinity of surface water

bodies.

The sediments of Gaj Series unconformabily overlie the Bhuj Series and comprise of

grey and yellowish gypseous shale inter-bedded with fossili ferous marls. Due to poor

permeability, only limited ground water development has been possible.

Manchhar Series (Pliocene)

This formation occurs in about 259 sq.km area lying between Faradi and Bhadreshwar,

overlying the Bhuj Series unconformably and comprises of buff light grey, yellowish

clay, mottled sandstone and sandy clays with gypsum.

The mottled sandstone forms productive aquifer at places. Wells range from 7 to 24 m in

depth with depth to water 3 to 15 m bgl.

In Mundrataluka, some scope of ground water development exists. In Eastern Kutch,

(Wagad Area), there is no ground water development in this formation.

In parts of BhachauTaluka, this formation occurs as up to 60 m thick undifferentiated

massive reddish brown gypseous clay, shale, some laminated silt stone, lenses of laterite

& trap gravel, mottled sandstone and occasionally some limestone. This formation yields

meagre supplies of brackish to salty water to wells.

In Anjar-Khedoi area, the sediments of Manchar Series occur as 185 m or more thick

semi-consolidated clayey sandstone and conglomeratic sandstone. Fossili ferous

sandstone with silt stone & conglomerate. Clay shale, lime cemented conglomerate.

They yield meagre to small supplies of brackish water to wells. Locally the water is

saline.

In parts of Abdasa and LakhpatTalukas, up to 550 m thick, semi-consolidated fine to

medium grained current bedded sandstone, conglomerate, mottled clay, pink & yellow

limestone occur. They yield moderate to large quantities of potable to brackish water.

Water is highly brackish/saline near the coast. In parts of Mandvi&AbdasaTalukas these

sediments are generally extensive and have permitted moderate of ground water

development by means of dug and dug-cum-bored wells. Ground water occurs under

water table conditions down to 25 m and under confined conditions further below down

to 180 m.

Chemically the ground water has fluoride content exceeding the permissible limits of

ICMR standards at many places, i.e., around Naliya. DTW ranges from 2 to 29 m bgl

with depth of wells ranging from 8 to 90 m.

Tube wells yield about 1.5 m3 /minute for drawdowns of 12 to 21 m. Trasmisivity

ranges from 14 to 173 m2 /day. Sp. Capacity ranges between 30 & 110 lpm/day.



Quaternary Sediments

Milliolite limestone, which is white to dull grey, medium-grained limestone comprising

Milliolite Foraminifer, occurs along hill slopes and faulted plains, e.g., near Sukhpur on

the northern slopes of Khatrod range west of Adhoi, near Ler, etc. There is no ground

water development in this formation.

Alluvium occurs in channels of large ephemeral streams, & coastal tracts spread over

almost whole district. The alluvium comprises of brown loamy, kankary, silt, clays,

sand, gravel, loam &kankar with a thickness of about 6 m most of the district. However,

in southern parts of the district, i.e., in Mandvi & Mundra as well as Bhachau & Anjar

Talukas, the thickness may be considerable.

The alluvium yields small quantities of brackish water to shallow wells in

Bhachautaluka. Coarse facies may yield small to moderate supplies of brackish water to

wells in Anjar-Khedoi region. In parts of Abdasa and Lakhpattalukas, the water table is

generally below the formation. In Mandvi & Mundratalukas, the ground water

development is extensive.

There is no possibility of further ground water development east and southeast of

Lakadiya by means of deep tube wells because exploratory boreholes drilled at Lakadiya

& Kumbhariya down to 450 and 305 m bgl respectively have not met with any

promising granular zones. Between Bidada and Bhadreshwar in about 450 sq.km area

dug wells are 4 to 22 m deep with depth to water 3 to 16 m bgl. The tube wells tap

aquifers down to 129 m depth. The value of T is 27.327 m2 /day.

Between Hand and Kanmer in about 500 sq.km area, dug wells are 7 to 22 m deep with

depth to water ranging front 3 to 15 m bgl. They yield 48 to 75 m3 /day.

There is no possibility of further ground water development east and southeast of

Lakadiya by means of deep tube wells because exploratory boreholes drilled at Lakadiya

& Kumbhariya down to 450 and 305 m bgl respectively have not met with any

promising granular zones. Between Bidada and Bhadreshwar in about 450 sq.km area

dug wells are 4 to 22 m deep with depth to water 3 to 16 m bgl. The tube wells tap

aquifers down to 129 m depth. The value of T is 27.327 m2 /day.



Between Hand and Kanmer in about 500 sq.km area, dug wells are 7 to 22 m deep with

depth to water ranging front 3 to 15 m bgl. They yield 48 to 75 m3 /day.

Depth to Water Unconfined Aquifier during 2015-2016

District Location May 2015 Aug 2015 Nov 2015 Jan 2016

Kachchh District Mundra 6.08 5.25 4.5 5.74



3.9 Flora & Fauna

Some of the flora found in this area is listed below:

Table 3.15: List of Plant Species Recorded From the Study Area

S.no. Scientific Name Local Name Habit Family

1. Acacia leucophloea Hirmo, Haramu Tree Mimosaceae

2. Acacia nilotica Deshi Bhaval,

Bavar

Tree Mimosaceae

3. Acacia Senegal Kher, kherio,

Garad

Tree Mimosaceae

4. Achyranthes aspera Agado,

Kandhero

Herb Amarathaceae

5. Aelurops lagopidea Kharo ga Grass poaceae

6. Areva persica Bou, Bour Herb Amarathaceae

7. Areva pseudotomentosa Sane panjo bur Herb Amarathaceae

8. A. Polycantha Garad Tree Mimoceae

9. Adina cordifolia Hed Herb Rubiaceae

10. Aegle marmelos Bela Herb Rutacea

11. Ailanthus excels Maharukh Herb Simaroubaceae

12. Apluda mutica Fulari ga Grass poaceae

13. Aristida adscensionis Jandhar lambha

ga

Grass poaceae

14. Aristida funiculate Laso lambh Grass poaceae

15. Asparagus dumosus - Under -shrub Liliaceae

16. Avicennia marina Cheria Shrub Avicenniaceae

17. Azadirachta indica Neem Tree Melliaceae

18. Blainvilles acmella Tal Bhangro Herb Asteraceae

19. Belapharis maderaspatensis Uti gan Herb Acanthaceae

20. Belapharis repens Sane panjo

kandho

Herb Acanthaceae

21. Belapharis sindica Ubhero kandho Herb Acanthaceae

22. Blumea lacera Piro fulavo Herb Asteraceae

23. Boerhavia diffusa Rati, satodi herb Nycrtaginaceae

24. Cadaba fruticosa Karo- pijaro Straggling shrub Cappatrace

25. Calotropis gigantean akado Shrub Asclepiadaceae

26. Capparis decoduas Kar jo zad under shrub Capparaceae

27. Cardiospermum

halicacabum

Tridhari val,

Popti

Herb Sapindaceae

28. Cassia angustifolia Son makai Shrub Caesalpiniaceae

29. Cassia auriculata Avar Shrub Caesalpiniaceae

30. Cassia italic Mindhiavar herb Herb Caesalpiniaceae

31. Cauratia carnosa Khatumvadi ji

val

Climber Vitaceae



32. Cenchus biflorus Dhaman gha Grass Poaceae

33. Cenchus setigerus Anjaniyo Grass Poaceae

34. Ceriops tagal Shrub Rhizophoraceae

35. Chloris barbata Rusad gha Grass Poaceae

36. Chloris varigata Punjaniu ga Grass Poaceae

37. Citrullus colocynthis Tru val, tru deda Climber Cucurbitaceae

38. Cleome viscose Beddhro Herb capparaceae

39. Coccinia grandis Tindora Climber Cucurbitaceae

40. Cocculus hirsutus Vagval, Asipal Straggling shrub Menispermaceae

41. Commlcarpus verticillatus Dhokariyar Herb Nyctaginaceae

42. Commiphora wlghtll Gugar Small tree Burseraceae

43. Convolvulus arvensis Neri val Herb Convolvulaceae

44. Convolvulus auricomus Rushad neri val Climbing herb Convolvulaceae

45. Convolvulus microphullus Mankhani Herb Convolvulaceae

46. Corchorus depressus Mundheri Herb Tiliaceae

47. Corchorus tridens - Herb Tiliaceae

48. Cordia gharaf Liyar, Desi

gunda

Tree Ehretiaceae

49. Cordia perrottetill Jangli Gundi Tree Ehretiaceae

50. Cressa cretica Oin, Bukan Herb Convolvulaceae

51. Ctenolepis cerasiformis Dad vel Climber Cucurbitaceae

52. Cucumis callosus Kotimbiyal Climber Cucurbitaceae

53. Cymbopogon jwarancusa - Grass Poaceae

54. Cymbopogon martini Rosha Gha Grass Poaceae

55. Cyperus alopecuroides - Sedge Cyperaceae

56. Cyperus atkinsonil - Sedge Cyperaceae

57. Dactyliandra welwitschii Dad val Climber Cucurbitaceae

58. Dactylocternium

aegypticum

Kagatango gha Grass Poaceae

59. Dactylocternium sindicum Chund gha Grass Poaceae

60. Dalechampis scandens Char val Climber Euphorbiaceae

61. Desmostachya bipinnata Darab gha Grass Poaceae

62. Digitaria pennata - Grass Poaceae

63. Echinchloa colonum Samu Grass Poaceae

64. Elusine compressa Gandhiro gha Grass Poaceae

65. Elusine indica Adbau madanu Grass Poaceae

66. Enicostema axillare Mamej Herb Gentinaceae

67. Eragrostis ciliare Fuliyu gha Grass Poaceae

68. Euphorbia caducifolia Thar Shrub Euphorbiaceae

69. Fagonia bruguieri Dhramau Herb Zygophyllaceae

70. Fagonia schwelenfurthii Hamaso Herb Zygophyllaceae

71. Goniogyana hirta Undrakani Herb Favaceae

72. Gossypium herbaceum vagdau Shrub Malvaceae

73. Grewia tenax Gangui Under -shrub Tiliaceae



74. Grewia villosa Luo Shrub Tiliaceae

75. Heliotropium bacciferum - Herb boraginaceae

76. Heliotropium rariflorum - Herb boraginaceae

77. Hibiscus ovalifolius Kurad val Under -shrub Malvaceae

78. Indigofera cordifolia Gadar gari Herb Fabaceae

79. Indigofera obligifolia Zeel Shrub Fabaceae

80. Ipomea nil Kari patiyar twiner Convolvulaceae

81. Ipomea pes-caprae Straggling herb Convolvulaceae

82. Jatropha curcas Ratan jyot Shrub Euphorbiaceae

83. Leptadenia pyrotechnica Khip Under -shrub Asclepiadaceae

84. Leptadenia reticulate Doda Twiner Asclepiadaceae

85. Leucas aspera Gumu Herb Lamiaceae

86. Leucas lavandulaefolia Sanepanjo gumu Herb Lamiaceae

87. Lyceum barbatum Garothi Shrub Solanaceae

88. Maerua oblongifolia Pinjoli Woody twiner Capparaceae

89. Maytenus emarginata Vigo Tree Celastraceae

90. Panicum antidotale Gum gha Grass Poaceae

91. Penatropis spiralis Dhodheji val Twiner Asclepiadaceae

92. Periploca aphylla Rati khip Under – shrub Periplocaceae

93. Peristrophe bicalyculata Kari adhedi Herb Acanthacae

Fauna

Some of the fauna found in this area is listed below:

Table 3.16: List of Fauna in the Study Area

Sl.no. Common name Scientific Name Schedule of Wild Life Protection Act in which Listed

Mammals

1. Common Mangoose Herpestres edwardsii IV

2. Jackal Canis aureus II

3. Indian Fox Vulpes bengalensis II

4. Common house rat Rattus rattus V

5. Nilgai Boselaphus tragocamelus III

6. Squirrel Funambulus pennanti IV

7. Wild Pig Sus scrofa III

8. Fulvous fruit bat Rousettus leschnaulti

Reptiles

1. Wall lizard Hemidactylus spp -

2. Cobra Naja Naja II

3. Yellow Rat Snake Ptyas mucosus II

4. Common skink Mabuya caninata II

5. Garden Lizard Calotes versicolor -

Birds

1. Pariah Kite Milvus migrans -

2. Common Crow Corvus spenderns V



3. Grey Partridge Francolinus pondicerianus IV

4. House sparrow Passer domesticus -

5. White wagtail Motacilla alba IV

6. Grey Wagtail Motacilla alba

7. Common Tailorbird Orthotomus sutorius IV

8. Drongo Dicrurus adsmilis IV

9. Crow Pheasant Centropus sinensis IV

10. Blue Jay/ Indian Roller Coracias benghalensis IV

11. White eared Bulbul Pycnonotus leucotis IV

12. Red bent bulbul Pycnonotus cafer IV

13. Koel Eudynamis scolopacea IV

14. Pegion Columba livia IV

15. Indian Ring Dove Streptopelia decacto IV

16. Red Turtle Dove Streptopelia tranquebarica IV

17. Black winged kite Elanus caeuleus IV

18. Jungle Babbler Turdoides striatus IV

19. Common Babbler Turdoides caudatus IV

20. Large Grey Babber Turdoides makolmi IV

21. Hoopoe Upupa epops IV

22. White Throated Munia Lonchura malabarica IV

23. Indian Robin Saxicoloides fulicata IV

24. Ashy wren warbler Prinia Socialis IV

25. Franklin’s Wren warbler Prinia hodgsonii IV

26. Shikra Accipiter badius IV

27. House swift Apus affinis IV

28. Steppe Eagle Aquila nipalensis IV

29. Grey Shrike Lanius excubitor IV

30. Bay-backed Shrike Lanius vittatus IV

31. Magpie Robin Copsychus saularis IV

32. Desert Wheat eater Oenanthe deserti IV

33. Barn Swallow Hirundo rustica IV

34. Wire Tailed Swallow Hirundo smithii IV

35. Northern House Martin Dellichon urbica IV

36. Green Bee-eater Merops Orientalis IV

37. Chestnut Headed Bee-eater Herops leschenaulti IV

38. Booted Warbler Hippolais Caligata IV

39. Paddyfield warbler Acrocephala agricola IV

40. Crested lark Galerida cristata IV

41. Malabar Crested Lark Galerida malabarica IV

42. Ashy Crowned Finch Lark Eremopterix grisea IV

43. Sand Lark Calandrella raytal IV

44. Red wattled Lapwing Vannelus indica IV

45. Black Winged stilt Himantopus Himantopus IV

46. White Breasted Kingfisher Halcyon smymensis IV

47. Intermediate Egret Egretta intermedia IV



48. Cattle Egret Bubukus ibis IV

49. Little Egret Egretta garzetta IV

50. Indian Reef Heron Egretta gularis IV

51. Pond Heron Ardeola grayil IV

52. Small Indian Cormorant Phalacrocorax niger IV

53. Whimbrel Numenius Phaeopus IV

54. Common Sandpiper Tringa hypoleucos IV

55. Stone Curlew Burhinus oedicnemus IV

56. Black Ibis Pseudibis Papillosa IV

57. White Ibis Thesliornis aethiopica IV

58. spoonbill Palatea Leucocordia IV

59. Grey Heron Ardea cinerea IV

60. Painted Stork Mycteria leucocephala IV

61. River Tern Stema aurantia IV

62. Little Tern Sterna albifrons IV

63. Common Tern Stema hindo IV

64. Caspian tern Hydroprogne caspis IV

Source: Baseline Survey



CHAPTER 4

ANTICIPATED IMPACTS & MITIGAITON MEASURES

4.0 INTRODUCTION

As stated in chapter 1, M/s Nilkanth Concast Pvt. Limited proposed expansion of

production capacity. In this chapter, the anticipated environmental impacts and the

proposed mitigation measures for the proposed expansion have been described.

4.1 IDENTIFICATION OF IMPACTS

Identification and prediction of impacts is the most important component in the

environmental impact assessment studies. The environmental impacts can be categorized

as either primary or secondary. Primary impacts are those, which are attributed directly

due to the project and secondary impacts are those, which are indirectly induced.

