submitted to moef, new...

Updated & Revised Form – I

Submitted to MoEF, New Delhi

for

SRIKALAHASTHI PIPES LIMITED (Formerly Lanco Industries Ltd.)

at Rachagunnari Village of Srikalahasti Mandal, Merlapaka & Chindepalli Village of

Yerpedu Mandal, Chittoor District, Andhra Pradesh

[REQUEST FOR EXTENSION OF VALIDITY & AMENDMENT IN ENVIRONMENTAL

CLEARANCE ISSUED VIDE NO. J-11011/914/2007-IA II (I) dated 25-07-2008]

6-3-652 | Flat # 7-3 | Dhruvatara Apartments | Amrutha Estates | Erramanjil | Somajiguda | Hyderabad- 500082

Prepared by:

Accredited by NABET - QCI ISO 9001: 2008 Certified

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APPENDIX I (See paragraph – 6)

FORM 1

Sr. No

(I) BASIC INFORMATION

1. Name of the project LANCO INDUSTRIES LTD

2. S. No. in the schedule 1 (d) and 3 (a) & (b)

3. Proposed capacity/area/length/tonnage to

be handled/command area/lease

area/number of wells to be drilled

Name of the product Proposed expansion capacity

Pig i ron 3,50,000 TPA Ducti le i ron Spun pipes 2,80,000 TPA Slag cement 3,00,000 TPA Coke oven plant 3,00,000 TPA

Captive power generation 20 MW & 6.0 MW

4. New/Expansion/Modernization The present proposal is to request the Ministry for

Extension of validity of the Environmental

Clearance to complete the unimplemented portion

of the Expansion project & Amendment in

Environmental Clearance.

5. Exis ting capacity/Area etc. Name of the product Existing capacity Pig i ron 1,75,000 TPA Ducti le i ron Spun pipes 1,20,000 TPA Slag cement 90,000 TPA Coke oven plant 1,62,000 TPA Captive power generation 12 MW

& 2.5 MW

Status of the Expansion project

The following are the capacities after expansion for which Environmental clearance was

obtained vide order No. J-11011 / 914 / 2007 – IA II (I) dated 25-07-2008

S.NO. NAME OF THE PRODUCT

EXISTING CAPACITY

PROPOSED EXPANSION

CAPACITY

TOTAL CAPACITY AFTER PROPOSED

EXPANSION 1. Ducti le Iron Pipes 1,20,000 TPA 2,80,000 TPA 4,00,000 TPA

2. Pig Iron 1,75,000 TPA 3,50,000 TPA 5,25,000 TPA

3. LAM Coke 1,62,000 TPA 3,00,000 TPA 4,62,000 TPA

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4. Captive Power

generation

12.0 MW

& 2.5 MW

20.0 MW & 6.0

MW

40.5 MW

5. Slag Cement 90,000TPA 3,00,000 TPA 3,90,000 TPA

The following is the implementation status of the expansion project

S.No. NAME OF THE

PRODUCT

EXISTING CAPACITY

PROPOSED EXPANSION

CAPACITY

TOTAL CAPACITY AFTER

PROPOSED EXPANSION

STATUS OF IMPLEMENTA

TION

1. Ducti le Iron

Pipes

1,20,000 TPA 2,80,000 TPA 4,00,000 TPA 1,05,000 has

been

implemented

2. Pig Iron 1,75,000 TPA 3,50,000 TPA 5,25,000 TPA 1,00,000 TPA

has been

implemented

3. LAM Coke 1,62,000 TPA 3,00,000 TPA 4,62,000 TPA 75,000 has

been

implemented

4. Captive

Power

generation

12.0 MW

& 2.5 MW

20.0 MW & 6.0

MW

40.5 MW Pending

5. Slag Cement 90,000TPA 3,00,000 TPA 3,90,000 TPA Pending

We also would like to bring to your kind notice that, due to improvement in market scenario

for some of our products, we are planning to implement some of the unimplemented units

which could not be taken up during the validity period of Environmental clearance. Our

bankers are also insisting for extension of Environmental Clearance certificate for sanctioning

of loan for those units.

Amendment in Environment clearance

Amendment in treatment system for effluent generated is sought as per Annexure (a)

6. Category of project i.e. ‘A’ or ‘B’. A

7. Does i t attract the general condition? If yes,

please specify.

No

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8. Does i t attract the specific condition? If yes,

please specify.

No

9. Location

Plot/Survey/Khasra No. 274,279/1,281 etc.

Vi l lages Rachagunnaeri, Merlapaka & Chindepalli

Tehs il Srikalahasti & Yerpedu Mandal

District Chittoor

State Andhra Pradesh

10. Nearest ra ilway s tation/airport along with

dis tance in kms.

Railway Station : Rachagunneri - 0.5 Km

Airport : Renigunta (15.0 Kms.)

11. Nearest Town, ci ty, District Headquarters

a long with distance in

Kms

Nearest Town: Srikalahasti (7.3 Kms)

Nearest City: Tirupathi.

