EXECU T I VS E U M M A R Y O F EXECUTIVE SUMMARY
1.0 Introduction
M/S Mahalakshmi Profiles Pvt. Ltd., established on Survey. No. 287, 288 & 289 in Kallakal village, Manoharabad Mandal, Medak District in Telangana state, is already manufacturing Steel Billets. Presently it has two induction furnaces (one stand by) with 12 tons capacity, with total production of 29,700 tons per Annum. It also has a Strip mill and Tube mill of 165tonnes per day capacity each. The existing plant is having valid Consent for Operation from TS Pollution control Board.
Now the company have proposed to expand the existing plant by installing 12TPH x 6 more (total 8 No. 12TPH) Induction Furnaces along with CCM for making 621 TPD (2,04,930 TPA) of MS Billets and New roughing stand/Modernization activities for making 534 TPD (1,76,220 TPA) of MS Skelp and installation of 3 new ERW Tube mills for production of 835 TPD (2,75,550 TPA) of MS Pipes and installation of scaffolding workshop for production of 50 TPD (16,500 TPA) of Scaffolding. It will also Install continuous coil Galvanizing unit for manufacturing of 300 TPD (99,000 TPA) of Galvanized Strips /Coils and installation of Hot Dip Galvanizing unit for manufacturing of 300 TPD (99000 TPA) of Hot Dip Galvanizing of MS ERW Tubes.
Project Proponent
M/S Mahalakshmi Profiles Pvt. Ltd. is a Private Limited Company. The Directors of the company are as under: Directors: The company is promoted by: Mr. Ramniranjan Agarwal and Mr. Vinod Kumar Agarwal. Address: Mahalakshmi Profiles Pvt. Ltd. Private Limited has its registered office at 1-9-8, I.D.A, Azamabad, Hyderabad, Telangana.
1.1 Location
M/S Mahalakshmi Profiles Pvt. Ltd.is situated at village Kallakal village, Manoharabad Mandal, Medak District in Telangana state , Latitude 17° 41' 54.3408"N and Longitude 78°29'4.8192"E. The project falls under the Manoharabad Mandal. The land area of the plant is 19 Acres and 17 Guntas (78,610.256 sq m) out of which 13.675 acres is being used for the Industrial processes and 5.75(33.0% )Acres has been allocated for green belt.
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2.0 Product and Capacities
The project proposes to expand the production capacity by upgrading existing capacity as given below: Capacity S. No. Product Existing Expansion After Expansion MS Billets though 1 90 TPD 621 TPD 711TPD Induction Furnace 2 MS Skelp through 165 TPD 534 TPD 699 TPD Strip mill 3 Pipes through Tube Mill 165 TPD 835 TPD 1000 TPD 4 Scaffolding -- 50 TPD 50 TPD 5 Galvanized Strips/Coils -- 300 TPD 300 TPD Hot Dip galvanizing of 6 -- 300 TPD 300 TPD MS ERW Tubes
The unit obtained CFO for Furnace on 16-08-2017 (valid up to 31-01- 2022) from State Pollution Control Board to manufacture 90 T/Day of MS Ingots ,60TPD MS Pipes and 70TPD hot Rolling strips . The unit obtained the respective Consent Orders accordingly and started its operations. Salient Features of the Project
Name of Project Mahalakshmi Profiles Pvt. Ltd. Proponent( Director) Mr. Ramniranjan Agarwaland Mr. Vinod Kumar Agarwal.
Nature of the Project Secondary Metallurgical Process based industry Latitude and Longitude S. LATITUDE LONGITUDE S. LATITUDE LONGITUDE NO. NO. 1 17°42'3.22"N 78°29'1.19"E 14 17°41'56.60"N 78°28'47.00"E 2 17°41'57.66"N 78°29'0.91"E 15 17°41'56.50"N 78°28'47.00"E 3 17°41'57.60"N 78°28'55.80"E 16 17°41'55.90"N 78°28'42.00"E 4 17°41'52.50"N 78°28'55.60"E 17 17°41'56.20"N 78°28'41.90"E 5 17°41'52.50"N 78°28'55.40"E 18 17°41'56.80"N 78°28'46.70"E 6 17°41'54.20"N 78°28'50.00"E 19 17°41'57.60"N 78°28'46.70"E 7 17°41'54.20"N 78°28'49.60"E 20 17°41'57.50"N 78°28'48.20" 8 17°41'54.10"N 78°28'49.10"E 21 17°42'0.80"N 78°28'48.50"E 9 17°41'55.30"N 78°28'48.80"E 22 17°42'0.70"N 78°28'50.60"E 10 17°41'55.40"N 78°28'49.40"E 23 17°42'2.00"N 78°28'50.90"E 11 17°41'56.60"N 78°28'49.40"E 24 17°42'2.30"N 78°28'56.20"E
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Name of Project Mahalakshmi Profiles Pvt. Ltd.