The environmental impacts have been assessed assuming that the pollution due to the

existing activities in the area where the project site has been identified and covered under

the present environmental scenario established by the monitored baseline data. During

expansion phase of proposed activities various impacts on environmental parameter will

be studied to estimate the impacts on environment and apply mitigation measures.

Several scientific techniques and methodologies are available to predict impacts of

proposed 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.

4.2 ASSESSMENT OF SIGNIFICANCE OF IMPACTS

The environmental impacts may include all those that are beneficial or adverse, short or

long term (acute or chronic), temporary or permanent, direct or indirect and local or

regional. The adverse impacts may include all those leading to harm to living resources,

damage to human health, hindrance to other activities, impairment of quality for use,

reduction of amenities, damage to cultural and heritage resources, and damage to physical

structures. For each identified potential environmental impact, the associated



Nilkanth Concast Private Limited management is conscious of the continuous threat

posed by pollution to society and is committed to use best environment management

practices at planning & design stage and during expansion & operation phase. The

mitigation measures have been designed within the framework of various Central/ State

legislative and regulatory requirements on environmental and socio-economic aspects

aiming at the following:

Minimize disturbance to native flora and fauna;

Prevent air, water, soil and noise pollution;

Protect sites of historical, cultural and archaeological significance, if any;

And,

Encourage the socio-economic development.

The likely impacts of the proposed project would be:

During expansion phase; and

During operation phase.

The impacts of the proposed project and corresponding mitigation measures

designed/planned during expansion and operation phase are described in the chapter

further.

4.3 IMPACTS AND MITIGATION MEASURES DUE TO PROJECT SITING

(LOCATION)

The project site is located at Survey No. 221, Village: Vadala, Taluka: Mundra,

District: Kutch, Gujarat as shown in (Chapter 1). The total land requirement for the

project is 35.38 Ha. There will be no displacement of people including home oustees,

land oustees and landless laborers, thus R&R issue are not applicable.

As indicated earlier, there are no archaeological sites, Inter-state boundary, defence

installations or airports within 10 km periphery of the plant. The area is located in seismic

zone III and lie in moderate zone. There is no national park, WLS, Biosphere Reserve

(existing as well as proposed), critically polluted zone within 10 km of the project site.



4.4 IMPACTS AND MITIGATION MEASURES DUE TO POSSIBLE ACCIDENTS

Impacts

A major accident in an industry has the potential to cause serious injury or loss of life and

extensive damage to environment or property or serious disruption outside the plant. It

may require the assistance of outside emergency services to effectively handle the

situation. Accidents are normally caused by a number of different factors, e.g. plant

failure, human error, earthquake, vehicle crash or sabotage. An important element of risk

mitigation is emergency preparedness, which is recognizing the potential situations &

consequences and prepare the site emergency plan.

Mitigation Measures

Proper onsite and offsite emergency plans & Disaster Management Plan given in the

chapter7. In addition, various fixed installations for fire detection, Alarm and Firefighting

are available to effectively tackle the situation before the fire escalates into conflagration,

regular mock drills are conducted to check the effectiveness of the system.

4.5 IMPACTS AND MITIGATION MEASURES DUE TO PROJECT DESIGN

From Chapter 1 & 2 it can be seen that the proposed expansion of Nilkanth Concast Pvt.

Ltd. is being envisaged based on the techno-economic feasibility of technology presently

available in the country. All the technological measures have been considered to reduce

the possible air emissions, effluent generation and waste generation. Thus, the impact due

to the designing of the proposed project is not envisaged.

4.6 IMPACTS AND MITIGATION MEASURES DURING EXPANSION PHASE

During expansion phase, the following activities are considered to be important towards

development of impacts:

Piling,cutting and drilling

Erection of concrete and steel structures

Road construction



Painting and finishing

Clean up operations

Landscaping and Afforestation

Expansion phase activities will have moderate impacts on land use, demography

and socioeconomic, on-site soil and on-site noise. It could also develop minor

impacts on air and water quality and ecology, which will be contained by using

water sprinklers and noise abatement measures.

4.6.1 Impacts on Air Quality

Impact on Air Environment

During the expansion phase, dust (particulate matter) is expected to be the main pollutant

to be emitted from the haul roads, stockpiles and material handling. In this case, pollution

emission sources shall be distributed throughout the project site and will fall under the

category of area source.

Vehicular emission of SO2, NO2, CO and CO2 will add onto the air pollution. Movement

of vehicles on unpaved roads will also add onto the dust emission.

The dust generated will be fugitive in nature, which can be controlled by sprinkling of

water. The impacts will be localized in nature and the areas outside the project boundary

are not likely to have any major adverse impact with respect to ambient air quality.

Air Pollution Mitigation

There will not be any major leveling operations required as it is an expansion project.

Hence, no significant impact due to excavation activities in the area, except for civil

work and foundation of equipments is envisaged.

Ambient SOx and NOx levels will increase due to operation of expansion machinery

such as bulldozers, trucks etc. However, increase in levels of these pollutants is expected

to be insignificant since these machines will be operated intermittently. These equipment

are not stationary and would be moving from one place to other, hence there will not be

increase in concentration of emissions at a single location. Nevertheless, it will be



ensured that construction vehicles are properly maintained to minimize exhaust

emissions. It is necessary to control the dust emissions particularly during dry weather.

This will be achieved by regular water sprinkling all over the exposed area, at least twice

a day using truck-mounted sprinklers.

4.6.2 Impacts on Water Environment

During expansion, water will be required for expansion activities, sprinkling on

pavements for dust suppression and domestic & non domestic usages.

Impacts on Hydrology and water Use

As the expansion activities will take place inside the plant premises and it will not alter

the local drainage pattern and thus, is not expected to have any impact on the local

hydrology.

Mitigation

The sewage generated during the expansion and operation phases will be treated in the

Packaged type STP. The treated effluent will be reused for green belt development.

4.6.3 Impacts on Noise Environment

The major sources of noise during the expansion phase are vehicles and construction

equipment like dozers, scrapers, concrete mixers, cranes, pumps, compressors, pneumatic

tools, saws, vibrators etc. The operation of these equipments can generate noise levels in

the range 85-90 dB (A) near the source. These noises levels will be temporary during the

day time only hence will not have any significant impact on surrounding during

expansion phase.

Mitigation

The noise control measures during the expansion phase include provision of caps on the

expansion equipment and regular maintenance of the equipment. Equipments will be

maintained appropriately to keep the noise level within 85 dB(A). Wherever possible,

equipment will be provided with silencers and mufflers. High noise producing expansion

activities will be restricted to day time only. Greenbelt will be further strengthen.



Further, workers deployed in high noise areas will be provided with necessary protective

devices such as ear plug, ear-muffs etc. Overall, the impact of increase in noise on the

environment would be insignificant, as it will be localized and mainly confined to the

day hours.

4.6.4 Impacts on Soil and land use

All the major construction activities tend to create certain changes in the soils of the

area. However, this will take place inside the plant premises and as such, there will be

no impact on the soil condition outside the plant boundary in terms of fertility.

During storms, some of the excavated soil and construction materials such as sand etc.

would be blown up in the air and dispersed around the project site; some would also tend

to be driven into the soil and clog inter granular spaces.

Total area envisaged for the project is only 35.38 Ha which is very small as compare to

the total study area, the impacts on the land use pattern of the study area will be

negligible.

However, in order to minimize such impacts, sprinkling of water shall be done.

Preparatory activities like construction of access roads, temporary offices, and godowns,

piling, storage of construction materials etc. will be confined within the project area.

These will not generally exercise any significant impact except altering the land use

pattern of the proposed site. There will be no impact on the adjoining land.

As a result, the impact of land use would be very insignificant and any impact due to

expansion will be confined within the project area and will not hamper the land use

aspects outside.

Overall, it could be easily inferred that there will be no adverse impact on soil quality &

land use in the study area.



4.6.5 Impacts on Socio-Economic Environment

The impact of the proposed expansion plant on socio economic conditions of the study

area are expected to be positive during expansion phase.

Increase in floating population.

Increase in demand of ancillary services including public transport and other

logistics services. This will help in up-liftment of local people in terms of

economy and social welfare.

Economic up-liftment of the area.

Raising of home rents, land prices and increase in labour rates.

The local population will have employment opportunities due to the proposed

project. The local people will be preferred as laborers during the expansion phase

Local people shall be given preference for employment depending on their

qualification

The kerosene/LPG will be provided to the workers to prevent cutting of nearby

trees.

4.7 IMPACTS AND MITIGATION MEASURES DURING OPERATION PHASE

The process description including quantum of pollution loads from effluents and their

control measures has been discussed in Chapter 2- Project Description.

During the operation phase, depending upon the operating conditions, environmental

releases may occur from the plant. Environmental Emissions may be in the form of:

Air emissions

Waste water discharges

Solid waste disposal

Noise etc.



4.7.1 Impacts on Air Quality [TOR 7.1]

SPONGE IRON PLANT

The impacts on air quality due to the proposed 144,000 TPA Sponge Iron Plant have

been identified. Emissions released from the stack during operation phase will get

dispersed in the atmosphere and finally reach the ground at a specified distance from the

sources. From the proposed activities the possible environmental impact on air quality

has been envisaged.

The exhaust gases coming out of WHRB, having temperature around 150-1750 C is

taken to pollution control equipment i.e. ESP. Different industries using different

type of pollution control equipment like bag filter, scrubber and some also have

Electrostatic Precipitators (ESP) the clean gas is let out through stacks.

Rotary kiln plants have emergency stack / safety cap above the ABC of feed end

column. The safety cap is required to maintain the positive pressure inside the kiln

and avoid chances of CO related explosion. In many of the plants it is observed that

continuous black smoke was discharged from this cap. At night the flame cum

black smoke is more visible. The owners resort to this practice of discharging

untreated emissions

Raw Material Handling /Transport System

The possible pollutants are fugitive dust emissions from raw materials handling areas,

viz., loading/unloading, fuel stockyard, crushing units, etc. Raw materials will be fed to

hopper with the help of pay-loader/tipper.

Mitigation Measures

M/S Nilkanth Concast Private Limited shall provide dust suction system which

will control fugitive emission due to raw material handling. Dust suppression

system will be provided in the form of water sprinklers.



All vibrating screens and weigh feeders below the hopper, day bins etc are totally

covered to prevent leakages of dust.

All bins are totally packed and covered so that there is no chance of dust leakage.

All material transfer points are connected with dust suppression water nozzles to

avoid air pollution.

From Sponge iron plant fugitive emission will be envisaged due to accumulation

of ash on finished product surface.

Finished product before move to the finished storage yard it will be passing

through the ash suction system which controls the fugitive emission.

Use of indoor or covered stockpiles or when open-air stockpiles are unavoidable,

use water spray system, dust suppressants, windbreaks and other stockpile

management techniques.

Induction Furnace

Bag filters with Suction hood will be provided for the extraction of dust particles.

The continuous casting operation is selected for the production of billets in

induction furnace, where there is less attack on refractory lining, the changing need

drastically comes down by 87%. This process results in the low gases emission.

Mitigation Measures

Installation of Bag filters with Suction hood followed by Stack.

RE-ROLLING MILL

In the re-rolling mill particulate matters and metals arise from the transfer of

molten steel to the mold and from the cutting to the length of the product by oxy-

fuel torches during continuous casting.

Scarfing and grinding activities may generate particulate matter emissions.

Mitigation Measures

Exhaust should be fitted to filters and other relevant abatement equipment,

especially in the casting, rolling, and finishing shops, wherever it is applicable.



POWER PLANT

Emission of fugitive dust from coal handling plant (CHP) and ash handling system will be

controlled through adequate dust suppression and/or extraction system so that the impact

will be negligible.

MITIGATION MEASURES

Minimize the height of coal drop to the stockpile

Use of water spray systems and polymer coatings to reduce the formation of

fugitive dust from coal storage

Use of bag filter or other particulate control equipment for coal dust emissions

from crushing / sizing activities.

Rationalizing transport systems to minimize the generation and transport of dust

on site.

Dust suppression system by water sprinkler at dump hopper of coal

Regular dust suppression with water sprinkler at transfer points;

Control of fugitive emissions from the ash pond through maintaining a permanent

blanket of water cover over the deposited ash

Green belt development and afforestation in the plant and surroundings of ash

disposal area.

The following measures will be adopted for the control of emissions from the stacks

Suitably designed ESP with efficiency of 99.89% will be placed downstream of

the stacks which will separate out the incoming dust in flue gas and limit the dust

concentration at its designed outlet concentration of 50 mg/Nm3.

For the effective dilution and dispersion of the pollutants stack height has been

proposed based on the CPCB guidelines.



The dust generated from coal handling plant will be insignificant because of

handling of fine coal is in closed circuit. For further suppression of dust adequate

water spray system will be provided;

Adequate thickness of insulating material with proper fastening will be provided

to control the thermal radiation;

The impacts on air quality due to source of the air pollution in the proposed facilities

have been identified.

Sources of Emissions

Emissions released from the stack during operation phase will get dispersed in the

atmosphere and finally reach the ground at a specified distance from the sources. From

the proposed activities the possible environmental impact on air quality has been

envisaged due to the following sources:

Raw Material Handling

The possible pollutants are fugitive dust emissions from raw materials handling areas viz.

loading / unloading, fuel stockyard, crushing units etc. The major sources of pollution

from proposed units can be classified under the following heads:

Pollutants in the waste gases namely, particulate matter (PM), sulphur dioxide,

NOX and Carbon monoxide, etc.

Fugitive dust generated during vehicular movement.

Mitigation Measures

Pollution equipment consists of I.D. fan, bag filter unit, ducting pipes, spark

arrester, pulse jet, dust collector.

M/s. Nilkanth Concast Pvt. Ltd. shall provide dust suction system which will

control fugitive emission due to material and raw material handling.

Dust suppression system will be provided in the form of water sprinklers.

All vibrating screens and weigh feeders below the hopper; day bins etc are totally

covered to prevent leakages of dust.



All bins are packed and covered so that there is no chance of dust leakage.

Regular monitoring of air polluting concentrations, etc.

Installation of Bag Filters, ESP and wet scrubbers followed by Stack

In this case the source emission is envisaged in operation phase Stacks of desired

height (12 stacks in existing & 6 stacks is proposed) for proper dispersion of

gases. Details of APCS is given in the Table 4.2.

Whenever, APCS is not working, then raw material feed will be stopped.

Consequently there will be no production in the unit till APCS is rectified.

Methodology: Impact Assessment in Air Environment [TOR 7.1]

As soon as the pollutants are emitted into the atmosphere, the dilution and dispersion of

the pollutants starts which are controlled by various meteorological parameters like wind

speed and direction, ambient temperature, etc. In most dispersion models the relevant

atmospheric layer is that nearest to the ground, varying in thickness from several hundred

to a few thousand meters. Variations in both thermal and mechanical turbulence and in

wind velocity are greatest in the layer in contact with the surface. The atmospheric

dispersion modeling and the prediction of ground level pollutant concentrations has great

relevance in the following activities:

Estimation of impact of industry on surrounding environment.

Estimation of maximum ground level concentration and its location in the

study area.

The mathematical model used for predictions on air quality impact in the present study

area is AERMOD. It is the next generation air dispersion model.

The AERMOD is actually a modeling system with three separate components:

AERMOD (AERMIC Dispersion Model), AERMAP (AERMOD Terrain Preprocessor),

and AERMET (AERMOD Meteorological Preprocessor).

Special features of AERMOD include its ability to treat the vertical in homogeneity of

the planetary boundary layer special treatment of surface releases, irregularly-shaped area



sources, a plume model for the convective boundary layer, limitation of vertical mixing

in the stable boundary layer, and fixing the reflecting surface at the stack base.

The AERMET is the meteorological preprocessor for the AERMOD. Input data can

come from hourly cloud cover observations, surface meteorological observations and

twice-a-day upper air soundings. Output includes surface meteorological observations

and parameters and vertical profiles of several atmospheric parameters.