District Head quarter : Tirupathi

12. Vi l lage Panchayats,Zilla Parishad, Municipal

corporation, Local body(complete postal

addresses with telephone nos. to be given)

Village panchayat : Rachagunneri, Merlapka &

Chindepalli

Zilla Parishad : Srikalahasti

Municipal Corporation: Tirupathi

13. Name of the applicant Srikalahasthi Pipes Ltd.

(formerly Lanco Industries Ltd. )

14. Registered Address Rachagunneri (V) & (PO)

Srikalahasti (Mandal),

Chittor District, Andhra Pradesh

15. Address for correspondence:

Name M. R. RAMESH BAPU

Des ignation(owner/partner/CEO) Sr.General Manager (Business Development)

Address Rachagunneri (V) & (PO)

Srikalahasti (Mandal),


Pin code 517641

E-Mai l [email protected]

Telephone No. 08578-286650-55

Fax No. 08578-286657

16. Details of Al ternative s i tes examined, i f Present proposal is request for extension of

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any. Location these sites should be shown

on a topo sheet

validity of Environmental clearance &

Amendment in Environmental Clearance only.

17. Interlinked Projects No

18. Whether separate appl ication of

interlinked project has been submitted?

Not Applicable

19. If yes , date of submission Not Applicable

20. If no, reason Not Applicable

21. Whether the proposal involves

approval/clearance under; i f yes, details of

the same and their status to be given.

(a) The Forest (conservation)Act,1980

(b) The Wi ldlife (protection)Act,1972

(c) The C.R.Z Noti fication, 1991?

No

22.

Whether there is any a government

order/policy relevant/relating to the s ite?

No

23. Forest land involved(hectares) Nil

24. Whether there is any litigation pending

against the project and/or land in which

the project is propose to be set up?

(a)Name of the court

(b)Case No.

(c) Orders/directions of the court, i f any

and i ts relevance with the proposed

project.

No litigation is pending against the project and /

or land in which the expansion project is propose

to be set up

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(II) ACTIVITY

1. Construction, operation or decommissioning of the Project involving actions, which will cause

physical changes in the locality (topography, land use, changes in water bodies, etc.)

S.No.

Information/Checklist confirmation

Yes/No

Details thereof (with approximate quantities /rates, wherever possible) with source of information data

1.1 Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to loca l land use plan)

Yes Present use of land is Industrial. Existing plant is already under operation and part of the expansion project has been implemented and is under operation. Some topographical changes have occurred due to the excavations, construction activities pertaining to the existing and expansion units under implementation. Hence there is no adverse significant impact due to the change in land use pattern due to the expansion project activities.

1.2 Clearance of existing land, vegetation and bui ldings?

No Part of the expansion project was implemented in the vacant area available in the existing plant premises. Unimplemented expansion project activities will be taken up in the vacant area available. However as a part of greenbelt development, 85 acres of Greenbelt (including expansion project) has been developed in the Plant premises.

1.3 Creation of new land uses? Yes Present use of land is already converted for the industrial purpose.

1.4 Pre-construction investigations e.g. bore houses , soi l testing?

No Investigations have been carried out for soil and water in the area where construction of the expansion project is planned

1.5 Construction works?

Yes Construction activities have been completed only part of the expansion project planned. Keeping in view of improvement in market scenario for some of our products, we are planning to take up construction activities pertaining to unimplemented units after obtaining extension of Environmental Clearance.

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All necessary precautions have been taken to prevent dust pollution during construction of existing project and similar practice will be carried out during construction of unimplemented expansion project activities.

1.6 Demol i tion works? No No demolition work is involved for implementing the remaining expansion project activities as it will be taken up in the vacant area available in the site premises

1.7 Temporary s ites used for construction works or hous ing of construction workers?

No Construction workers will be taken from local areas and from other areas. Temporary Labor colony housing will be envisaged for non-local construction workers

1.8 Above ground buildings , s tructures or earthworks including l inear s tructures , cut and fi l l or excavations

Yes Most of the structures in remaining expansion project activities will be above the ground. However excavations are involved for foundations in construction and cut will be used for filling within the site.

1.9 Underground works including mining or tunneling?

No No mining and tunneling is involved in remaining expansion project activities

1.10 Reclamation works? No No reclamation works are envisaged in remaining expansion project activities

1.11 Dredging? No No dredging activity is involved in remaining expansion project activities

1.12 Offshore s tructures ? No No offshore structures are envisaged in remaining expansion project activities

1.13 Production and manufacturing processes?

Yes The detailed process description of all units is attached as Annexure (b).

1.14 Faci l i ties for s torage of goods or materia ls?

Yes Raw materials such as iron ore, coke, Limestone and Dolomite are being stored in open yards. Quartz and Manganese is being stored in closed shed. Fines generated will be stored in silos only. Hence there will not be any adverse impact on environment due to the proposed expansion.

1.15 Faci lities for treatment or disposal of sol id waste or l iquid effluents?

Yes

There will be no effluent generation in the Sinter plant, Cement plant and Annealing furnaces, as closed circuit cooling system will be adopted. The boiler blowdown will be have pH between 9.5 – 10.5. The pH of RO Rejects will be between 5 – 10. These two streams after neutralization will be mixed with cooling tower blowdown in central monitoring basin (CMB). The effluent from

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GCP & from DI pipe division will be treated in a thickener. The treated effluent will be sent to CMB. The concentrated slurry will be dried on sludge drying beds. The filtrate from sludge drying beds will be taken to CMB. Part of the treated effluent from CMB will be utilized for dust suppression and remaining for green belt development. RO reject water from 12 MW CPP is neutralized with blow down cooling tower and boiler in neutralization pit and consumed entire quantity in coke quenching which gets totally evaporated in the process. Also RO reject water from 2.5 MW CPP is neutralized with blow down water of DIP and MBF in Central monitoring basin (CMB) then treated in ETP. Treated effluents entirely consumed in slag granulation, gas cleaning plant, dust suppression etc. which gets totally evaporated. The effluent from the Coke oven plant will be totally recycled. The sanitary wastewater will be treated in STP. Regarding the Solid waste disposal, granulated slag from the Blast furnace will be utilized in the cement plant in the same premises. Slag from Induction Furnace will be utilized in the road construction as sub-base material. Dust from Air pollution control facilities in the steel plant expansion will be utilized in the sinter plant. Hence there will not be any adverse impact on environment due to the proposed expansion project.