12 17°41'56.70"N 78°28'49.60"E 25 17°42'2.20"N 78°28'56.20"E 13 17°41'56.90"N 78°28'49.70"E 26 17°42'2.79"N 78°29'0.25"E
Site Location Survey. No. 287, 288 & 289 in Kallakal village, Manoharabad Mandal, Medak District in Telangana state Total land area 78,610.255 sq. m Total area of green belt developed 2,594.22 sq. m (33.0%)
Nearest High way The plant site approached by small road which connect NH-7 and Industry Nearest Rly Stn Dabilpur Rail Way Station is 2.8 Km from the site Nearest Air Port Rajiv Gandhi International Airport, Shamshabad, Hyderabad is 70 km from the site Nearest fire station Narsapur 21 km (North –West) Nearest village Kallakal Village North 1km Nearest surface water bodies Pond near Gomaram 9.0 km (West-North West) Water body near Meenjipeta 5.5 km(North East) Water body near Tunki Makta 8.0 km (NE) Medchal Lake 8.63 km (South) Nearest Reserve Forest Ellampet Reserve Forest 2.0 km South –South West Any ecologically sensitive areas None Fresh Water Requirement Industrial: 16 KLD; Domestic: 3.6 KLD (Existing) Industrial: 57KLD; Domestic: 16 KLD (Proposed) Source of Water Telangana: Gram Panchayat and tanker supply
Man Power 500 Members to be employed directly and around 100 people may be employed indirectly
Power Demand 15500 KVA and is supplied by Telangana Electricity supply board DG Set Existing one DG set of 380 kVA Project Cost The cost of the project is Rs 150 crores (15000 lakhs) along with all the accessories
3.0 Requirement of the Proposed Project 3.1 Raw Materials c
The existing unit is using the MS Scrap; Sponge Iron and Alloying metals for the MS Billets. It is proposed to increase the production capacity of MS Ingots/Billets from 27,000 TPA to 213,300 TPA, thus the raw material requirement will also increase which is mentioned below. Raw Materials Requirement for Existing Unit S.N Raw Source Transportation Quantity o Material TPD TPA For Existing (90 TPD)
1 Sponge Iron Local/adjacent States By Road 63.54 19,062 2 Iron Scrape Local/Imported By Road 9.9 2,970 3 Pig Iron Local/adjacent States By Road 18.63 5,589 4 Ferro Alloys Local/adjacent States By Road 0.81 243 Strip mill Conveyors and In plant generation and 1 Billets By Road 165TPD purchased from Market (Covered trucks) High grade Imported/Purchased from By Road 2 9 TPD coal thermal Traders (Covered trucks) Tube Mill By Road 1 MS Skelp In plant generation 166 TPD (Covered trucks) Material Balance for Existing Billets 90 27,000 Slag 2 600 Cutting& Scaling 1.5 450 Raw Materials Requirement for Expansion of the Unit Source of Raw Method of Transport S.No. Raw Material Consumption Materials Induction Furnaces with concast From Sponge iron 1 Sponge Iron 551 TPD By Road (covered trucks) plants 2 Scrap 164 TPD Local By Road (covered trucks) 3 Ferro Alloys 6 TPD Local By Road (covered trucks) Strip mill
1 Billets 587 TPD In plant generation Conveyors
High grade coal Imported/Purchased 2 32 TPD By Road (Covered trucks) thermal from Traders
Tube Mill
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1 MS Skelp 699 TPD In plant generation By Road (Covered trucks)
Purchased from 2 HR Coil 354 TPD SAIL/TATA/JSW/ By Road (Covered trucks) Other Manufacturers Scaffolding
1 MS Tubes 47 TPD In plant generation By Road (Covered trucks)
Accessories/ Purchased from local 2 3 TPD By Road (Covered trucks) Components Manufacturers
Continuous Coil Galvanizing
1 MS Skelp 150 TPD In plant generation By Road (Covered trucks) Purchased from 2 HR Coils 150 TPD By Road (Covered trucks) SAIL/TATA/JSW Hindustan Zinc/ Other 3 Zinc By Road (Covered trucks) reputed Manufacturers
Hot Dip Galvanizing
1 MS ERW Tubes 300 TPD In plant generation By Road (Covered trucks)
Hindustan Zinc/ Other 2 Zinc By Road (Covered trucks) reputed Manufacturers