The AERMAP is a terrain preprocessor designed to simplify and standardize the input of

terrain data for the AERMOD.



Table 4.1: Stack Details

S.N. Operational

Parameters

Existing Proposed

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6

1. Stack Height

(m)

30 30 53 30 30 12 18 6 12 22 30 30 53 30 6 22

2. Stack

Diameter (m)

1 1 1.5 1.0 1.5 0.3 0.8 0.48 0.3 0.8 1 1 1.5 1.0 0.48 0.8

3. Flue Gas

Velocity

(m/s)

5.91 5.91 5.97 6.21 6.35 5 4.84 3.20 5 5 5.91 5.91 5.97 6.21 3.20 5

4. Flue Gas

Temp.(K)

412 412 402 417 323 310 310 350 320 330 412 412 402 417 350 330

5. Emission(mg/Nm3)

PM10 29.56 29.56 26.96 35.93 17.98 16.57 13.98 21.0 15.24 17.24 29.56 29.56 26.96 35.93 21.0 17.24

SOx 8.82 8.82 13.2 - - - - - - - 8.82 8.82 13.2 - - -

NOx 7.51 7.51 10.56 - - - - - - - 7.51 7.51 10.56 - - -

6. Air Pollution

Control

System

ESP ESP ESP ESP Bag

Filter

Bag

Filter

Bag

Filter

Bag

Filter

Bag

Filter

Bag

Filter

ESP ESP ESP ESP Bag

Filter

Bag

Filter

Existing: 1)Rotary Kiln 1, (2) Rotary Kiln 2 3) AFBC boiler 4) WHRB 1& 2 (5) Induction Furnace (6) Iron ore

Crusher (7) Coal crusher /Screen house (8) Coolar discharged building (9) Intermediate bins 10) Product

Separation/Storage house

Proposed: 1)Rotary Kiln 3, (2) Rotary Kiln 4 (3) AFBC 4) WHRB 1& 2 5) Coolar discharged building 6)

Product Separation/Storage house



Post Project Scenario [TOR 7.1]

Predictions have been carried out using AERMOD for study period. Predicted maximum

ground level concentrations considering micro meteorological data superimposed on the

maximum baseline concentrations obtained during the study period to estimate the post

project scenario, which would prevail at the post operational phase.

Predicted value superimposed on the existing baseline value gives the overall scenario,

which would prevail during the operational phases. The resultant and incremental

concentrations of PM10 and SOx for existing and proposed plants and their cumulative

effects are presented in Table 4.2, The isopleths for pollutants PM10 and SOx for existing

and proposed plants are presented in Figures 4.1, 4.2, 4.3 and 4.4.

Maximum Incremental Levels

(g/m3)

Distance (km) Direction

PM10

Cumulative 2.27 1000 m NNE

Proposed 0.95 1000 m NNE

SOx

Cumulative 2.82 975 m NE

Proposed 1.6 750 m NE



Table 4.2

The Resultant Concentrations of PM10 due to incremental GLCs for Plant

(Proposed + Existing) [TOR 7.1]

Sr.

No.

Station

No

Description of

monitored

stations

Baseline

Conc(g/m3)

Predicted

Conc(g/m3)

Resultant

Conc(g/m3)

1. A1 Project Site 83.4 0.69 84.09

2. A2 Vadala 71.6 0.46 72.06

3. A3 Bhadreshwar 73.4 0.23 73.63

4. A4 Pavdiara 81.6 1.62 82.22

5. A5 Bharudia 68.9 0.23 69.13

6. A6 Hatadi 64.3 0.23 64.53

7. A7 Kukadsar 71.3 0.00 71.3

8. A8 Luni 69.5 0.00 69.5

Table- 4.3

The Resultant Concentrations of SOx due to incremental GLCs for Proposed Plant

(Proposed + Existing)

Sr.

No.

Station

No

Description of

monitored

stations

Baseline

Conc(g/m3)

Predicted

Conc(g/m3)

Resultant

Conc(g/m3)

1. A1 Project Site 21.1 1.72 22.82

2. A2 Vadala 18.2 0.29 18.49

3. A3 Bhadreshwar 15.3 0.29 15.59

4. A4 Pavdiara 19.4 1.43 20.83

5. A5 Bharudia 16.4 0.29 16.69

6. A6 Hatadi 13.5 0.29 13.59

7. A7 Kukadsar 16.9 0.00 16.9

8. A8 Luni 18.0 0.29 18.29



Discussion on Modelling Results

For prediction of the impacts for any proposed project, in general, the emission

contributions from the proposed units is added to existing background AAQ

concentration and the resultant AAQ expected is predicted.

The predicted ground level concentrations obtained when superimposed on the baseline

concentrations are within the prescribed NAAQ Standards for residential areas.

In point source emissions, the stacks are subjected to plume rise which again is dependent

on force of buoyancy and momentum. The higher is the plume rise or stack, the lesser

will be ground level concentrations (GLC’s).The emissions when released into the

atmosphere are subjected to transportation, dispersion, transformation, and fall out and

wash out and finally reach the ground level at a particular distance.



Figure 4.1: Predicted GLC of PM10 due to Proposed Plant (AERMOD )



Figure 4.2: Predicted GLC of PM10 due to Existing + Proposed Plant (AERMOD )



Figure 4.3: Predicted GLC of SO2 due to Proposed Plant (AERMOD)



Figure 4.4: Predicted GLC of SO2 due to Existing + Proposed Plant (AERMOD)



4.7.2 IMPACTS DUE TO THE TRANSPORTATION OF RAW MATERIAL

The emissions due to transportation of vehicles in the study area were determined from

fuel-based emission factors and number of vehicles plying on roads in the area. Loading

and transportation of raw materials are the significant sources of emissions.

The majority of trucks (95%) plying in the study area are manufactured in India as per the

standard norms hence it is assumed that emission from these trucks will be similar and

is mandatory for the vehicle manufactures to follow emission norms under the Motor

Vehicle Act. The emissions through transportation are assessed based on Emission

factors for on-road vehicles (CPCB Publication 1998).

Mitigation Measures

The vehicles transporting raw materials will be covered by tarpaulin in order to

prevent dust emission during the transport.

The vehicles used in transportation will comply norms as per the motor vehicle

act.

The repair and maintenance of vehicle will be taken care by transporter

Vehicles with PUC will be only allowed to operate

The finished product will be transported by the same trucks carrying raw material.

Green belt shall be provided around the plant area. Plantation along the internal

roads in the plant premises will also be undertaken.

Particulate matter will be controlled below 50 mg/Nm3 by providing efficient dust

suppression and extraction system. Water spray system shall be installed in the

material handling system transfer points.



Overall impacts are rated as:

Impact Rating Ambient Air Quality

Nature of impact Adverse

Duration of impact Long term

Impacted Area Localized

Likelihood of occurrence High

Severity of impact Low

Significance of impact Minor

As the maximum 24 hourly average incremental GLC values for PM, SOx and NOx due

to operation of proposed expansion project is minimal and within the limit prescribed in

NAAQS, impact of the above parameters on the Proposed Expansion. Further, the impact

is considered to be localized in nature after the control measures are implemented in-

place.

4.7.2.1 IMPACTS DUE TO VEHICLE MOVEMENT

Products, Raw Materials and wastes will be transported in covered trucks with

tarpaulin by road and ensured no spillage during transportation. Hence, there

will not be much fugitive dust generation during transportation of raw materials

and wastes. Site is well connected by Pucca road which is capable of absorbing

additional truck movement due to transportation. Green belt is developed on

both sides of internal road and also village road.

4.7.2.2 TRAFFIC STUDY [TOR 6.9]

The traffic studies have been conducted to know the prevailing traffic volumes on the existing

roads. It is essential to consider these details for assessing the anticipated future traffic volumes

as a part of overall impacts assessment for the project.

The variations of traffic densities depend upon the working days and time and also vary in day

and night times. In order to assess the prevailing traffic volumes on the roads, the survey was



conducted during normal working days of the week by avoiding local holidays or abnormal

situations to reflect the true picture of the traffic densities.

Methodology

Vehicle Count

The vehicles passing through the road (in both ways) were counted separately for 24

hours at one location from 06:00 hrs to 06:00 hrs next day continuously. Category-

wise vehicle counting has been done continuously and recorded in the traffic volume

count on hourly basis under respective categories.

Categorization of Traffic

The engine driven vehicles were categorized into various heads viz. Trucks/Bus, Light

Carriage Vehicles (LCV), Car/Jeep, Multi Axle Vehicles, Two/Three Wheelers and

Cycles/others. Survey was conducted during the weekdays and weekend.

Table 4.4 Transportation Details

Existing - Weekdays Traffic Details

Fast Vehicle Slow Vehicle

Day

Car/jeep/ van & four

wheelers Bus/ coach

Heavy motor vehicle Trucks

Motor cycle &

scooter

Three wheelers

Farm vehicle (tractor/ combine harvester

Up Down

Up Down

Up Down

Up Down

Up Down

Up Down

up Dow

Mon 135 130 14 15 2 3 95 80 205 226 37 34 3 5

Tue 104 102 12 14 1 1 115 95 210 218 34 42 2 2

Wed 130 130 12 15 2 1 113 95 246 210 37 45 6 7

Thu 127 125 13 14 1 1 105 86 230 248 27 36 5 5

Fri 130 125 15 17 2 2 138 127 236 250 35 45 6 8

Total 616 612 66 75 8 8 566 483 1127 1152 28 30 22 27

Sat 85 80 14 15 2 2 87 75 202 214 26 29 3 3

Sun 65 58 10 10 0 0 90 64 86 86 12 14 4 3

Daily Average

102 13 1 95 220 28 3



Existing Traffic Scenario along Study Road

The road connects the project site to State Highway through other mediator roads. All types of vehicles

are observed during the study. Buses / Couch and in addition to Heavy Motor Vehicle are also using

this road. Since the road is not divided, the speed of moving vehicles is also less. The operating speeds

of vehicles are within the prescribed limit.

The traffic count was taken on weekdays as well as on holiday (weekend) to observe & compare the

variation on a working day with a holiday. It was found that working day traffic is slightly higher than

the holiday. Although the compositions of heavy vehicles like truck, etc. was found to be more or less

same for both weekdays and weekends. Accordingly the traffic data is presented for calculation and

analysis obtained for the working day.

Road safety measures will have to be practiced as it does not exist due to the absence of activities in the

area. Presently the pedestrian movement is almost negligible, however their safe movement must be

ensured during construction stage as well as after construction.

TRAFFIC MANAGEMENT MEASURES

All gates are manned with efficient security who can guide the entry and exit of vehicles.

GGL has one way traffic movement to exit gates and this ensures safety. All precautionary measures

are ensured for the safety of construction laborers while working at the site.

4.7.3 Noise Levels

During operation, the major noise generating sources are grinding mill, loading sections,

blenders etc. These sources will be located far off from each other. Under any

circumstances the noise level from each of these sources will not exceed 85 dB (A).

Noise levels generated in the project site will be confined within the proposed plant the

impact of noise levels on surrounding will be insignificant.

Mitigation Measures

The noise levels stipulated by Central Pollution Control Board at any point of time will

not exceed the standards.

By providing padding at various locations to avoid sharp noise due to vibration.

Other than the regular maintenance of the various equipment, ear plugs/muffs are



recommended for the personnel working close to the noise generating units;

All the openings like covers, partitions will be designed properly

Inlet and outlet mufflers will be provided which are easy to design and construct.

All rotating items will be well lubricated and provided with enclosures as far as

possible to reduce noise transmission.

The insulation provided for prevention of loss of heat and personnel safety will

also act as noise reducers.

4.7.4 Impact on Water


generation and Dust suppuration, Water is also required for drinking, sanitary, Green

Belt Development and fire-fighting purpose.

In order to conserve water and minimize the makeup water requirement, it is proposed

to adopt re-circulating systems for equipment cooling. In re-circulating system same

water re-circulates again and again and some make up water is added for evaporation

losses.

Out of the Fresh water requirement of 1450 KLD for the existing as well as proposed

plants only 257 KLD waste water will be generated and 157 KLD will be recirculated.


The drainage map of 5km radius of the proposed expansion project is given below:



Figure 4.5 :Drainage Map



4.7.5 Impact on soil

The reserved forests in the study area are in patches. There is no designated ecological

park or Bio Reserve/Wild life sanctuary in the 10 km radius of the proposed plant site.

The impact on terrestrial ecology will be negligible in the first instance and shall be

insignificant.

4.7.4 Solid Waste Generation

The major solid wastes for existing as well as Proposed Project are ESP and Bag filter

collected dust, Slag from steel making, Ash from CPP and Coal Char / Dolchar from

Sponge Iron Production

TABLE 4.5: Solid Waste Generation & Mitigation Measures


TPA

Utilization

1. ESP and Bag

filter dust

Sponge Iron Plant&

RMH Units

14,400 Shall be used in Fly Ash brick

Manufacturing.

2. Ash CPP 4914 Shall be used in Fly-Brick

Manufacturing Unit

3. Slag Induction Furnaces 26460 Shall be used in Road

construction and back filling.

4. Coal Char/

DolChar

Sponge Iron Plant 10080 Shall be used in CPP

5 Mill Scale Rolling Mill 18000 Re-utilized in Induction Furnace

Slag Analysis

Submerged Arc Furnace Slag and Induction Furnace Slag will be generated. The analysis

report of the proposed Slag is given here under:

Type of

waste

Source of

Generation Typical Chemistry (%)

IF Slag Induction

Furnace

operation

CaO : 30-31

SiO2 : 32-33

Al2O3 : 18-22

MgO : 8-10

FeO :0.2-0.6



S :1.5-1.7,

Hazardous Waste Inventory

S. No. Hazardous

Waste

Quantity Utilization







4.7.6 Impact on Demography and Socio-Economics

The impacts of the proposed project, during its operation, on demography and socio-

economic condition can be identified as follows.

Increase in employment opportunities and Reduction in migrants to outside for

employment.

The proposed expansion project creates direct employment and indirect

employment to 395 people.

Increase in consumer prices of indigenous produce and services, land prices,

house rent rates and Labour prices.

Improvement in transport, communication, health and educational services.

Increase in employment due to increased business, trade commerce and service

sector.

The overall impact on the socio economic environment will be beneficial.

The management of M/s. Nilkanth Concast Private Ltd. has proposed to give

preference to local people for recruitment in skilled and semi-skilled category.

4.8 Measures for minimizing and / or offsetting adverse impacts identified

The potential adverse environment impacts possible verses the change expansions have

been summarized in the Table 4.7:-



Table 4.6 Potential impacts verses Mitigation Measures Adopted

S.N. Impact Topics Impact On Impact Due to Adopted Measures

1. Physical

Resources

Air

Environment

Release of air

pollutants

Incorporation &

installation of air

pollution

control systems and

ensuring their

effective functioning.

Water

Environment

Drawl of water

and release of

polluted waste

water

Maximum recirculation

of water and

Incorporation &

installation of water

pollution control

systems and

ensuring their effective

functioning.

Soil Release of

polluted waste

water,

Deposition of

PM released &

Dumping of

solid waste

Incorporation &

installation of water and

air pollution control

systems, Handling &

disposal of solid waste

including

hazardous waste in

accordance with

statutory norms.

2 Biological

Resources

Vegetation Release of

polluted

wastewater,

Deposition of

pollutants

released.

Incorporation &

installation of water and

air pollution control

systems

3. Land

Acquisition

Land

environment,

Aesthetics

Conversion of

existing

land use pattern

The total land

requirement for the

project is 35.38 Ha in

possession.

4. Noise Habitats Use of

equipment

having

operating

sound level

Noise Control measures

as required have been

envisaged. All noise

levels will be maintained

within the permissible



more than the

statutory level.

statutory limits.

5. Solid Waste Habitats and

Surrounding

environment

Release of toxic

chemicals

Reuse and minimization

of solid waste

6. Transportation Habitats and

Surrounding

environment

Release of

pollutant,

Improper traffic

management.