1.16 Faci l i ties for long term hous ing of operational workers?

No Quarters are provided for Emergency staff and some of Executives. There are about 24 quarters in the township of the existing plant. The township with all infrastructural facilities is situated side of the existing plant.

1.17 New road, ra i l or sea traffic during construction or operation?

Yes During construction phase of part of expansion project additional road/rail traffic has been generated for supply of construction materials and plant equipment. Similarly during construction phase of

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remaining expansion project activities, additional road/rail traffic will be generated for supply of construction materials and plant equipment. During operation of the expansion project, most of the raw materials will be transported by railway wagons. A railway siding is available up to the plant site. Other raw materials in small quantity will be transported by road in covered trucks. The existing roads can handle this minor increase in traffic. Hence there will not be any adverse impact on road traffic/rail traffic/sea traffic due to the remaining expansion project operations.

1.18 New road, rail, air waterborne or othe r transport infrastructure including new or a l tered routes and s tations , ports , a i rports etc?

No A railway siding has already been laid up to the plant from the nearest railway station. No new road / air transport infrastructure is proposed for the expansion project.

1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?

No Not Applicable

1.20 New or diverted transmiss ion l ines or pipel ines?

No Water required for the part of expansion project implemented is being met from Tirupathi Municipal Sewage treatment plant For the remaining expansion project also water required will be met from Tirupathi Municipal Sewage treatment plant An agreement copy with Tirupathi Municipal Corporation for supply of sewage water is enclosed as Annexure – (c)

1.21 Impoundment, damming, culverting, rea l ignment or other changes to the hydrology of watercourses or aquifers?

No No damming, culverting, realignments are envisaged. There will not be any changes to the hydrology of watercourses or aquifers due to the implementation remaining expansion project activities

1.22 Stream cross ings? No Not Applicable 1.23 Abstraction or transfers of water form

ground or surface waters? Yes Water required for the part of expansion

project implemented is being met from Tirupathi Municipal Sewage treatment plant For the remaining expansion project also water required will be met from Tirupathi Municipal Sewage treatment plant An agreement copy with Tirupathi Municipal Corporation for supply of sewage water is enclosed as Annexure – (c)

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1.24 Changes in water bodies or the land surface affecting dra inage or run-off?

No No changes in water bodies, drainage and land surface are anticipated, as the site is more or less flat without many undulations.

1.25 Transport of personnel or materia ls for construction, operation or decommiss ioning?

Yes A few vehicles will be provided for transport of personnel during construction & operation of the remaining expansion project. Construction materials will be transported in contractor’s vehicles. Total no. of vehicles for transport of personnel and materials will be 10 per day during construction. Most of the raw materials will be transported by railway wagons. The existing road is capable of handling the additional vehicular traffic due to the proposed activities.

1.26 Long-term dismantl ing or decommissioning or restoration works?

No Not Applicable

1.27 Ongoing activi ty during decommissioning which could have an impact on the environment?

No Not Applicable

1.28 Influx of people to the area ei ther temporari ly or permanently?

No During construction local people will be involved. During operation of the plant preference will be given to the local people for employment.

1.29 Introduction of a l ien spe cies? No Not applicable 1.30 Loss of native species or genetic

divers i ty?

No Not Applicable

1.31 Any other actions? No Not Applicable

2. Use of Natural resources for construction or operation of the Project (such as land, water, materials

or energy, especially any resources which are non-renewable or in short supply):

S.No. Information/checklist confirmation Yes/No Details thereof (with approximate quantities /rates, wherever possible) with source of information data

2.1 Land especia l ly undevelope d or agricul tura l land (ha)

No 183.85 acres of land is in the possession of the management. The present use of the land is industrial. Out of which 1/3rd of the total area will be developed with greenbelt.

2.2 Water (expected source & competing users ) unit: KLD

Yes Water required for the plant will be met from Tirupathi Municipal Sewage Treatment Plant. Total water requirement for the expansion project is 7750 Cum/day. An agreement copy with Tirupathi Municipal Corporation for supply of sewage water is

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enclosed as Annexure – (c) 2.3 Minera ls (MT) Yes Please refer to Annexure – (d) 2.4 Construction materia l – s tone,

aggregates, sand / soi l (expected source – MT)

Yes All construction materials such as stone, sand, soil are available locally.

2.5 Fores ts and timber (source – MT) No Not Applicable 2.6 Energy including electrici ty and

fuels (source, competing users ) Unit: fuel (MT), energy (MW)

Yes Power generation : Expansion from 14.5 MW to 40.5 MW

2.7 Any other natura l resources (use appropriate s tandard units )

No Not Applicable

3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health. S.No. Information/Checklist confirmation

Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data

3.1 Use of substances or materia ls , which are hazardous (as per MSIHC rules ) to human health or the environment (flora, fauna, and water suppl ies )

Yes Zinc dust and Used Oil will be stored and will be disposed as per CPCB / APPCB norms.