Use of vehicles meeting

the statutory

norms related to

emission, transport by

railway, proper traffic

management

7. Social &

Economic

Human,

livelihood,

Education

etc

Influx of

people,

Settlement,

Stress on

existing

infrastructure

etc.

No negative impact

envisaged. Moreover

additional social

improvement activities

have also been planned

by the project

management in the

region.

8. Cultural

resources

Human Influx of

people,

Settlement

No negative impact

envisaged

4.9.1 Irreversible and Irretrievable Commitments of Environments Component

The people are not expected to create any irreversible and Irretrievable impacts as:

The proposed expansion will be done in the existing land in which 35.38 Ha in

possession and the plant is in operation in this land, hence there is no change in the land

use pattern. No forest land is involved, no homestead involved, no land oustees and R& R

not required. All the impacts created by the project can be mitigated by adoption of

suitable mitigation measures.

Impacts Evaluation

The evaluation of the impacts of the proposed expansion on the environment, both in

terms of quality and quantity have been made. The environmental impact evaluation of

possible impacts as a result of proposed project activities on various environmental

parameters is primarily based on careful study of plant operations, surrounding

environment etc. The aspects such as air, water, land, noise and related issues of



environment have been assessed on the basis of plant operations for similar plants and

baseline of the study area. For quantification of impacts, matrix system as modified to

some extent has been used as per given below:

For quantifying impacts on the environment, the guidelines and standards prescribed by

Ministry of Environment & Forests, Central Pollution Control Board and State Pollution

Control Board are being considered.

1000 numbers are distributed as per the weight-age to each parameter considered based

on its importance as per given below:

Parameters Importance Value

Air Quality 150

Water quality 100

Water resources 100

Noise and vibration 50

Solid waste 150

Land Use Pattern 50

Forest & Vegetation 50

Wild life 50

Socio – economic 150

Employment 150

The severity has been divided in impact scores from 0-5 for calculating the severity of

impacts on the environmental parameters due to various project activities as given below.

Severity criteria Impact score

No impact 0

Significant impact-slight and short term 1

Significant impact-slight and long term 2

Moderate impact- short term 3



Moderate impact- long term 4

Major Impact - Permanent 5

The impact score can be -ve or +ve depending on whether the impact is adverse

or beneficial.

Based on the above importance values and impact scores, the impact value (impact score

x importance value) for each environmental parameters is calculated. The impact value

for individual parameter is added to arrive at the total impacts value. The criterion used to

make conclusive statement is based on the total impacts value without control measures

is defined as given below.

Total impact value Conclusions

Upto(-)1000 No appreciable impact on environment

(-) 1000 to (-) 2000 Appreciable but reversible impact. Mitigation measures important.

(-)2000 to (-) 3000 Significant impact which is mostly irreversible. Mitigation measures

crucial.

(-) 3000 to (-) 4000 Major impact which is mostly Irreversible. Selection of process and

raw material to be crucial.

Above (-) 4000 Permanent irreversible impact, alternative sites to be considered.

The environmental impact matrix based on the above principles has been attempted for

the proposed project and is given in Table 4.7

TABLE 4.7: QUANTITATIVE IMPACT EVALUATIONS DURING EXPANSION &

OPERATION PHASE

Environ

mental

parameters

Importance

value

Expansion

Phase

Operation Phase Impact Value

Without

EMP

With

EMP

Expansion

Operation

Without

EMP

Operation

With

EMP

Air Quality 150 (-)1 (-)3 (-)1 -150 -450 -150



Water quality 100 (-)1 (-)3 (-)1 -100 -300 -100

Water

resources

100 (-)1 (-)4 (-)1 -100 -400 -100

Noise and

vibration

50 (-)1 (-)3 (-)1 -50 -150 -50

Solid waste 150 (-)1 (-)4 (-)2 -150 -600 -300

Land Use

Pattern

50 (-)2 (-)2 0 -100 -100 0

Forest &

Vegetation

50 (-)2 (-)2 0 -100 -100 0

Wild life 50 (-)1 (-)1 0 -50 -50 0

Socio –

economic

150 (+)2 (+)2 (+)4 300 300 600

Employment 150 (+)2 (+)2 (+)3 300 300 450 Total

-200 -1550 350

The total impact value for the project works out to be:

During expansion stage : (-) 200

During operation stage without EMP : (-) 1550

During operation stage with EMP : (+) 350

The results indicate no appreciable environmental change. To summarize, most of the

project activities does not affect the surrounding environment.



CHAPTER 5

ANALYSIS OF ALTERNATIVES

(TECHNOLOGY & SITE)

5.0 ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)

Alternate technologies were explored considering the following

Capacity of the Plant.

Conservation of scarce and costly energy input.

Amenability of available raw materials.

Cost consideration.

The availability of infrastructure facilities and logistics of operation are also kept in

mind while evaluating a technology for its possible adoption.

The raw materials for Sponge Iron production are:

Iron Pellets.

Dolomite

Coal

Use of Pre-reduced iron pellets have been established as it reduces coal consumption as

well as steel scrap quantity in Induction Furnace.

Sponge pellet plant, Induction furnace, Rolling Mill and Section Mill is well known and

proven technologies all over the world. Hence, no alternative technologies are

considered.

5.1 ALTERNATE SITES/SITE SELECTION

This is an Expansion project hence no analysis of alternate site selection is required.



CHAPTER 6

ENVIRONMENTAL MONITORING PROGRAMME

6.1 POST PROJECT ENVIRONMENTAL MONITORING

The environmental monitoring is important to assess performance of pollution control

equipment installed in the expansion project of M/s. Nilkanth Concast Private Limited.

The proposed project is an expansion of their 72,000 TPA Sponge Iron to 1,44,000 TPA

by Installation of additional Two no. Kilns of 100 TPD each, Mild Steel (Ingots, Billets,

TM Bars & Channel/ Angles) from 1,80,000 TPA to 3,60,000 TPA by installation of

additional two nos. of Induction furnaces 20 T capacity each, Rolling & section mill,

Captive power plant from 4MW to 6 MW and Waste Heat Recovery Power Plant

(WHRB) from 6 MW to 10 MW at Survey No.221, Village: Vadala, Taluka: Mundra,

Dist: Kutch, Gujarat. The sampling and analysis of environmental attributes including

monitoring locations will be as per the guidelines of the Central Pollution Control

Board/ State Pollution Control Board.

Environmental monitoring is being carried out on regular basis by M/s. Nilkanth

Concast Private Limited to assess the pollution level in the plant as well in the

surrounding area. Therefore, regular monitoring program of the environmental

parameters is essential to take into account the environmental pollutant of the study

area. The objective of monitoring is:

To verify the result of the impact assessment study in particular with regards to

new developments;

To follow the trend of parameters which have been identified as critical;

To check or assess the efficiency of the controlling measures;

To ensure that new parameters, other than those identified in the impact

assessment study, do not become critical due to the commissioning of proposed

facilities;

To check assumptions made with regard to the development and to detect

deviations in order to initiate necessary measures;



To establish a database for future Impact Assessment Studies for new projects.

The attributes, which needs regular monitoring, are specified below:

Air quality

Water and wastewater quality;

Noise levels;

Soil quality;

Ecological preservation and afforestation; and

Socio Economic aspects and community development

The post project monitoring to be carried out at the industry level is

discussed below:

6.2 MONITORING AND REPORTING PROCEDURE

Regular monitoring of important and crucial environmental parameters is of

immense importance to assess the status of environment during plant operation. With the

knowledge of baseline conditions, the monitoring programme can serve as an indicator

for any deterioration in environmental quality due to operation of the plant so as suitable

mitigation steps could be taken in time to safeguard the environment. Monitoring is as

important as that of control of pollution since the efficiency of control measures can only

be determined by monitoring. The following routine monitoring programme would

therefore be implemented by M/s. Nilkanth Concast Private Limited. The monitoring

schedule for the environmental parameters is suggested in Table 6.1.



TABLE 6.1

MONITORING SCHEDULE FOR ENVIRONMENTAL PARAMETERS

Sr.

No.


Frequency

Method of

Sampling

Parameter

I Air Pollution & Meteorology

A Stack Monitoring

1 Stacks Continuous Online

CEMS

PM10 , PM2.5, SO2,

NOx

B Air Quality Monitoring

1 Locations in and

around the plant

Continuous 24 hr

continuously

PM10, PM2.5 ,

SO2, NOx

2 Work zone monitoring Twice in a month High volume

sampler

PM10, PM2.5 ,

SO2, NOx

C Fugitive Emissions

Raw material handling,

feed area, and other

areas specified by SPCB

Twice in a month 8-hour basis with

High Volume

Sampler

PM10 , PM2.5

II Water and Wastewater Quality

Water Quality

1

Ground water

Once in a season Grab (Class C) and

IS:10500, 1986

2 Surface water Once in a season Grab Parameters

specified in

IS:2296

III Ambient Noise Levels

1 On the Plant Boundary

at three locations

Once in three months

for the various Units of

24 hr continuous

with one hr

Noise levels in

dB(A)



Sr.

No.


Frequency

Method of

Sampling

Parameter

the plant interval

2. Surrounding Area Once in each season

for ambient noise

levels

24 hr continuous

with one hr

interval

Noise levels in

dB(A)

IV Soil Quality

In and around the plant

Area

Once in Pre-Monsoon

and Post Monsoon

season

Grab Physico-chemical

parameters and

heavy metals

6.2.1 DATA ANALYSIS

All the parameters are being analyzed as per IS procedures specified for those

parameters. All water samples will be analyzed for various parameters as per IS: 10500

with the specified procedures.

The methodology adopted for monitoring & analysis of PM2.5 & PM10 is as per IS: 5182

Part IV SO2 & NOx as per IS: 5182 Part II & Part VI respectively. PM2.5 & PM10 in

ambient air are monitored by using APM 550 Dust Sampler. Samples were analysed for

SO2 using improved West-Gaeke method for air samples using a spectrophotometer at a

wavelength of 560 nm. Samples were analyzed for NOx using Jacob and Hocheiser

modified (Na-As) method for Air samples using a spectrophotometer at wavelength of

540 nm.

6.2.2 REPORTING SCHEDULE

After completion of analysis copies of all the analysis reports are being sent to GPCB &

Regional Office, MoEF on monthly basis. A copy of the report is made available in the

plant to the concerned inspecting authorities.



6.2.3 EMERGENCY PROCEDURES

Whenever the Air pollution control systems fail to comply with the norms, then feeding

of Raw material is being stopped immediately and subsequently there will be no

production. The production restarts only after ensuring compliance with norms. `

6.3 DETAILED BUDGET & PROCUREMENT SCHEDULES

The budgetary allocation for Environmental Monitoring Plan for the industry is Rs. 25

Lakhs with an O&M cost of 20 lakhs/Year. A third party will be engaged to monitor all

the environmental parameters as per CPCB / GPCB norms once the expansion project

comes into operation. The detail EMP budget are given in Table 6.2 .

Table 6.2: Environment Monitoring Cost

.

Hu@@@@

(Fig in Rs Lac)

Sl

No Particular

Capital

Cost

Recurring

Cost

1 Third Party Monitoring 3 12.5

2 ETP / STP Maintainance 4 4.5

3 Training on Safety 6 2

4 Maintenance of Monitoring Instruments 12 1

Total 25 20



CHAPTER 7

ADDITIONAL STUDIES

7.1 PUBLIC CONSULTATION

The public hearing for the expansion project of M/s Nilkanth Concast Pvt Ltd was

conducted in the existing premises of the project on 20th December 2016 as per EIA

Notification 2006 for proposed expansion of Sponge Iron (2 no.of kilns), Billet /Ingots

(2 no.of Furnace), TMT Bars /Channels/Angels (Rolling Mill and Section Mill), CPP (2

MW) and Waste Heat Recovery Boiler (4 MW). Public Hearing meeting was presided

by Resident Additional Collector and Additional District Magistrate, Bhuj – Kutch,

Gujarat.

The Regional Officer of Gujarat Pollution Control Board stated that there were two

written representations received before Public Hearing.

The issues raised in the Public Hearing and reply by the Project Proponent along with

time bound action plan and budgetary provision is given below:

Sr.

No.

Question/issue/suggestion Response by

project

proponent

Time bound

Action plan

proposed

Budgetary

Provision

1. Mr. Kiritsinh Narubha Jadeja,

Village : Bhadreshwar, Taluka

Mundra , Dist: Kutch

He represented that...

Nilkanth Concast is a

small company & is

manufacturing steel.

Company does good

welfare work for benefit

of people & gives co-

operation in village

Vice president of

company Mr.

Suresh bhai replied

that we will try to

hire local employee

as much as possible.

About 150 to 180

people will be hired

for new project &

priority will be

given to local

The company

will identify

the local

unemployed

youth and

train them in

skill

development

centres which

were

established

Budgetary

Provision of

Rs. 10.00

Lakh

earmarked

for trainee‟s

model

workshop.

Provision of

Rs. 10.00

lakh is



Bhadreshwar. Company

give funds every year to

Gau Seva Samiti of our

village, company has

given steel for

construction of temple,

paid total expenditure for

painting of goddess

Ashapuramataji temple.

Company has

constructed pucca road

from its waste for

approaching the sea for

fishermen.

About fifty people of

village Bhadreshwar

work in company &

company should give

employment to people as

per their eligibility.

He added that company

does good CSR

activities. Company

helps socioeconomically

to village Bhadreshwar.

similarly, company

should aid surrounding

affected villages.

We keep watch on the

company about

people for

employment.

He said that

company helps to

villages for socio

economic activities

& our director

believes that

company would

remain with nearby

villages & give co-

operation for

solving their

problems. Company

as well as village

People will be

benefited by the

expansion of the

project.

Vice President of

Company Mr.

Sureshbhai replied

that company will

be solved the

problems regarding

pollution. We will

try to our best, not

to harm

environment &

people.

nearby and

thereafter will

engage them

in

construction

and operation

of the plant.

The company

committed to

take pollution

control

measures at

sources and

environmental

mitigation

plan by green

belt

development,

avenue

plantation and

rainwater

harvesting in

nearby

villages, dust

suppression,

etc.

Within 6

months from

inception of

the project.

earmarked

for

construction

of rainwater

harvesting

structures in

villages in

consultation

with local

panchayat raj

engineer.



environment. We draw

attention of company if

issues of pollution arise

& company also co-

operates in this regard.

He further added that

company should beware

about abatement of

pollution. Hence, there

would be no adverse

impact on agriculture,

Herding & Fishery.

2. Mr. Pradyumansinh

Bahadursinh Jadeja, Village

Bhareshwar, Taluka Mundra,

Dist. Kutch.

He represented that…

When Industrial unit

comes, Issue of pollution

comes first. Company is

having coal based power

plant hence Pollution will

occur, but benefits for

nearby villages under CSR

activities. It is

responsibility of company

management to control the

pollution. Blackish dust

see here, necessary steps

should be taken for this.

Mr. Chetan

Kabariya,

EIA consultant

replied that

company will

develop more green

belt to control

pollution. Company

will install ESP, bag

Filter and Dust

collector as Air

Pollution Control

Measures to control

Pollution and

sprinkle the water

regularly.

The company

will identify

the local

unemployed

youth and

train them in

skill

development

centres which

were

established

nearby and

thereafter will

engage them

in

construction

and operation

of the plant.

Budgetary

Provision of

Rs. 10.00

Lakh

earmarked

for trainee‟s

model

workshop.

Provision of

Rs. 10.00

lakh is

earmarked

for

construction

of rainwater

harvesting

structures

in villages



The company has been

doing good works for

many years like funding

to our village for fodder.

Company give

employment to local

people, but company

should give employment to

local people on basis of

their qualification & skill.

Minimum wages should be

given to workers as per

government law. We do

not oppose the industrial

units. Employment only be

increased if there is

industrial growth as per

the prevailing government

policy. After the

earthquake, industries

come in Kutch district and

employment is also

increased.

He informed that,

Company shall do more &

more work under CSR

activities.

Vice president of

company Mr.

Sureshbhai assured

That company will

give employment

On basis of

qualification &

skill.

The company

committed to

take pollution

control

measures at

sources and

environmental

mitigation

plan by green

belt

development,

avenue

plantation and

rainwater

harvesting in

nearby

villages, dust

suppression,

etc.

Within 6

months from

inception of

the project.

in

consultation

with local

panchayat

raj

engineer.

3. Mr. Ranjitsinh Kanaksinh

Jadeja, Village Bhadreshwar,

Taluka Mundra, Dist Kutch

Vice president of

company Mr.

Sureshbhai stated the

The company

will install air

pollution

Budgetary

provision is

given in the



He represented that Black dust

deposits on terraces of

villagers & it will increase

after Proposed expansion. It is

published in Newspaper on

01/12/2016 that black dust is

harmful for agriculture,

herding & fodder. Company

should care regarding this.

company will install

ESP and Dust

collector as Air

Pollution control

measures to control

pollution.

control

equipment at

all sources.

Regular

environmental

monitoring

shall be

conducted to

keep check on

the emissions.

Interlocking

system shall be

provided to

stop operations

in any

eventuality

occurs during

abnormal

operating

conditions.

EMP report.

7.1.1 The activities were identified to implement under the provisions of Corporate

Environment Responsibility in accordance with Office Memorandum dated 1st May

2018 issued by Ministry of Environment, Forest and Climate Change, are based on

issues raised in the Public Hearing and needs identified in Social Impact Assessment.

Sl.

No

Item 6

months

12

months

18

months

Total in

Rs.

Lakhs

1 Village Infrastructure development :

1.1 Construction of Road in Vadala,

Pvadiyara, Bharudia, Bhadreshwar, Luni

& Vovar Villages

4.00 4.00 4.00 12.00



1.2 Construction of Toilets 20 Nos. X 6

villages

3.50 3.50 3.50 10.5

1.3 Construction of Lakes Or Up gradation

of Existing Lakes in above six Villages

for Rain Water Harvesting

4.00 4.00 4.00 12.0

1.4 Toilets in schools, play grounds facilities

construction.

3.50 3.50 3.50 10.5

2 Sustainable livelihood / skills development programs :

2.1 Skill Development Workshop 3.50 3.50 3.50 10.5

2.2 Facilities for veterinary and animal

,husbandry

3.50 3.50 3.50 10.5

3 Health facilities :

3.1 Ambulance facility and equipment for

medical Centre

3.0 3.0 3.0

9.00

5 Plantation program

5.1 Development of nursery for plantation of

in villages and distribution beyond the

immediate villages

1.00 1.00 1.00 3.00

Total 22.5 22.5 22.5 67.5

Lakhs

7.2 RISK ASSESSMENT

Hazard analysis involves the identification and quantification of the various hazards

(unsafe conditions) that exist in the plant. On the other hand, risk analysis deals with the

identification and quantification of risks. The workers are exposed to, accidents

resulting from the hazards due to accident occur in the plant area.

Risk analysis follows an extensive hazard analysis. It involves the identification and

assessment of risks the neighbouring populations are exposed to as a result of hazards

present. This requires a thorough knowledge of failure probability, maximum credible

accident scenario, vulnerability of population etc. Consequently, the risk analysis is

often confined to maximum credible accident studies.



In the sections below, the identification of various hazards, probable risks in the

proposed plant, maximum credible accident analysis, consequence analysis are

addressed which gives a broad identification of risks involved in the plant. Based on the

risk estimation for fuel and chemical storage Disaster Management Plan (DMP) has

been prepared.

7.2.1 Approaches to the Study

Risk involves the occurrence or potential occurrence of some accidents consisting of an

event or sequence of events. The risk assessment study covers the following:

Identification of potential hazard areas.

Identification of representative failure cases.

Visualization of the resulting scenarios in terms of fire (thermal radiation) and

explosion.

Assess the overall damage potential of the identified hazardous events and the

impact zones from the accidental scenarios.

Assess the overall suitability of the site for hazard minimization and disaster

mitigation points of view.

Furnish specific recommendations on the minimization of the worst accident

possibilities

Preparation of broad Disaster Management Plan (DMP), On-site and Off-site

Emergency Plan, which includes Occupational and Health Safety Plan.



7.2.2 Hazard Identification

Risk analysis and possible hazards details

Area Operation/

Process

Equipment

/Area

Possible Hazards Couse/Effect Precautionary

Measure to be

Done

Measures to be taken

If Hazards Occurs

Induction

Furnace

Blast in Furnace

Induction wiring

damaged/burn

Spillage of molten

metal

Recirculating cooling

water coming in

contact with the

molten iron or slag.

Leakage of water from

the refractory walls

Feeding material is

checked and sorted to

avoid any explosive

or pressurized

material to inter in

furnace

Temperature near

furnace is monitored

Structural barrier to

be provided to avoid

fallout.

The temperature

of the furnace to

be maintained

properly no

overheating to be

allowed.

The plant operation to be

stopped immediately. The

area to be sealed until

cooled for reinstallation.

Molten

metal

Fall of molten metal

during transfer

Over filling of

material

Ladle will be

cleaned regularly

Stop the operation

immediately.



Area Operation/

Process

Equipment

/Area


Measure to be

Done


If Hazards Occurs

transfer

through

ladle

Fall of ladle

Distraction/jerk

during transfer

Crane rope damaged

Ladle damaged due

to improper

maintenance

to remove the

metal and slag.

Ladle transferring

way will be

cleared and

monitored during

operation.

SOP will be

followed

Evacuate the worker

Stop the metal to spread.

Let cool the metal using

proper coolant and then

remove.

Power

Plant

Boiler,

Turbine

generator,

condenser.

Heat Radiation

Noise

Injury may possible if

come in contact

with any

moving

part

All machines are

compact and whole

process is done under

consistent watch of

supervisors and by

adopting all safety

precaution /

measure's.

All workers are not

permitted to come

near to the machine

safety railings are

provided all round

the machines. Victim

is first aided by

Even after if any

workers get hurt then

first aid is given to

him and if hurt is

serious then refers to

the doctor / hospital of

further treatment and

checkup.



Area Operation/

Process

Equipment

/Area


Measure to be

Done


If Hazards Occurs

trained person and

then carried to the

doctor.

Steam

pipeline

Leak of steam

from pipeline

Leakage of steam may

cause superficial burn

if victim directly

come in contact.

Emergency kit is kept

ready which consists

of: Tools for stopping

leakage

through boiler

/ condenser and

pipeline.

The entire pipeline

is covered with

insulations.

Detector solution to

detect

Percentage of

leakages

(available at site)

At various points

valves

Protective systems

are

Provided personals of

Ammonia torch is

Used to find out the

leakage.

In the event of major

leakage the production of

steam will stop and

maintenance of leakage

point may carry quickly.

If victim is serious,

then refer to doctor /

hospital for further

treatment.



Area Operation/

Process

Equipment

/Area


Measure to be

Done


If Hazards Occurs

emergency team are

always ready to take

care and to give first

aid to victim.

Switch gear

Yard

Bursting of the electric

equipment‟s.

Fire Electrification of

person

Protection relay Fire

Extinguisher Sand

buckets

Electric supply to

be isolated. Area to be

Restricted for movement's

fire extinguishers, sand

buckets to be used.

Cable

Galleries

Defective of cables.

Over loading

do do do

Transformer Fire hazard possible Loss of human life,

property

Transformer should

be Operated within

the

prescribed load.

Temperature of

transformer should

be observed

continuously.

Unauthorized persons

are restricted entry

to

transformer room.

Power line should be

immediately put off.

Fire fighting steps

should be taken to

stop fire.

Further operation

must be done.

Electric

Substation

Electric shock and

electric burn

Slip , trip and from the

Loss of human life,

property

Tripping system will

be provided.

Proper load balance

Give the first aid treatment

to injured person.

Shift to hospital if needed.



Area Operation/

Process

Equipment

/Area


Measure to be

Done


If Hazards Occurs

height

Cable gallery/room fire

hazard

on phase and cable.

Cable insulation to be

measures

Cut off the power supply.

Use the firefighting

extinguisher.

Air

Receivers

Bursting of Pressure

vessel or pipeline joint

may lead to cause of fire

or human

injury.

Injury to worker

Loss of equipment

Yearly checking of

receivers and

hydraulic test to be

conducted as per

factory Acts and

Static & Mobile

pressure vessel rule

1981.

Even after if any workers

get hurt then first aid is

given to him and if injury

is serious then refer to the

doctor / hospital of further

treatment and checkup

E.O.T Crane Hoist Rope Breakage

possible

Injury to worker

Loss of

equipment/structure

a) No movement of

strange people in

crane bay will be

permitted.

b) Frequent check of

the rope and other

load bearing

material shall be

done

c) Light indication

movement of crane

shall be provided.

d) Prescribed load

shall only be

Weak rope shall be

immediately replaced.



Area Operation/

Process

Equipment

/Area


Measure to be

Done


If Hazards Occurs

allowed

Crane operator to

give alarm before

movement

Lab

Chemicals

In case of bottle

breakage, causes burns

and damage

to respirator systems

due to inhalation.

Injury to worker

a. Proper care

should be taken

while handling

the chemicals.

b. First Aid Box

should be

available at Site

with all necessary

and required

medicines.

Firefighting

equipment like

Extinguishers, sand

buckets should be

available always.

Instruction Boards to be

displaced for knowledge

of other workers to take

care of the situation in the

event of occurrence.



7.2.3 Occupational health impacts on the workers

Hazards in heat treatment include burns and scalding, mechanical hazards from steel

handling, and hazards arising from the annealing gases, including nitrogen, hydrogen and

carbon monoxide. Furnace insulation wools can expose workers to hazardous fibers.

HEAT STRESS

Hazard description

In heat treating, steel products are heated and cooled in a controlled way to change their

physical or mechanical properties without changing their shapes. Heat treating is used to

relieve stresses in the metal created during cold rolling, to improve its hardness or

strength, or to change its electromagnetic properties. Some heat treating is done by

quenching, in which heated steel is plunged into a cold bath of water or oil to rapidly cool

it. The most common heat-treating process is annealing, in which the steel is slowly

heated, maintained at temperature, then cooled. Often this takes place in a closed furnace,

using an inert gas to prevent oxidation, or a gas that conveys desired properties to the

steel.

Hazards in heat treatment include burns and scalding, mechanical hazards from steel

handling, and hazards arising from the annealing gases, including nitrogen, hydrogen and

carbon monoxide. Furnace insulation wools can expose workers to hazardous fibers.

Heat radiation around the furnace is 480 C to 55

0 C temperature near the furnace.

Mitigation Measures Proposed to Avoid the Human Health Hazards

Hazard control

The work area and the flow of material through it shall be designed so as to minimize the

possibility of worker contact with hot steel, or to scalding in the case of quenching

operations.



Inert annealing gases shall be handled in a way that prevents their build-upon enclosed

spaces other than the furnace itself, so as to prevent asphyxiation. Annealing furnaces

shall be considered to be hazardous confined spaces.

The system for handling flammable annealing gases like oxygen shall be minimize the

possibility of an explosive build-up.

Carbon monoxide shall not be used for carburizing (a process for adding carbon to the

surface) where safer processes are practicable.

The safest practicable furnace insulation shall be used. In general, this means using

insulation wools with a low content of respirable fibres, and which do not convert to

silica when heated.

Adequate drinking water arrangement shall be provided for worker

Natural ventilation and air conditioner room is available for worker.

Control strategies

Training

Personnel handling molten metal shall have been trained in the proper procedures to

adopt, and in the relevant safety and health precautions, including use of appropriate PPE.

Completion of training shall be documented, and training repeated as necessary.

Persons who are untrained shall not be employed in the transport of molten metal.

Work practices

Only essential personnel shall be in the vicinity of pouring operations.

Moulds and tun dishes shall not be damp, nor should there be any means whereby water

could enter the melt because of the risk of explosion.

The area shall be cordoned off prior to the transport of molten metal if there is a

possibility of spillage.



Safety inspection of ladles

A competent person shall regularly inspect ladle buckets and their supporting, locking

and tipping mechanisms.

Before each filling, the pouring of, or transport of slag ladles and their related appliances

should be visually inspected.

Test results, including remedies for cracks and other defects, shall be recorded.

Corrective repair measures that are recommended shall be planned and implemented on a

timely basis.

There shall be a system for checking and ensuring that the corrective measures have been

completed.

Personal protective equipment

1. Appropriate PPE, such as helmets, gloves, aprons and boots shall be provided and used.

Where appropriate, molten metal resistant clothing should be provided and used.

First aid

Injuries caused by molten metal, dross or slag or exposure to alkaline dust shall receive

immediate medical attention.

Ventilation

Proper ventilation will be provided.

Thermometer for work zone temperature monitoring will be place at appropriate location

Drinking water

Water cooler will be provided.

Purified water will be made available.

General

Job rotation will be done for worker



Glucose and head relief drink will be made available for worker

Bath shower and hand wash will be provided at appropriate location

Air conditioning room will be provide for heat relief.

7.2.4 Do’s & Don’ts of preventive maintenance

CLEANING THE FLOOR

Do’s

1. While Cleaning Use the mildest cleaning agent that does the job effectively.

2. Follow the polishing lines when using abrasive cleaners.

3. Rinse thoroughly after every cleaning operation.

4. Wipe dry to avoid water marks

5. Handle with clean gloves/cloths to guard against stains/finger print

Don’t

1. Do not use an ordinary steel scraper or knife to remove dirt.

2. Do not allow chemicals or bleaching agents to remain in prolonged contact with

stainless steel.

3. Avoid cleaning with chloride containing detergents/solvents.

4. Do not allow steel tools, containers or implements to lie on stainless surfaces.

EOT CRANE

Do

1. Ensure that only authorized slingers/signaler attached or detached load, or signal the

crane operator

2. Discuss operation with the crane operator(special operation)

3. Ensure that the capacity of the crane is sufficient

4. Seek expert advice when using eye bolts, plate clam etc.

5. Use tag line always



Don’t

1. Don‟t Wrap tag line around hand of body

2. Don‟t leave a suspended load unattached

3. Don‟t Pass load over people

4. Don‟t ride of climb on suspended load

5. Don‟t stand or walk beneath the loads

6. Don‟t use pipe to support for landing the load

WORKING AT HEIGHT

Do

1. Do as much as work as possible from ground

2. Ensure worker can get safety to and from where they work at height

3. Ensure equipment is suitable, stable and strong enough for the job. Maintained and

checked regularly

4. Take precautions when working near hot surface

5. Provide protection from falling object

6. Consider emergency evacuation and rescue procedure

Don’t

1. Don‟t overload the equipment or materials workers are carrying before working at

height. Check the pictogram or label on the lubber for information.

2. Don‟t overreach on ladder or stepladders

TOOL BOX

Do

1. Use specific tool for specific work

2. Maintain proper tool box

3. Arrange tool in proper order

4. Keep tool in tool box after use



Don’t

1. Don‟t leave tool box at work place

2. Don‟t hammer with by tools

3. Don‟t play with tools

4. Don‟t carry tool in pockets or in hand

PERSONAL PROTECTIVE EQUIPMENT

Do

1. Use proper PPE

2. Al ways weal helmet in working premises

3. Use cotton cloth while working near furnace

4. Always follow the safety instruction

5. Take permission for use of PPE

Don’t

1. Don‟t use other of PPE

2. Don‟t place jock while working

3. Don‟t wear polyester cloth while working near hot area.

PLAN FOR PERIODIC EXAMINATION

1. Pre-employment medical examination will be done.

2. Post-employment medical examination plan is one in every year from government

authorized medical institute/ fractioned.

3. Every six month medical examination of worker working in suspicious condition.

4. Bronchitis and chest diagnostic of worker working near furnace, EOT crane operator

and smoky environment after every six month.

7.2.5 Fire Protection System

Fire protection systems will be provided in the proposed project as follows:



Hydrant system covering the entire plant including all important auxiliaries and

buildings.

The system will be complete with piping, valves instrumentation, hoses, nozzles

and hydrants, valves etc.

Portable extinguisher such as pressurized water type, carbon dioxide type and foam

type will be located at strategic locations throughout the plant.