3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases)

No

3.3 Affect the welfare of people e.g. by changing l iving conditions?

No Not Applicable

3.4 Vulnerable groups of people who could be affected by the project e.g. hospita l patients , chi ldren, the elderly etc.,

No Not Applicable as the proposed project will create more employment opportunities in the area and thereby a substantial improvement in the socio-economic status.

3.5 Any other causes No State-of-the-art control systems will be installed to bring down the emissions in the exhaust gas to within the stipulated standards of CPCB/APPCB. The treated effluent will be utilized for recycle, dust suppression and for greenbelt development within the premises after ensuring compliance with the CPCB/APPCB standards. All the solid waste generated will be utilized / disposed as per the methods approved by CPCB/APPCB. A thick greenbelt of 85 acres will be developed. There are no hospitals and schools in the vicinity of the plant. Hence there will not be any adverse impact on vulnerable groups due to the proposed project.

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4. Production of solid wastes during construction or operation or decommissioning (MT/month)

S.No.


Yes/No

Details thereof (with approximate quantities/rates, where ever possible) with source of information data

4.1 Spoi l, overburden or mine wastes Yes The dug soil during excavation is will be used for filling of low lying areas in the already implemented / yet to be implemented units.

4.2 Municipal waste (domestic and or commercia l wastes)

Yes Small quantities of domestic wastes generated from staff quarters and administrative areas will be disposed off as per MSW norms.

4.3 Hazardous wastes (as per Hazardous Waste Management Rules )

Yes Waste lube oil – 391.5 lit/day Zinc dust – 500 Kg/day

4.4 Other industrial process wastes Yes Please refer to annexure – (e)

4.5 Surplus product No Not Applicable 4.6 Sewage s ludge or other s ludge

from effluent treatment Yes Sludge from STP is being disposed off as per APPCB

norms in environment friendly manner.

4.7 Construction or demol i tion wastes

Yes Construction wastes are will be disposed off as per guidelines.

4.8 Redundant machinery or equipment

No Not Applicable

4.9 Contaminated soi l s or other materia ls

No No contamination of soils or no contaminated materials will be kept in the plant.

4.10 Agricul tura l wastes No Not Applicable

4.11 Other sol id wastes No Not Applicable

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5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

S.No.


Yes/No

Details thereof (with approximate quantities/rates, wherever possible) with source of information data

5.1 Emiss ions from combustion of foss i l fuels from stationary or mobi le sources

Yes The emissions from major concern will be PM, SO2 & NOx, to control these emissions state of art pollution control systems will be installed as per CPCB / APPCB norms.

5.2 Emiss ions from production processes

No Dust emissions from production process are generated, to control these emissions state of art pollution control systems will be installed as per CPCB / APPCB norms.

5.3 Emissions from materials handling including s torage or transport

Yes Dust suppression system will be provided in unloading areas. Dust extraction systems will be provided in coal crushing and screening, etc. Most of the raw materials will be transported through railway wagons. Pucca external & internal roads exist. Raw materials will be stored in yards with water spraying systems. Hence there will not be any adverse impact due to fugitive emissions from the transport and storage of raw materials.

5.4 Emiss ions from construction activi ties including plant and equipment

Yes Some dust emissions will be generated during construction. Dust curtains will be provided all round the work area to prevent the dust emissions. Water spraying will be done to prevent the dust emanation due to vehicular movement.

5.5 Dust or odours from handl ing of materials including construction materia ls , sewage and waste

Yes Not applicable

5.6 Emiss ions from incineration of waste

No Not applicable

5.7 Emissions from burning of waste in open air (e.g. slash materia ls , construction debris )

No All such wastes will be disposed off as per norms.

5.8 Emissions from any other sources No Nil

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6. Generation of Noise and Vibration, and Emissions of Light and Heat:

S.No.


Yes/No

Details thereof (with approximate quantities/rates, wherever possible) with source of information data with source of information data

6.1 From operation of equipment e.g. engines , venti lation plant, crushers

Yes The sources of noise generation in the will be DG Sets, Boiler, Compressors, etc All machinery will be manufactured as per OSHA/MOEF guidelines. Noise enclosures will be provided to Turbines. Earplugs will be provided to workers working in the noise prone areas. Ambient noise levels will be in accordance with MOEF notification dated 14-02-2000 i.e. noise levels will be < 75 dBA during daytime and < 70 dBA during nighttime.

6.2 From industria l or s imi lar processes

Yes Nil

6.3 From construction or demoli tion Yes Construction equipment will cause some noise. Ear plugs will be provided to construction workers who work near the noise generating equipment.

6.4 From blasting or pi l ing No No such operations are involved.

6.5 From construction or operational traffic

Yes Vehicles used by construction staff are minimal. The noise levels will be in accordance with MOEF notification dated 14-02-2000.

6.6 From l ighting or cooling systems No Not applicable 6.7 From any other sources No Not applicable

7. Risks of contamination of land or water from releases of pollutants into the ground or into

sewers, surface waters, groundwater, coastal waters or the sea:

S.No.


Yes/No


7.1 From handl ing, s torage, use or spi llage of hazardous materia ls

Yes Used oil generated from the expansion activities will be stored in covered HDPE drums and will be given to APPCB approved vendors. Good Housekeeping practices are being followed in the existing plant and similar practices will be followed during operation of the expansion project. Hence there will not be any spillage which will affect the environment.

7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of

Yes There will be no effluent generation in the Sinter plant, Cement plant and Annealing furnaces, as closed circuit cooling system will be adopted.