Modular type carbon dioxide panel injection fire extinguishing system will be

provided at unmanned electrical and electronic equipment room.

7.2.6 OCCUPATIONAL HEALTH AND SAFETY

Occupational health needs attention both during erection, operation and maintenance

phases. However, the problem varies both in magnitude and variety in the above phases.

To control any occupational health and safety impact a detailed planning for mitigation

measures has been done in the design stage of the project. Apart from the occupational

exposure mitigation plans for various activities and work areas of hazards, following

existing administrative control measures will be undertaken to ensure occupational health

and safety of the employees:

All employees will be trained for EHS policies and practices.

Periodic health check-up for employees.

All employees will be trained in first aid and emergency handling during fire

breakout.

Preparation and training of the employees in safety and emergency preparedness.

Compliance to PPE use.

Safety display sign board in the plant.

Nilkanth Concast Pvt Ltd have provision of fund of 15-20 lakhs/ annum for safety and PPE



7.2.7 SAFETY PLAN

Safety of both men and materials during operation phases is of prime concern. The

preparedness of an industry for the occurrence of possible disasters is known as

emergency plan. Possibility of disaster in the proposed plant is due to leakage of fuels,

chemical hazard, collapse of structures and fire/explosion etc. Keeping in view the safety

requirement during operation and maintenance phases and the plant shall formulate safety

policy with the following regulations:

To allocate sufficient resources to maintain safe arid healthy conditions in

working environment.

To ensure that all known safety factors are taken into account in the design,

construction, operation and maintenance of plant, machine all equipment.

To ensure that adequate safety instructions are given to all employees.

To provide wherever necessary protective equipment, safety appliances and

clothing and to ensure their proper use.

To inform employees about materials, equipment or processes used in their work,

which are known to be potentially hazardous to health/safety.

To keep all operations and methods of work under regular review for making

necessary changes from the point of view of safety in the light of experience and

up to date knowledge.

To provide appropriate facilities for first aid and prompt treatment of injuries and

illness at work.

To provide appropriate instruction, training and supervision to employees in

health and safety, first aid and to ensure that adequate publicity is given to these

matters.

To ensure proper implementation of fire prevention methods and an appropriate

firefighting service together with training facilities for personnel involved in this

service.



To organize collection, analysis and presentation of data on accident, sickness and

incident involving personal injury or injury to health with a view of taking

corrective, remedial and preventive action.

To publish/notify regulations, instructions and notices in the local language of

employees.

To prepare separate safety rules for each type of occupation/processes involved in

the project.

7.2.8 Safety Organization

Erection Phase

A qualified and experienced safety officer shall be appointed. The responsibilities of the

safety officer include identification of the hazardous conditions and train/advice the

workers on preventive actions, conduct safety audit, organize training programs and

provide professional expert advice on various issues related to occupational safety and

health. He is also responsible to ensure compliance of safety rules/ statutory provisions.

Operation and Maintenance Phase

When the erection is completed the posting of safety officers shall be in accordance with

the requirement of Factories Act 1948 and their duties and responsibilities shall be as

defined thereof.

7.2.9 Health and Safety Monitoring Plan

All the potential occupational hazardous work places such as storage area shall be

monitored regularly. The health of employees working in these areas shall be monitored

once in six months for early detection of any ailment.

A medical care with the following responsibilities are being carried out by company

a) Examination of workers‟ health in relation to work. Recent check-up of workers

sheet is attached as Annexure 13



b) Surveillance of working environments.

c) Identification and evaluation of environmental factors which may affect the workers

health.

d) Assessment of conditions of occupational workers‟ health.

e) Observance of safety norms and reduce/eliminate exposure to hazardous environment.

Company will take up monitoring activities periodically to assess hazards due to gases,

7.3 DISASTER MANAGEMENT PLAN

The word 'disaster' is synonymous with 'emergency' as defined by the Ministry of

Environment and Forests (MoEF). An emergency occurring in Iron and steel

manufacturing plant is one that may affect several sections within it and/or may cause

serious injuries, loss of lives, extensive damage to environment or property or serious

disruption outside the plant. It will require the best use of internal resources and the use

of outside resources to handle it effectively. It may happen usually as the result of a

malfunction of the normal operating procedures. The project is in its formative stage and

detail engineering is yet to be done, so the DMP are based on the following concepts.

7.3.1 Emergency Procedure

1. The emergency preparedness team will be constituted within the organization

consisting of the senior officials from managerial level from the different department

like production, Health and Safety, Environmental, Material Handling, Security to

handle the emergency.

2. The team will meet once in three months to discuss the possible or probable causes /

instance leading to any disaster that may occur in and around the plant premises.

3. The team will assess the required resources to deal with the situation that may be

identified as above.

4. The team leader will lay down a detailed procedure or oral information to the each

member to follow in case of any impending or possible or actual disaster.



5. The team will conduct mock drill once in six months to understand the practical

problems that may arise while implementing the emergency preparedness

6. Action plan including the response time and take necessary steps to make the system

effective.

7. The team will make the necessary recommendation /suggestions to the Management

for identifying/monitoring /dealing with any possible or probable disaster.

8. The minutes of the meeting of the team shall be prepared including the probable

cause of incident, response time and corrective & preventive actions required to be

taken to avoid the reoccurrences of the same and kept as record.

9. The team may draw an action plan and modify the same from time to time.

10. The Emergency Preparedness Team will come into force in case of any disaster by

establishing the control room at an appropriate place nearer to the affected area.

11. The team shall record the actual performance/procedure followed/short comings

while dealing with any actual disaster, which will be discussed at various levels to

strengthen the plan and approach.

12. The Plant Manager shall inspect all the places where disaster occurred, along with

Emergency preparedness Team.

13. He shall ensure that all the affected places are safe to resume the normal works, and

the give permission to start the plant operation.



Figure7.1 : Onsite Emergency Chart

Assembly point

All senior officials shall meet to discuss about the actions to be taken, to deal with

disaster at office /control room. All the workers shall be directed to assemble at pre-

decided points to ensure the safety.

Control Room:

All the activities connected to emergency shall be controlled from the nearest convenient

and safe place or from the office as may be necessary.

Natural Disasters

Keep track of predictable natural hazard events such as floods, cyclones etc.

Organize training and capacity building programmes on disaster management for

individual in the establishments.

Periodic monitoring of Emergency Response Plans and the corresponding

procedures of individual establishments.

Organize post –Disaster evaluation and update the DMP accordingly.

Operator

Shift Incharge

Safety Officer

Site ControllerRoom

Emergency Control

Emergency Co-ordinator Emergency Co-ordinator

(Medical,Mutual,Aid

Rehabilitation,Transportand Communication)

(Rescue,Fire Fighting)

Electrician, First Aid,Transport-Driver

Telephone-Operator

ElectricianPump Operator

Emergency Co-ordinator

(Essential Services)

Pump Operator

Shift Incharge

Incident Controller



We closely associate with District Disaster Management Authorities effective

management of disasters in the District through the implementation of District

Disaster Management Plans.

7.3.2 Maintenance of Site Disaster Management Plan

Following are the steps envisaged for maintenance of disaster management plan:

Training

Safety section shall arrange for appropriate training/refresher program for all personnel.

Every incident controller, in consultation with safety officer and medical officer, shall

identify and arrange for specific training to be imparted to his workmen, supervisory staff

and engineers to combat emergencies, which can arise in areas under his jurisdiction

Firemen, in addition to their normal firefighting training, shall also be trained for natural

disaster, toxic gas releases and chemical spills. Evaluation and monitoring program shall

be introduced for assessing emergency preparedness in this case also.

Maintenance of equipment

Safety section shall test the equipment once in three months. Medical section will test the

equipment in emergency vehicle once in three months/ after every usage. Electronics and

Instrumentation section shall test the emergency communication system at prescribed

intervals.

Mock Drills/Exercises

Safety section will plan and carry out mock drills at stipulated interval to acquaint the

safety group and all employees about relevant aspects of “DISASTER MANAGEMENT

PLAN”, to detect any lacunae in the plan and to eliminate panicness at the time of actual

emergency. Feedback will be obtained and corrective action will be taken accordingly.

To ensure the sirens are working correctly, they shall be tested regularly. The testing is a

part of routine maintenance.



Updating of Plan

Safety section shall update the contact details once in every six months. Safety section

shall update and revise the plan every five years or whenever there is a change in plant

activities. Following are important contact numbers in case of emergency.

Sr.

No.

Name/Designation Telephone No.(Office)

1. Mr. Ramaya Mohan (District Collectors)

District Management Office

02832-250923

2. Mr. Deepak Gala, Sarpanch, Village :

Vadala

8866237581

3. Commissioner of Police,

Gandhidham A Div

Gandhidham B Div

02836-258100

02836-233752

4. Fire Station Gandhidham Municipality 02836-226573

5. Commissioner of Rescue & Relief

1070

6. Chief Inspector of Factory (DISH,

Adipur),

02836-260020

7. Nearest Government hospital (Govt.

Hospital, Adipur)

Distance from our plant to Adipur is 29

Kms.

02836-261626

8. Ambulance Services, Kutch 108 and Company

having 24/7

Ambulance

9. Municipal Corporation of Bhuj 2832 220375

10. India Meteorological Department (IMD) 099799 95441

11. Disaster Management Control Room 02832-252347

Record maintenance

Emergency Data

The chronological log of events during the entire period of disaster shall be maintained

by plant in-charge, Safety.

Training

The records of training shall be maintained by Head Safety.



Maintenance of Equipment

Maintenance records of equipments shall be with safety head. Permit system (General,

Hot Work, and Electric Lock out) shall be issued with due ensuring the safety

instructions while attending the requisite job.

Drills/Exercises

Records of all drills/exercises shall be maintained by Heads of HSE.

7.4 OFF SITE EMERGENCY PLAN

Sr.

No.

Action Required to be taken to

Mitigate Disaster by Aid giving agency

Responsible

Agencies for

taking action

Equipment’s/Material

facilities required at site to

mitigate Emergency

A

1

Arrangements for evacuation/ rescue of

persons from zone of influence to

predetermined camps

Police

Department

Self-Breathing apparatus

with spare cylinder

Chemical gas mask with

spare canister

Vehicle with PA system

Transportation for

evacuation of people

2 Caution to public by announcement

3 Traffic and Mob control by cordoning of

the area

4 Law & order

B Control of fire

District Fire

Brigade

Self-breathing apparatus

with spare cylinders

Foam/water fire tenders

Gas mask with spare

canisters

Lime water

Neck to toe complete

asbestos suit, PVC hand

gloves, gumboots, safety

1 To rescue trapped persons

2 If fire is big, keep surrounding area cool

by spraying water

3 Communication to State Electricity Board

to continue or cut off electric supply



Sr.

No.



Responsible

Agencies for

taking action



mitigate Emergency

4

Communication to water supply

department for supplying water

goggles

Mobile scrubbing system

along with suction

arrangement.

C Medical facilities for affected persons

(first aid and treatment)

Hospital and

public health

Ambulance with onboard

resuscitation unit, first aid,

stretchers

D Removal of debris and damaged

structures

Municipal

corporation

Provide bulldozers

Provide cranes

E

1

Monitor the incoming and outgoing

transports

Transport

department

Provide traffic police at site

Provide emergency shifting

vehicles at site

Provide stock of fuel for

vehicles

2

Arrange emergency shifting of affected

persons and non-affected person to

specified area

3 Arrange diesel/petrol for needed vehicles

F

1

Give all information related to

meteorological aspects for safe handling

of affected area for living beings

Meteorological

Department

Provide wind direction and

velocity instruments with

temperature measurements

Mobile van for

meteorological parameter

measurements 2

Forecast important weather changes, if

any

G

1

Representatives of all departments are in

the local crisis group; therefore they are

expected to render services available with

them. Since it is a group of experts with

authority, the mitigating measures can be

Local Crises

Group

Must have all resources at

hand, specially disaster

management plan and its

implementation method.



Sr.

No.



Responsible

Agencies for

taking action



mitigate Emergency

implemented speedily. The

representatives from locals are also there

so that communication with local people

is easy and quick.

All relevant information

related to hazardous

industry shall available with

crisis group

Newspaper editor shall be a

part of the group so that

right and timely media

release can be done

2

The district emergency or disaster control

officer / collector shall be the president

and he shall do mock drill etc so that

action can be taken in right direction in

time

I 1

Collector shall be the President of District

Crisis Group therefore all district

infrastructure facilities are diverted to

affected zone District Crisis

Group

All necessary facilities

available at district can be

made available at affected

zone

Control of law and order

situation 2

All other functions as mentioned for local

crisis group

7.5 SOCIAL IMPACT ASSESSMENT

An understanding of the issues related to social, economic and cultural factors of the affected

people is very important for the sustainable development of the project. A social impact

assessment (SIA) therefore was carried out incorporating social analyses and participatory

processes into project design and implementation to make it responsive to social

development concerns. SIA also helped in enhancing the project benefits to poor and

vulnerable people while minimizing or mitigating concerns, risks and adverse impacts.

Further as the project implementation entails a large number other social issues such as influx

of labour during construction and others, a systematic assessment provided the basis to

prepare a Social Management Plan.



Objectives of the Study

The main objective of the study is to ensure that the project addresses the adverse impacts on

the livelihood of the people and that nobody is left worse off after implementation of the

project and those affected Project have access to project benefits, during project operation.

Specifically, the objectives of the study are:

To carry out a socio-economic, cultural and political/institutional analysis to identify the

project stakeholders and social issues associated with the project;

To assess the extent of asset loss and undertake the census of potential project affected

people;

To develop a Resettlement Action Plan (RAP) if any, in consultation with the affected

people and project authorities;

To develop a consultation framework for participatory planning and implementation of

proposed mitigation plan.

PROFILE OF PROJECT AREA AND PROJECT AFFECTED POPULATION

Following salient observations were recorded:

Education facilities are available in all the villages, in the form of primary and middle

schools. In some of the villages it is extended up to high schools. For higher studies, people

have to avail this facility from the nearest town.

Primary health centres and sub centres are run by the Govt. agencies catering its services to

the rural people. Roads in the surveyed villages are mostly pucca. Transportation service is

good but in some of the villages due to bad condition of roads, people have to walk 2-3 kms

to catch the bus.

Communication facilities are very poor in the villages surveyed.

Unemployment is a crucial problem. Though literacy rate is good, youths do not have

technical education to be absorbed in the industries on permanent basis.

Rehabilitation and Resettlement (R & R) Plan

The total land of M/s. Nilkanth Concast Private Limited is barren land and in possession.

There was no displacement of people. Thus R & R issues are not applicable.



CHAPTER 8

PROJECT BENEFITS

8.1 IMPROVEMENTS IN THE PHYSICAL INFRASTRUCTURE

Once the proposed expansion activity is commissioned, the socio-economic status of the

local people will improve and there by infrastructure facilities like communication

systems will improve.

8.2 IMPROVEMENTS IN THE SOCIAL INFRASTRUCTURE

M/s. Nilkanth Concast Private Limited is equally conscious for the all-round socio-

economic development and is committed to raise the quality of life and social well- being

of communities where it operates. Its activity initiatives will be prioritized on local needs,

which focus on Health, Education, Sustainable Livelihood, Social Mobilization,

Infrastructure Development and Environment Conservation.

M/s. Nilkanth Concast Private Limited will put the efforts towards socio-economic

activities for the betterment of the society.

8.3 EMPLOYMENT POTENTIAL

As project will be considerable employment & trade opportunities with the

commencement of the production activities. Secondary jobs will also bind to be

generated to provide daily needs and services to the work force. This will also

temporarily increase the demand for essential daily utilities in the local market. The

manpower requirement for the proposed expansion project will generate permanent and

secondary jobs for the operation and maintenance of plant. Proposed requirement of

manpower is 395 employees. The project will benefit the people living in the neighboring

villages by giving preference to them in relation to direct employment associated with the

various project activities. Construction and operation phase of the proposed expansion

project will involve a certain number of laborers. There is a possibility that local people

for construction phase as well as a number of local skilled and unskilled people will be

engaged in the employment which will improve the existing employment scenario of the

region



8.4 OTHER TANGIBLE BENEFITS

Construction Phase

Employment

The major benefit due to the proposed project will be in the sphere of generating

employment for people of that area. The proposed project will benefit local population.