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discharge)

The boiler blow down will be have pH between 9.5 – 10.5. The pH of RO Rejects will be between 5 – 10. These two streams after neutralization will be mixed with cooling tower blow down in central monitoring basin (CMB). The effluent from GCP & from DI pipe division will be treated in a thickener. The treated effluent will be sent to CMB. The concentrated slurry will be dried on sludge drying beds. The filtrate from sludge drying beds will be taken to CMB. Part of the treated effluent from CMB will be utilized for dust suppression and remaining for green belt development. RO reject water from 12 MW CPP is neutralized with blow down cooling tower and boiler in neutralization pit and consumed entire quantity in coke quenching which gets totally evaporated in the process. Also RO reject water from 2.5 MW CPP is neutralized with blow down water of DIP and MBF in Central monitoring basin (CMB) then treated in ETP. Treated effluents entirely consumed in slag granulation, gas cleaning plant, dust suppression etc. which gets totally evaporated. The effluent from the Coke oven plant will be totally recycled. The sanitary wastewater will be treated in STP. Regarding the Solid waste disposal, granulated slag from the Blast furnace will be utilized in the cement plant in the same premises. Slag from Induction Furnace will be utilized in the road construction as sub-base material. Dust from Air pollution control facilities in the steel plant expansion will be utilized in the sinter plant. Hence there will not be any adverse impact on environment due to the proposed expansion project.

7.3 By depos i tion of pol lutants emitted to a i r into the land or into water

No State-of-the-art Gas cleaning plant will be provided to treat the gases from the proposed Blast Furnace and will be discharged into the atmosphere through a stack of 30 m height. Fume extraction system with bag filters will be provided to treat the gases and the secondary fugitive emissions from the melting sections. Unloading areas will be provided with water

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sprinklers to prevent the fugitive dust. All conveyors will be completely covered with GI sheets. A thick greenbelt of 34 acres will be developed in addition to the existing 51 acres of greenbelt. This greenbelt will be developed as per CPCB guidelines in consultation with DFO. Hence there will not be any deposition of pollutants into the air/land/water.

7.4 From any other sources No Not applicable 7.5 Is there a ri sk of long term bui ld

up of pol lutants in the environment from these sources?

No Not applicable

8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment. S.No.


Yes/No


8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances

No Good housekeeping practices are being followed in the existing plant. Similarly good housekeeping practices will be maintained in the expansion project also. Used oil will be stored in covered HDPE drum and will be disposed off to APPCB approved vendors.

8.2 From any other causes No Not applicable 8.3 Could the project be affected by natura l

disasters causing environmental damage (e.g. floods , earthquakes , lands l ides , cloudburst etc)

No Not applicable

9. Factors which should be considered (such as consequential development) which could lead to

environmental effects or the potential for cumulative impacts with other existing or planned activities

in the locality

S. No.


Yes/No


9.1 Lead to development of supporting uti l i ties , anci l lary development or development s timulated by the project which could

No

No such activities are envisaged.

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have impact on the environment e.g.: • Supporting infrastructure (roads ,

power supply, waste or waste water treatment, etc.)

• hous ing development • extractive industries • supply industries • other

9.2 Lead to after-use of the s i te, which could have an impact on the environment

No Not applicable

9.3 Set a precedent for later developments

Yes With the improvement in the socio-economic status of the people in the area, later developments are expected.

9.4 Have cumulative effects due to proximity to other existing or planned projects with s imi lar effects

No Nil

(III) Environmental Sensitivity

S.No.

Areas

Name/ Identity

Aerial distance (within 15 km.)

Proposed project location boundary

1 Areas protected under international conventions, national or local legis lation for their ecological, landscape, cultural or other related va lue

Yes Sri kalahasthi temple ( 8.5 Kms)

2 Areas which are important or sens i tive for ecologica l reasons - Wetlands , watercourses or other water bodies, coastal zone, biospheres , mountains , forests

Yes Pallam RF, Ramapuram RF, Yerpedu PF

3 Areas used by protected, important or sens i tive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

Nil Not applicable

4 Inland, coasta l , marine or underground waters

Nil Not applicable

5 State, National boundaries Yes SH – 61 (1 Km)

6 Routes or facilities used by the publ ic for access to recreation or other tourist, pilgrim areas

Nil Not applicable

7 Defense insta l lations Nil Not applicable

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8 Densely populated or bui l t-up area Yes

Srikalahasti (7.3 Kms.)

9 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship, community facilities)

Yes Rachagunneri (1.0 Km.)

10 Areas containing important, high qual i ty or scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)

Yes Swarnamukhi river (4.5 Kms.)

11 Areas a l ready subjected to pol lution or environmental damage. (those where existing legal environmental standards are exceeded)

Nil Not applicable

12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)

Nil Based on the historical data, the site is not likely to prone to earthquakes, floods, etc.

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(IV). PROPOSED TERMS OF REFERENCE FOR EIA STUDIES

NOT APPLICABLE

We request the Honorable Ministry to kindly extend the validity of the Environmental Clearance

& amendment in Environmental Clearance order issued earlier vide order No. J – 11011 / 914 /

2007 – IA II (I) dated 25-07-2008 in order to complete the remaining unimplemented portion of

the project for which Environmental Clearance has been accorded.

“I hereby given undertaking that the data and information given in the appl ication and

enclosures are true to the best of my knowledge and belief and I am aware that i f any part of the

data and information submitted is found to be false or misleading at any s tage, the project wi l l be

rejected and clearance give, i f any to th e project wi l l be revoked at our ri sk and cost.

Date: 28-10-2014 Place : Chittoor

For Srikalahasthi Pipes Limited (formerly LANCO INDUSTRIES LIMITED)

M.R. Ramesh Bapu, Sr.General Manager (Business development)

Rachagunneri (V) & (PO) Srikalahasti (Mandal),


Annexure-(b)

PROCESS DETAILS

Lanco Industries Ltd. is manufacturing total 4 products namely Pig iron, Slag cement, D.I.

Spun pipes and LAM Coke. Major saleable products are D.I Spun pipes and Slag cement.

Produced LAM Coke is used to produce Pig Iron and Molten Iron is used to produce D.I Spun

pipes.

Manufacturing process of each product as follows:

A) MANUFACTURING PROCESS – PIG IRON:

Pig Iron is manufactured using Korf Technology, Brazil. Pig Iron is made with its state -of-

the-art facilities conforming to national & international standards. The process of

manufacturing of Pig Iron is detailed in this section to give an insight about the world

class manufacturing facilities available at the plant.

Raw material handling system:

Basic raw materials used for production of pig iron are Iron ore, Metallurgical coke,

Limestone, Dolomite, Quartzite and Manganese-ore.

These raw materials are stored / heaped in the respective yards with proper

identification, based on the raw material specification / supplier.

Raw materials are transported from respected yards to ground hopper by means of trucks

or tippers and dumped into the ground hopper, they are sent to respective day bins

through conveyors.

Batching & charging system

Automatic batching & charging system has been envisaged through Honeywell PLC. The

batching will be done automatically as per the burden set by the operation. The burden

will be decided by the operation based on the required quality of the pig iron. The

material, which is weighed, will be sent to the blast furnace via conveyors as per the

recipe. Charging will be done to MBF by means of upper & lower bells.

Preparation of hot blast

There are HT fans installed for generating blast required for blast furnace operation.

Based on the requirement of pressure and flow, the fans will be switched on to operate in

series to maintain the pressure. The cold blast generated from the blower fans is

preheated in Metallic Blast Pre-heaters (MBP) before sending to blast furnace.

There are three MBPs envisaged for pre-heating the cold blast. Based on the process

requirement, MBPs will be started & taken in to service. MBPs will be lighted with oil and

finally used in blast furnace as fuel for firing. The cold blast will be indirectly heated in

MBPs upto required temperature as per process requirement. This hot blast will be sent

to Blast furnace.

Blowing system:

There are 10 tuyers and blowpipes envisaged for blowing hot air in to the furnace. The

hot blast will flow upward in the blast furnace opposite to the direction of movement of

the raw material. The iron ore gets pre-heated, reduction process takes place and iron

start melting at different zones & finally become hot metal. It is collected in the hearth.

The hot metal collected will be tapped from blast furnace at regular intervals. The hot

metal tapped will be collected in ladles and weighed. The weighed ladles will be sent to

spun pipe division through trucks as per the requirement. The excess hot metal will be

converted into pigs through Pig Casting Machine (PCM). The pigs will be collected in

trucks and dumped at pig iron yard with batch identification.

By product / waste generation from mini blast furnace

a. Slag generation

Slag is a bi-product from blast furnace, which is granulated by means of slag granulation

system. A part of the granulated slag is sent to cement plant for making Portland Slag

Cement (PSC). Excess slag is stored at designated storage yard for disposal / sales.

b. Flue gas

The flue gas from MBPs will be used at cement plant for slag drying. Remaining flue gas

will be released to atmosphere.

c. Blast furnace gas

The blast furnace gas coming-out from the furnace is used as fuel for MBPs, Boiler,

Laddle, Spun pipe division annealing furnace. Any excess gas will be let out to

atmosphere through flare stack chimney, after burning the gas using flare ignition system.

d. Flue dust from dust catcher

The flue dust generated will be collected at dust catcher. It is periodically loaded to

trucks and dumped at designated places from where it is used for making sinter in

sintering plant.

e. Captive power plant

2.5 MW BF gas fired captive power plant has been installed to utilize BF gas generated

from the furnace. This will reduce the power cost and also saves the environment from

emission of gas to atmosphere.

f. Effluent treatment plant

ETP has been installed for treatment of wastewater generated from the process and for

reuse at SGP, GCP, sintering plant and PCM cooling.

g. Dispatch

The Pig Iron will be stored at the Pig Iron Yard, which will be dispatched to customers

through trucks / rakes.

B) MANUFACTURING PROCESS SLAG CEMENT

The Main Raw materials required for Slag Cement production are Lime Stone, Coke Fines,

Clay, Slag and Gypsum. Limestone brought from mines in boulder form is crushed to -

20mm size in crusher.

The crushed limestone chips are ground along with Clay, Iron ore and Coke fines in

grinding mills. The resultant product is called ‘Raw Meal’, which is mixed with water and

made into globules in a nodulizer.

These nodules are fired in a vertical shaft kiln at a temperature of 1300 to 1400oC, to get

clinker, which is nothing but Ordinary Portland Cement in unfinished form.

But cement made from above clinker will not have proper setting properties. Hence 2%

Gypsum is added to clinker & ground into a fine powder to make cement.

In our case to make use of the Slag coming from Mini Blast furnace, we are adding slag

with clinker to make slag cement, which is mixed upto 70% depending on the nature of

Slag.