Expansion Phase

The significant positive impact on employment and occupation is envisaged on account

of :-

Better economic status of the community due to better earnings.

Higher input towards infrastructural facilities due to the proposed activities by

establishing the new plant unit.

Provision of Enhancement of the literacy due to the educational facilities under

CER activities have been made in operation phase.

Community infrastructure and services will be further improved in operation

phase under CER.

Education

M/s. Nilkanth Concast Private Limited has initiated action plan for social upliftment in

the area like female education and vocational training. Financial support will also be

extended to strengthen the educational infrastructure in the region.

Transportation

There will also be small increase in the vehicular traffic due to passenger transport. This

increase in traffic will not have any impact on the existing transportation facilities. One

should expect that the increased passenger load in the sector would prompt the state

government to start new and frequent public transport services to this area, bringing

upliftment of the area.



8.5 CORPORATE ENVIRONMENTAL RESPONSIBILITY (CER)- ACTIVITIES

Apart from business, M/s. Nilkanth Concast Pvt. Ltd. shall be devoted to social

commitments and will continue to do the same as per the needs of nearby village people.

For Corporate Social Responsibility, Various Programs/ Projects related to Social &

Economic development of surrounded area has been planned, which are as follows,

Planned for providing Water purifier for Village people, conducting medical camps for

Cataract operation, Senior Citizen Check-up, deputing teacher for literacy development

to Senior Citizens.

Company will contribute 1% of profit for CER activities. This fund will be administered

by a local area development committee in accordance with the orders of the appropriate

Government. This fund will be used for the creation of infrastructure and overall

economic development of the project area. Other such activities as stated as below:

1. Integrated Agricultural Growth Project – For improvement and use of the modern

techniques and thereby would certainly contribute to prosperity in the agriculture

sector and reduce the rural poverty by programs like Farmers Training, Nursery

Growing Trainings, Modern agriculture equipment distribution programs etc.

2. Income Generation Program

a. Establishment of Self -help groups

b. Rural Entrepreneurship Development Program

c. Vocational Training

d. Business process outsourcing

3. Health, Education & Infrastructure

a. General Health Camps

b. Innovative Teaching Methods

c. Adult Education

d. Sanitation



e. Infrastructure Development Projects

Recommendation for CER activities:

Based on the various studies conducted during the baseline survey the following

points related to social environment have been highlighted in the study area.

Workers from nearby villages shall be given priority for employment as per their

skills.

Community Awareness programmed like Aids awareness, Polio camps, Eye camps

and blood donation camps will be organized in the company and in its vicinity

from time to time for the benefit of employees and their families and people living

in the surrounding area.

As per the Notification dated 1.05.2018 issued by MOEF&CC, it is mandatory to

prepare Corporate Environment Responsibility Plan (CER) to spend 1 % (as

project cost is < 100 crores) of total capital cost of the project on social,

economical and peripheral development activities. Hence, a detailed socio-

economic analysis of pre-project status of 10 km buffer zone villages is required so

as to establish a bench mark for measuring changes due to project‟s CER

interventions over a period of time. As per the above mentioned new office

memorandum CER dated 1.05.2018. Rs. 67.5 lacs has been allocated for CER

based on public hearing issues. The details of CER are as follows:-

Table 8.1: CER Budget Plan (Rs. In Lakhs)

Sl.

No

Item 6

months

12

months

18

months

Total in

Rs.

Lakhs

1 Village Infrastructure development :

1.1 Construction of Road in Vadala,

Pvadiyara, Bharudia, Bhadreshwar, Luni

& Vovar Villages

4.00 4.00 4.00 12.00

1.2 Construction of Toilets 20 Nos. X 6

villages

3.50 3.50 3.50 10.5



1.3 Construction of Lakes Or Up gradation

of Existing Lakes in above six Villages

for Rain Water Harvesting

4.00 4.00 4.00 12.0

1.4 Toilets in schools, play grounds facilities

construction.

3.50 3.50 3.50 10.5

2 Sustainable livelihood / skills development programs :

2.1 Skill Development Workshop 3.50 3.50 3.50 10.5

2.2 Facilities for veterinary and animal

,husbandry

3.50 3.50 3.50 10.5

3 Health facilities :

3.1 Ambulance facility and equipment for

medical Centre

3.0 3.0 3.0

9.00

5 Plantation program

5.1 Development of nursery for plantation of

in villages and distribution beyond the

immediate villages

1.00 1.00 1.00 3.00

Total 22.5 22.5 22.5 67.5

Lakhs

Table 8.2: Year- wise CSR activities (Rs. In Lakhs)

( Supporting Document is attached as Annexure 14)

Year Particular Amount in

Rs.Lakhs

2015-

2016

Under the Nirmal Gujarat scheme Gujarat state government

constructed toilets in Vavar Village.

15.00

2016-

2017

Grass feeding to village cow due drought situation in the district. 4.92

2017-

2018

Bhadreshwar Gou Seva Samity (for Grass Distribution) 1.23

Bhadreshwar Muslim Samuhlagn Samity (Silver Ornaments to 9

Muslim girls on their Mass Marriage function)

0.27

Shri Chokhanda Mahadev Mandir Trust (For development of 2.50



Parking plot during the Annual Mela)

Kukadsar Gram Panchayat (For development of Parking plot at

Shri Vankalma Temple for Annual Mela)

3.50

Shri Kukadsar Juth Gram Panchayat (for Grass Distribution) 0.51

2018-

2019

Shri Vadala Juth Gram Panchayat (for Drinking Water Pipeline) 0.85

Shri Kutch Vadala Mahajan Sanchalit Panjrapol (for Grass

Distribution during the Draught season)

2.41

Shri Vadala Juth Gram Panchayat (for Grass Distribution) 1.25

Shri Vadala Sunni Muslim Jamat (for construction of Motapir

Dargah)

0.16

Water Recharging at Lake of Village Vadala under Sujalam

Sufalam Jal Abhijaan 2018 by providing 1 No. of JCB machine

& 2 Nos. of Tractor with trolley for 28 days.

1.00

Shri Vovar Gram Panchayat (for Grass Distribution) 0.91

2019-

till

July

construction of Modern Class Room for the youth of Vill : Vovar

for preparation of Competitive Exams.

3.00

Seminar for Youth Boys & Girls of Vill : Vovar on Encouraging &

Guiding on how to prepare for Competitive Exams under the

guidance of Senior Retd. IAS Officer.

0.70

Distribution of Grass to Vill : Vovar. 0.89

Grass Distribution to Shri Vadala Juth Gram Panchayat. 1.70

Shri Vadala Juth Gram Panchayat for transporation of Grass. 1.00

Transporation of Grass for Vill : Vovar, Hatdi, Luni & Bhadreshar 2.08

Shri Nadeshwar (Chokhanda) Mahadev Mandir Trust for

Construction of New Chabutra (2.55 MT of steel)

1.00

Total Rs. 44.88 Lakhs



CHAPTER 9

ENVIRONMENT COST BENEFIT ANALYSIS

9.1 ENVIRONMENTAL COST BENEFIT ANALYSIS

As per EIA Notification dated 14th

September, 2006 as amended from time to time; the

chapter on “Environmental Cost Benefit Analysis” is applicable only, if the same is

recommended at the Scoping Stage.

As per the ToR points issued by MoEF&CC, vide letter no. J-11011/85/2008-IA II (I)

dated 14th

September, 2015 for proposed project, the Environmental Cost Benefit

Analysis is not required.



CHAPTER 10

ENVIRONMENTAL MANAGEMENT PLAN

10.1 INTRODUCTION

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 suggesting post project

monitoring program. Environmental management may suggest revision of project site or

operation to avoid adverse impacts or more often additional project operations may have

to be incorporated in the conventional operation.

It has been evaluated that the study area has not been affected adversely and is likely to

boost local economy. The affected environmental attributes in the region are air quality,

water quality, soil, land use, ecology 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.

The Environmental Management Plan (EMP) has been prepared for the Existing and the

expansion Project of M/s. Nilkanth Concast Private Limited to minimize negative impacts

and is formed on the basis of prevailing environmental conditions and likely impacts of

this project on various environmental parameters during operation phase. This plan shall

also facilitate monitoring of environmental parameters. EMP includes scheme for proper

and scientific treatment and disposal mechanism for air, liquid and solid hazardous

pollutants. Apart from this, green belt development, safety aspect of the workers, noise

control, and fire protection are also included in the plan.

Various purposes of the environmental management plan are:

To treat and dispose of all the pollutants viz. liquid, gaseous and solid waste so as to meet

statutory requirements (Relevant Pollution Control Acts) with appropriate technology.

To support and implement development work to achieve environmental standards

and to improve the methods of environmental management.



To promote green-belt development and biodiversity in the surrounding area.

To encourage good working conditions for employees.

To reduce fire and accident hazards.

Budgeting and allocation of funds for environment management system.

To adopt cleaner production technology and waste minimization program.

10.2 MANAGEMENT PLAN DURING CONSTRUCTION PHASE

Environmental pollution is inevitable during the construction/ Expansion phase. The

project proponent should take appropriate steps to control pollution during construction

phase. The following are the factors requiring control during construction phase.

10.2.1 Site Preparation

Site development activities such as contour survey, soil investigation, site preparation,

site drainage, construction water, construction power, construction storage yards etc. are

already completed.

During Expansion of Sponge Iron Plant & Induction Furnaces: Particulate

matter would be the predominant pollutant affecting the air quality during the

construction phase. Dust will be generated mainly during excavation, back filling

and hauling operations along with transportation activities.

Sprinkling of water from tankers or other suitable means would be undertaken at

the construction sites for the suppression of fugitive dust.

Undesirable gaseous pollutants will be generated mostly by the traffic and use of

machineries. However, this would not lead to any tangible effect, as the expected

emission volume is low.

10.2.2 Water Supply and Sanitation

The employees at the plant shall be provided with water for their requirement and

for the construction activities. The site shall have sufficient and suitable toilet



facilities to allow proper standards of hygiene. These facilities would preferably

be connected to a septic tank and shall be maintained properly to have least

environmental impact.

10.2.3 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.

10.2.4 Solid and hazardous Waste

The solid waste during construction / expansion shall be collected in collection beans

and disposed off as per norms.

The hazardous material such as welding gas, Painting material, Oil & Grease, shall be

stored at suitable designated places and empty drums of the oil and paints shall be

discarded as per norms.

10.3 MANAGEMENT PLAN DURING OPERATION PHASE

10.3.1 Air Environment

The major sources of air pollution in the plant are fugitive emission from material

handling & transfer points and gases like Carbon Dioxide, Sulphur Dioxide, Nitrogen

Oxides etc.

The installed system as well as proposed system for air pollution control provides

acceptable environment conditions in the working areas and abates air pollution in the

surrounding areas of the site. The technological equipment and processes have been

selected with the above objective. Depending upon the quality of emissions from

different sources, suitable air pollution control systems are provided.

The air pollution control system provided in the existing plant and the proposed for

expansion project are shown in the table:



Table 10.1: Air Pollution control System for existing & proposed expansion

Sr.

No.

Stack

Attached To

Fuel

Consumption

Stack

Height

APCM %

Efficiency

Emissions

Existing

1 Rotary Kiln -1&2 Coal 30 m ESP 93 % PM, SO2,

NOx

2 AFBC Boiler Mixture of

Coal,

Lignite and

Char

53 m ESP 95 % PM, SO2,

NOx

3 WHR Boiler – 1&

2

30 m ESP 93 % PM, SO2,

NOx

4 Induction Furnace

1&2

-- 30 m Bag Filter 92 % PM

5 Iron pellet Crusher -- 12 m Bag Filter 90 % PM

6 Coal

Crusher/Screen

House


7 Cooler Discharge

Building


8 Intermediate Bin -- 12 m Bag Filter 90 % PM

9 Product

Separation/ Storage

House


Proposed

1 Rotary Kiln -3 & 4 Coal 30 m ESP 93 % PM, SO2,

NOx

2 WHRB Boiler 3 & 4 -- 30 m ESP 93 % PM, SO2,



NOx

3 Cooler Discharge -- 30 m Bag Filter 90 % PM

4 Product

Separation/ Storage

House


The overall efficiency of the pollution control equipments is more than 90% at present,

which is to be enhanced to 95% in future with optimization of process and operation

along with periodic maintenance of the equipments. The ESPs will be periodically

cleaned and from the online monitoring process, the efficiency will be monitored and

necessary steps will be taken to rectify any issues thereby. Similarly, the Bag House

cleaning and health checkup of the bag filters shall reduce any damage of bag filters and

its particulate arresting efficiency. The Bag filter arrested material is collected in cillos to

be sold to the briquetting unit, which supplies the briquette to this plant. The on-line

monitoring system of existing units shall be extended to the proposed units for regular

operational health checkups.

All internal roads have been compacted and metalled in the factory premises with good

housekeeping practices adopted in house.

10.3.2 Water Environment

The total water requirement for the Existing Plant along with proposed expansion is

estimated to be 1293 KLD fresh water and 157 KLD is recycled from the system.

Closed circuit cooling system is envisaged in the existing as well as in the expansion

project.

Out of the total water requirement of 1293 KLD for both the existing as well as

proposed plants 257KLD waste water will be generated. The treatment/disposal

methodologies envisaged/existing are as under:



Sl.

No

Type of Waste

Water

Quantity


1 Domestic 36

Treated in septic tank attached with soak pit.

In addition to this STP will be provided. The

treated water will be utilized for Greenbelt

development.

2 Boiler Blow

Down 51 This Waste water is processed in ETP and the

treated water is utilized in Coal yard sprinkler

system. 3 Cooling Tower

Blow Down 170

Total 257

Zero Water Discharge System

Nilkanth Concast Pvt Ltd follows 3Rs of water conservation i.e. Recirculation,

Reclamation, and Reuse of water. Nilkanth concast Pvt Ltd have a motto of “ZERO

WATER DISCHARGE” i.e. Elimination of discharge of waste water (treated or

untreated) into the external environment.

Rain Water Harvesting

Rainwater harvesting structures will be provided to recharge the groundwater

resources in the region. The run-off water from the roof of the structures and paved

areas shall be collected through storm water drainage system and led to rain water

harvesting structure. The typical rainwater harvesting structure is shown inFigure-

10.1.



Figure 10.1:Typical rainwater harvesting structure

Rainwater harvesting Quantity

Rainwater Harvesting at Site

Description Area m2 Rain fall in

Meter m Run off Co

efficient Total in M

3

Roof top area of building/sheds

136184.73 0.4 0.85 46302.8082

Road and Paved area 46532.73 0.4 0.65 12098.5098

Open land 53746.54 0.4 0.20 4299.7232

Green belt area 117334 0.4 0.15 7040.04

Total 353798 Total potential of

available runoff

(cum/y)

69741.08



Average recharge of rail water annually is 69741.08 m3. The net annual recharge

of ground water is 69741.08 m3 from the plant premises. The company is having

pond having size of 12.5*10m *2.5m (L*W*D) is constructed. The collected

water is used for recharging of ground water, sprinkling and Gardening etc.. Thus,

the overall impact on water environment during expansion and operation phase of

the plant is temporary and insignificant.

10.3.3 Noise Environment

The major noise generating sources in the plant are DG sets, compressors,

Crushers, Screens etc. Acoustic enclosure will be provided to Noise enumerating

instruments. The major noise levels will be confined to the working zones of the

plant. The Leq of eight hours will be within the prescribed standards. Community

noise levels are not likely to be effected due to the proposed thick green belt

developed around the boundary areas and attenuation due to the physical barriers.

The ambient noise levels will be less than 75 dBA during day time & less than 70

dBA during night time. As the nearest habitation is about 1.5 Km. from the plant,

there will not be any adverse impact on habitations due to the propagation of

noise.

10.3.4 Green Belt Development

The plantation and green belt development will also be taken care in the plant and the

space reserved for plantation will be more than 33% (11.73Ha) of the total plant area.

Every year tree plantation is undertaken in a planned manner on a massive scale. Most

of them including species having capability of pollution control and some of them are

capable to survive in high saline conditions & low fertile soil. Soil management is also

the part of us for better use of soil within the plant premises and out-sides as well.

Extensive Plantation & grassing has been carried out to check the erosion from various

plant activities.

Adequate plantation will substantially abate the dust pollution, filter the polluted air,

reduce the noise and ameliorate the plant environment.



Nilkanth Concast Pvt Ltd has already planted 13,800 Trees in its plant area with 60%

survival rate. This is due to the fact that for last three years, there is very less average

rainfall in this area and hence due to dry soil conditions, the survival of saplings has

been issue.

Year wise plantation details are given in table as under

A] Area Wise Report :

Sr. No. Existing Plantation Area

Proposed Plantation Area

(In Sq. Mtr.) (In Sq. Mtr.)

01 118187.00 11889.00

B] Species Wise Report : Year Wise Plantation Details

Year No. Plants Species Location Area Covered (In Sq. Mtr.)

2008-2015

2000 Neem, Saru & Nilgiri Nearby 2nd Gate of plant

18881

2016 2000 Mehdi, Black Fighter, Bottle Pum

Nearby Main Office 18881

2017 4800 Do Do 32469

2018 5000 Neem, Saru, Gulmohar, Champa

Near Dispensary 47103

2019 100 Nilgiri, Konocarpet, Gulmohar, Neem

Backside of Main Office

853

TOTAL 13900



Green Belt around Plant



10.3.5 Solid waste Management


collected dust, Slag from steel making, Ash from CPP and CoalChar / Dolochar from

Sponge Iron Production. The quantity of solid waste generation and their utilization

shall be as mentioned below in the table:

Re-Utilization of Solid Waste Inventory


TPA Utilization

1. ESP and Bag

filter dust

Sponge Iron

Plant,Material

handling plant , IF

14,400

Shall be used in Brick

Manufacturing and Briquette

Manufacturing.

2. Ash CPP 4,914 Shall be used in Brick

Manufacturing.

3. Slag Induction Furnaces 26,460 Shall be used in Road

embankment.

4. Coal Char/

Dolo Char Sponge Iron Plant 10,080

Shall be used in CPP (AFBC)

along with fresh coal

5. Mill Scale Rolling Mill 1260 Re-Utilized in Induction Furnace

6. Metal Scrap Billet Caster 18000 Re-Utilized in Induction Furnace

Bricks, Blocks and Tiles manufacturing Plant



Management of Nilkanth Concast Pvt Ltd recognizes its responsibility to provide safe

and healthful working conditions, safe work procedures and rules based upon

experience and safety knowledge and competent work direction for employees.

Every employee has the responsibility to prevent accidents and injuries by observing

established working rules, following the directions of supervisors, practicing the

principles taught in safety training and providing ideas so our safety and health efforts

will be further strengthened.

Nilkanth Concast Pvt Ltd and its employees have the responsibility to comply with all

laws and regulations related to safety and health programs. An effective safety and

health program extends beyond normal working hours and, accordingly, safety for

employees and their families off the job activities is also encouraged. Along with the

Pre-Employment Health Checkups, periodic health checkups are carried out for all

employees as per the industrial standards. The facility has a First Aid center within the

premises to cater to the on-site emergency needs.

Noise, Dust Exposure, Heat stress, Fire etc. all are within Permissible Exposure level

(PEL). Only Heat exposure areas near by the Sponge Iron Kiln Area & Induction

Furnaces and Coal Crusher area are not within PEL. Drinking water is been provided at

all major work terminals. The Facility has public lavaratories and showers for all

employees. Canteen facility is extended to all employees and staff.

Preventive Measure-

1. Heat Exposure: proper used PPE's in relative area like Apron, Face shields & Flame

retardant cloths and working hours in rotation basis of the relevant areas

2. Coal Crusher Area : proper water spray apply in regular basis & around the coal

Yards. Use of proper PPE”S in this area Like Dust mask (Daily Basis Silicon based),

high reflective jackets, gum boots etc.

Nilkanth concast Pvt Ltd has functional occupational health centre. Health check-up at

regular interval is being carried out of the workers under the factories act 1948 rule



172.The Health register of workers in the Form 21 for the pre and post health check-up

is maintained.

10.3.6 Environmental Management Cell

Environment Management will be headed by a manager and will constitute

environmental engineer, safety officer and ecologist/horticulturist.

The cell is responsible for environment management activities in the proposed project.

Basically, this department will supervise the monitoring of environmental pollution

levels viz. source emission monitoring, ambient air quality, water and effluent quality,

noise level either departmentally or by appointing external agencies wherever

necessary.

In case the monitored results of environmental pollution found to exceed the allowable

limits, the environmental management cell will suggest remedial action and get these

suggestions implemented through the concerned authorities. The environmental

management cell also co-ordinate all the related activities such as collection of statistics

of health of workers and population of the region, afforestation and greenbelt

development.

The organization structure for environmental management has been shown in Figure

below:



Figure 10.2: Environment Management Cell

Plant Head

Manager Environment

Officer (Horticulture)

Supervisor

Gardeners

Workers

Officer (Environment)

Chemist

Officer (Safety)

Supervisor



10.4 Environment Management Plan Cost (EMP)

The EMP cost is been estimated based on the plant and machinery to be installed for

Control of Pollution as well as the O&M cost for maintainance and operation of the

equipments and facility.

Table 10.2 EMP Budget

(Fig in Rs Lac)

Sl

No Particular

Capital

Cost

Recurring

Cost

1 Air Pollution Control 271.0 16.0

2 Water Pollution Control 18.0 7.0

3 Noise Pollution Control 10.0 4.0

4 Waste Handling & Disposal 30.0 12.0

4 Environment Monitoring & Management 25.0 20.0

5 Occupational Health 26.0 15.0

6 Green Belt / Plantation 20.0 10.0

Total 400.0 84.0



CHAPTER 11

SUMMARY & CONCLUSION

11.1 SUMMARY

This present proposal is for expansion of their 72,000 TPA Sponge Iron to 1,44,000

TPA by Installation of additional Two no. Kilns of 100 TPD each, Mild Steel

(Ingots, Billets, TM Bars & Channel/ Angles) from 1,80,000 TPA to 3,60,000 TPA by

installation of two nos. of Induction furnaces 20 T capacity each, Rolling & section

mill, Captive power plant from 4MW to 6 MW and Waste Heat Recovery Power

Plant (WHRB) from 6 MW to 10 MW, located at Survey No.221, Vill: Vadala ,

Taluka: Mundra, Dist: Kutch, Gujarat.

The Terms of Reference (ToRs) for the proposal were earlier prescribed by the Ministry

vide letter No. J-11011/85/2008-IA.II(I) Dated: 14th

September, 2015. Thereafter,

Ministry vide letter of even No dated 27/05/ 2016 amended the ToR dated 14/09/2015

with respect of production capacities of various units. The Public Hearing was

conducted on 20.12.2016 at 11:00 am at Project Site of M/s. Nilkanth Concast Private

Ltd. Further the validity of ToR was extended by the Ministry vide letter No. J-

11011/85/2008-IA.II(I) Dated: 01.05.2019, which is valid up to 13.09.2019.

The proposal was earlier considered by the EAC in 36th

meeting held during 9-10

October, 2018, in which the Honarable Committee that the EIA report was not as per the

generic structure prescribed and hence needs to be modified, with fresh baseline data

collected during the period OCT-DEC 2018. Based on their recommendation, the

Proposal was re-considered by the EAC in 7th meeting of the Re-constituted EAC

(Industry-I) held during 29-31st May, 2019, in which the Project Proponent withdrew the

proposal and requested the Ministry to consider the proposal after submission of the

revised EIA report with incorporation of additional one-month‟s baseline data. The



committee, in view of the aforesaid, recommended returned the proposal to the PP in the

present form.

Considering the above developments, the current site conditions are considered for the

baseline data and completion of the EIA Report. The Base Line data monitoring was

carried out during Oct-Dec 2018 and again One Month‟s data is been generated during

1st June 2019 to 30

th June 2019 for referential integrity and to be considered in this

revised EIA report.

Although, the application is been made based on 365 days of operation, the actual

operable days for sponge iron and induction furnace can be only 330 days, keeping in

mind the days for scheduled outage and maintenance. Based on the actual operability the

existing production, it will enhance to 1,32,000 TPA for Sponge Iron from 4 DRI kilns

(4X100TPD) after expansion. Similarly the rolled product production will enhance to

3,00,000 TPA from 4X20T IF (12 H) and 2 stands of CCM. The captive power

generation will enhance from 4 to 6 MW by complete usage of dolchar and coal (AFBC

boiler) and 6 MW to 10 MW by WHRB. However for all purposes in this report, all

environmental parameter used for assessment and evaluation of impacts are based

on TOR quantities rather than the actual quantifications, which is less than the

proposed quantities.

The proposed expansion project is intended to integrate the Steel Manufacturing process

with CCM to produce the final product as TMT bars. In order to utilize the solid waste

from DRI as well as the Flue Gas, Captive Power generation is optimized to consume the

waste heat as well as Dolchar in order to generate a sum of 16 MWH of power.

Further on the subject of water conservation, the industry is planning to optimize its

water consumption from 1450 KLD to 1293 KLD with recycle and reuse of waste water.

On the same line in alignment with Swachha Bharat Program, the industry shall convert

all its septic tanks to a combined STP for appropriate treatment and reuse of treated water

to tune of 36 KLD. Therefore, the industry shall operate with zero discharge norms.



Proposed expansion project will generate 395 Nos. of employment. And priority will be

given to local employment. The infrastructural and social amenities shall grow in the

region leading to regional development with enhanced livelihood support.


various dry material handling & transfer points and from flue gases generated from

Furnaces. The other source of emission is gaseous from Chimneys mainly contributed by

Raw material and Coal.

Many operations in the Sponge Iron Plant, CPP, Induction Furnaces & Rolling Mill

produce objectionable level of noise which may not be practicable to eliminate entirely.

Noise from compressor, fans, centrifugal pumps, electrical motors etc. will be kept in

control so that the ambient noise level shall not exceed 75 dB (A) during day time & 70

dB (A) during night time. Noise pollution control measures will be provided in respective

departments by way of providing silencers, soundproof cubicle / covers & proper

selection of less noise prone machinery and by development of green belt. In some areas

where due to technological process, it is not feasible to bring down the noise level

within acceptable limits, personnel working in these areas are provided with noise

reduction aid such as ear muffler and also the duration of exposure of the personnel

are limited as per the norms.


collected dust, Slag from steel making and Ash from CPP. The scrap generated to a tune

of 18000 TPA from the CCM is been utilized in the IF. The ash amounting to 4914 TPA

generated from the AFBC and DRI kiln are 100% utilized in the own brick

manufacturing unit. The Char from DRI is 100% consumed in the AFBC Technology for

power generation. The Slag from IF is proposed to be utilized in the land filling and road

constructions. Therefore, it not only utilizes the waste, but also reduces the storage space

and avoids any contamination to the soil and water bodies.

The plantation and green belt development will also be taken care in the plant and the

space reserved for plantation will be more than 33% of the total plant area. Out of the



total land of 35.38 Ha (35,37,989 sqm) Ha. Nilkanth concast Pvt Ltd has earmarked

11.73 Ha (1,17,334 sqm) of land for development of green belt. Every year tree

plantation is undertaken in a planned manner on a massive scale. Most of them including

species having capability of pollution control and some of them are capable to survive in

high saline conditions & low fertile soil. Soil management is also the part of us for better

use of soil within the plant premises and out-sides as well. Extensive Plantation &

grassing has been carried out to check the erosion from various plant activities. Nilkanth

concast Pvt Ltd has already planted 13,800 trees in its plant area.

11.2 CONCLUSION

It can be concluded from overall assessment of the impacts, in terms of positive and

negative effects on the various environmental components, that the project activities will

have minimum adverse effect on the surrounding environment.

The environment Health & safety Department (EHS) shall develop simplified standard

operating procedures for workers and technicians with existing safety practices and this

will be part of the induction training for all new entrants. In the existing practice the

compliance and operational issues are raised on a daily basis and resolved in the

following days in the Morning meeting. For a practice of minimization of risk, henceforth

identified issues will be recorded in the event register with appropriate solution /

resolution as derived for the same. This will not only identify issues, but with the trend of

complaint, root cause analysis done by management for a permanent resolution.

The pollutants in the form of solids, liquids and gases, generated from various

technological units of M/s. Nilkanth Concast Pvt. Ltd. have no drastic effects on the

environment. Pollution of the environment not only adversely affects all life forms, but

also shortens the life of plant and equipment. This vital aspect, therefore, has been taken

into account while planning the plant and equipment and adequate measures are being

taken to limit the emission of pollutants within the stipulations of statutory norms.

Adoption of technology like recovery of dust/ash for re-use as raw material fulfills the

twin objectives of material conservation and pollution control with sustainable growth.



To mitigate impacts due to the operation activities, a well-planned EMP and detailed post

project monitoring system is provided for continuous monitoring and immediate

rectification at site. Due to the project activities, Socio - economic condition in and

around the project site will improve with a sustainable development.



CHAPTER 12 DISCLOSURE OF CONSULTANTS ENGAGED

12.0 INTRODUCTION

The EIA/EMP report for M/s. Nilkanth Concast Private Limited at Survey No.221,

Village: Vadala, Taluka: Mundra, Dist: Kutch, Gujarat, has been prepared by Pollution

and Ecology Control services (PECS), Nagpur accredited by QCI/NABET for preparing

EIA/EMP reports in 10 major sectors, including “Metallurgical Industries (Ferrous &

Non-Ferrous)” vide certificate no. NABET/EIA/1720/RA 0101 dated 07.09.2018. This

certificate is valid up to 15.11.2020. The details of sectors accorded to PECS under the

QCI-NABET scheme for accreditation of EIA consultant organization is given below:

Table 12.1 Details of sectors accorded to PECS under the QCI-NABET scheme for

accreditation of EIA consultant organization



12.1 PROFILE OF EIA/EMP CONSULTANT

PECS established and NABET accredited Environmental Consultant and Engineers based

in Nagpur and working since last 28 years. We are having tie up with well-equipped

laboratory for field studies as well as for testing and monitoring of Air, Water, Noise,

Soil and other related activities of Environment of Mines and Industries.

PECS is having a qualified and experience staff comprising of trained professionals in

their respective fields. PECS is backed by the services of retired scientists form National

Environmental Engineering Research Institute (NEERI) and retired Engineers of Thermal

Power Stations and Coal India Ltd. A team of experience Geologists is with us for

various surveys. PECS is also having a computers and software facility for modeling

purposes.

PECS is specialized in Environmental Services as mentioned below:-

o Environmental Impact Assessment (EIA)

o Environmental Risk Analysis and Assessment.

o Monitoring of Air, Water, Noise and Soil.

o Preparation of Documents for Clearance of Forest Land.

o Environmental Management Plan.

o Environment Audit Statement.

o Disaster Management Plan.

o Study and Treatment of Industrial Effluents.

o Design, Engineering and Commissioning of Effluent Treatment Plant, Sewage

Treatment Plant and Water Treatment Plant.

o Designing, Engineering and Commissioning of Air Pollution Control Devices.

o Dust Suppression.

o Dealing with Solid Waste Management.



o Planning on Waste Recycle, Reuse and Control

o Follow up with Explosive Department and IBM, HQ, Nagpur.

o Preparation of “ON SITE” and “OFF SITE” emergency plans and health survey.

o Geo Hydrological, Ground and Surface Water Survey and Transit Survey.

o Rain water harvesting including design and execution.

o Clearing of Project form Ministry of Environment and Forest, New Delhi

(MOEF),) and State Pollution Control Board (SPCB)/SEIAA.

PECS has completed more than 50 projects in EIA sector successfully since its

incorporation.



Fig. 12.1: NABET Accreditation Certificate