The Cement manufacturing process is semi dry process. Raw meal is prepared by grinding

and mixing in the pre-worked proportions of main raw material (Lime Stone) with the

additives (Iron Ore, Coke fines, Clay, etc.) Then the raw meal is burnt at a high

temperature attained in the initial ignition system in a vertical shaft kiln result in

penultimate end product called clinker. Clinker after cooling, along with slag and gypsum

are fed into the cement mill and are ground to fineness to produce the finishe d product

i.e. Portland Slag Cement (PSC).

C) MANUFACTURING PROCESS OF D.I SPUN PIPES

Pre- analyzed liquid metal from Blast Furnace is taken into Induction Furnace. The metal

is superheated to a temperature of about 15200C and adjusted for chemical composition

by addition of steel scrap and Ferro Silicon. The adjusted metal is taken into converter for

treatment to convert into SG Iron. The metal is analyzed for chemical composition before

and after the treatment of conversion with the help of spectrometer. The treated metal

from converter is transferred to spinning machines through ladles. The metal is kept

poured to unlined water-cooled metallic moulds through a runner. The mould is kept at

slightly inclined position and rotated at high speed. The uniform flow of metal and

uniform travel of the mould is ensured through flow control valves to achieve the

uniformity in thickness. Due to the centrifugal force, the metal is held against the mould

wall and the solidification of metal takes place due to water-cooling of the mould. The

pipe cast through above process known as delavud process is heat-treated in furnace.

The pipes are heated to a temperature of 9200C to 970

0C and soaked at this temperature

for a period of 20 to 25 minutes. Then the pipes are cooled to a temperature of 700 to

7500C in 8 to 10 minutes time inside the furnace and held at the above temperature for a

period of 12 to 15 minutes before final cooling. Samples are collected for mechanical

testing of physical properties and microstructure. After heat treatment the pipes are

finished by cleaning the socket configuration and inside surface of the pipes with grinders

by using abrasive grinding wheels before testing them with recommended hydrostatic test

pressure. The tested pipes are inspected and sent for coating/lining as per the customer’s

requirement.

1. External coating of Metallic Zinc, Cement mortar lining of internal surface without

seal-coat, and finishing layer of bitumen paint over metallic Zinc coating on

external surface.

2. External coating of bitumen paint and internal coating of Cement mortar lining

without seal-coat.

3. External and internal coating of bituminous paint.

Coatings:

a. Pipes are coated externally with metallic Zinc by spraying process. Before

coating of zinc, the external surface of the pipe is cleaned with wire brush

manually if required, to ensure good surface.

b. Cement mortar lining inside the pipes is done by centrifugal spinning

process. Before lining the inside surface of the pipes, it is cleaned with

barrel grinders using abrasive grinding wheels. Sand quality is ensured and

controlled by screening of sand and analyzing with sieve shaker on regular

basis. The thickness of cement coating is measured with the help of coat

meter.

c. Finishing layer of Bitumen paint over metallic zinc coating is applied on pipe

surface by spraying process. The coating of thickness is measured with a

thickness gauge (coat meter).

After coating/lining the pipes as per customer’s requirement / choice are marked and

sent to dispatch yard for stacking/ dispatch.

D) MANUFACTURING PROCESS OF LOW ASH METALLURGICAL COKE (LAMC) & CAPTIVE POWER GENERATION PROCESS (NON-RECOVERY COKE OVEN PLANT) The Low ash metallurgical (LAM) Coke making process is basically carbonization of coal to

higher temperature around 11000C in an Oxygen deficient atmosphere, which aids

concentration of carbon. There are two types of manufacturing process available viz.

byproduct (Recovery) and non-recovery types.

Lanco has opted for non-recovery (Heat Recovery) type method for various advantages

over the by product (Recovery) type coke oven as listed below.

a. Less investment cost as no byproduct related equipments and related auxiliaries

are required.

b. Low operation and maintenance cost.

c. Low conversion cost.

d. High coke yield.

e. Any oven in a battery can be isolated and cooled down to repair at any time

without affecting the life of the oven.

f. No effluent generation, only emissions of burnt i.e clean flue gas resulting to

minimal environmental impact.

g. Oven of non-recovery type is being operated under negative pressure, no fugitive

emissions through the doors and hence no pollution problems.

h. Extensive flue path system ensures complete combustion of all hydrocarbons,

resulting in clean stack discharges into the atmosphere.

The individual ovens are rectangular cross sections and horizontally positioned. A row of

such ovens is called battery.

Lanco Industries Limited is having two batteries, battery I & battery II, Each battery

consist of 34 ovens and each battery is connected to separate stack or emissions are sent

to each boiler of captive power plant. After passing through the boiler, the emissions are

discharged into atmosphere through a common stack of both the boilers.

The imported coal (coking coal) is powdered, charged into the oven from top through

charging ports using a changing car, which moves, on top of the oven to feed coal into the

oven. The charging car receives powdered coal from bunkers stock. The bunkers are filled

with powered coal through a belt conveyor from the ground stock of pulverized coal; the

charged coal in the oven is leveled and compacted by the leveler cum pusher, which will

improve the cycle. The other facility also provided for charging i.e. the powdered coal

also compacted in a machine and formed cake then it is charged in to the oven from the

front door as stamp charging. These both options are used for charging of coal into the

ovens. As gases are evolved, they are combusted. Thus the entire coal charges get

carbonized thoroughly by combustion inside the oven. Then by opening the side doors

after cycle time (app.36 hours) oven temperatures are monitored from time to time to

determine now coke is ready. With the help of lever cum pusher the ready hot coke is

pushed into the quenching car, and then it is quenched with water. The lumps are stored

and fed to coke cutter to sizing.

Combustion and temperature can be controlled to achieve required coke quality for the

steel industry while assuring clean exhaust gas.

The primary air for combustion is introduced into the chamber through several ports

located above the charge level in both the side doors. Partially combusted gas exits at the

top chamber through down corner passages in the oven wall and enters the sole flue path

thereby heating sole of the oven.

Since the air is drawn into the oven at upper end and off gases is combusted within the

oven chamber itself, the oven has been provided with long flue path thus burning of all

the exhaust gases from oven which contain various volatile organics etc. The fully

combusted waste flue gases containing mostly CO 2 and Nox go through the chimney and

that’s how it meets the pollution control requirements.

As the exhaust gases from oven battery are collected into common tunnel and exit

through a 37.25 m height chimney c reates natural draft inside the oven and there will be

no fugitive emissions/leaks through doors etc. of ovens.

For power generation, the hot exhaust gas is diverted into waste heat recovery boilers

without letting into atmosphere through battery chimneys. The hot gas heats up the water

and convert into steam were it generates 12 MW power, then cooled gas is discharged into

atmosphere through a common chimney of the height 55 m.

The new oven design ensures excellent thermal efficiency. Anyone oven can be shut down

for any fault without affecting the production. The emission of smoke from the chimney is

without any harmful gas. The harmful gasses that are generated in the process are reused

as combustible material and the gasses are totally burnt within the oven battery itself,

hence free from pollution and discharged into atmosphere through 37.25 m height stack

when captive power plant if not working. Process flow for coking coal to LAM coke

manufacturing and power generation process is shown in Fig.1 and Fig.2.

The water used as quenching and cooling agent is collected in the canals surrounding the

ovens and the same is sent to settling tank and the clear overflow from settling tank is

collected into a clear water tank and reused. The required quantity of water is

replenished to compensate the evaporation losses.

The settled particles in the settling tank are reclaimed and this has large demand in mini

cement plants and briquetting plants.

Annexure – (d)

RAW MATERIAL REQUIREMENT

RAW MATERIAL

QUANTITY (TPA)

SOURCE METHOD OF

TRANSPORTATION EXISTING EXPANSION TOTAL

DUCTILE IRON PIPE DIVISION

Molten metal 127,925 2,97,500 4,25,425 In plant generation EOT crane

Scrap 13,244 30,800 44,044 Open market Covered trucks / rail

Ferro silicon 2,007 4,667 6,674 Open market Covered trucks / rail

Cement 12,642 29,400 42,042 In plant generation Cement transfer poucher

Sand 15,010 34,908 49,918 Open markets Covered trucks

Silica sand 903 2,100 3,003 Open market Covered trucks

Bitumen paint 662 1,540 2,202 Open market Covered trucks

Zinc 662 1,540 2,202 Open market Covered trucks

Magnesium 146 339 485 Open market Covered trucks

LDO/LVFO 520 1,040 1,560 Open market Oil tankers

PIG IRON DIVISION

Sinter 2,27,500 4,55,000 6,82,500 In plant generation Conveyor

Coke 78,834 1,57,500 2,36,334 In plant generation Conveyor

Coal fines 17,667 35,000 52,667 Imported & Indigenous Rail / Covered truck

Lump ore 63,500 1,05,000 1,68,500 Hospet / Bellary

Karnataka

Railway rakes & Covered

trucks

NON RECOVERY COKE OVEN

Imported coking

coal 2,48,400 4,60,000 7,08,400 Australia

Through sea ways followed by

rakes & trucks

CEMENT DIVISON

Lime stone 104,400 348,000 4,52,400 Kadapa Covered trucks/Rail

Clay 6,207 20,690 26,897 Kadapa Covered trucks

Coal 4,655 15,518 20,173 Imported & Indigenous Covered trucks / rail

Coke breeze 4,654 15,518 20,172 In plant generation Conveyors

BF slag 25,430 1,22,500 1,47,930 In plant regeneration Conveyors

Gypsum 3,103 10,345 13,448 Open market Covered trucks

Annexure – (e)

SOLID WASTE GENERATION

S.NO SOLID WASTE EXISTING

(TPD)

EXPANSION

(TPD)

TOTAL AFTER

EXPANSION (TPD)

METHOD OF DISPOSAL

DI PIPE DIVISION

1. Furnace waste

(CI / DI scrap) 60.0 140.0 200.0

Sold to the authorized

dealers

2. Burnt core sand 2.6 6.0 8.6

Reclaiming low lying areas

in industry premises

3. Waste sand

cement slurry 4.0 12.0 16.0

Reclaiming low lying areas


4. Slag 2.0 5.5 7.5 Used for road laying

5. Zinc residue 0.07 0.15 0.22

Sold to the authorized

dealers

6. Mg converter waste

0.02 0.05 0.07 Used in Sinter plant

SINTER PLANT 1. Sinter return -- 460 460 Used in Sinter plant

PIG IRON 1. By product

(Slag)

140.0 350.0 490.0 Used to produce slag

cement

2. Sludge 10.0 20.0 30.0 Reclaiming low lying areas


3. Dust from

settling chamber

23.5 47.0 70.5 Used in sinter plant to

produce sinter

submitted to moef, new...

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