3.2 Water requirement
Fresh Water Industrial: 15KLD; Domestic: 3 KLD (Existing) Requirement Industrial: 75KLD; Domestic: 15KLD (Proposed) Source of Water Gram Panchayat and tanker supply
4.0 Manufacturing Process
Billets Sponge iron, scrap and metal alloys are charged to furnace. Small quantity of silico-manganese and flux chemicals will be added to molten metal. The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting process compared to most other means of metal melting.
Raw materials for the process are scrap, fluxes and Ferro alloys. Sponge iron can substitute e
scrap up to 50%. The 16”x16” size Scrap bundles will be Lifted and Transported by Overhead cranes and fed to Induction Furnace. Scrap/ sponge iron, fluxes, Ferro alloys are melted in an Induction furnace, wherein electric current is passed through it. In the Induction Melting Furnace the scrap melts at temperature of about 1650C. When the total charge is melted into hot liquid metal then the metallurgy of steel in terms of carbon, phosphorus content, alloy elements etc., is controlled at this stage. Based upon the Composition of the molten steel, additives will be added to get the requisite composition and grade of Steel. The molten material is poured into mould to produce ingots. The ladle is placed over the Continuous Casting machine to cast the molten steel into required size of billets. The Cut Billets are transported by a Billet handling crane and stored in the Storage yard as per the Grade and Quality for dispatch.
Strip Mill Reheating of semi-finished steel slabs of steel nearly to their melting point, then roll them thinner and longer through 8 successive rolling mill stands driven by motors totaling 10,000 HP and finally coiling up the lengthened steel strip for transport to the next process. Tube Mill The coil as per desired width and thickness is received from the stock yard and loaded onto decoiler. The end of the strips are sheared and butt-welded and fed into a storage cage. The strip is passed through the forming section of the pipe mill and then into the Fin-pass section, it gradually takes the shape of a round tube.
Continues Coil Galvanizing Coating gauge is designed for online measurement of metal coatings on both sides of metal sheet in Continuous Galvanizing Lines (CGL). The deviations from preset target values are instantly detected allowing immediate corrections to the production process to maintain uniform coating. As the steel exits the furnace, it enters into a vacuum chamber, or snout, before entering the molten zinc bath to prevent and air from re-oxidizing the heated steel product. ERW Pipe are completely immersed in a bath of molten zinc. The bath chemistry is specified by ASTM B6, and requires at least 98% pure zinc, to form series of bonded zinc-iron alloy layers.
4.1 Material Balance and Emissions
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Material Balances for (Existing )M.S. Billets to the tune Material Balances for (Expansion) M.S. Billets to the of 27,000 tune of 213,300 TPA
5.0 Measures for Mitigating the Impacts
The purpose of mitigation measures is to avoid, reduce or minimize unwanted impacts on the environment. To minimize & control the Flue Gas emission from the stack attached to Boiler & DG Set, M/S Mahalakshmi Profiles Pvt. Ltd. shall be installing Separate Bag filters with Induction Furnaces & canopy with DG set. 51.76 TPD of Slag from furnaces is given to cement plant for reuse for land filling. Solids from APCD are disposed off at designated TSDF site. Used Oil from DG set is being sold to the authorized Recyclers. STP is provided for treatment of domestic effluent. Treated effluent is used for plantation in the premises. The industry is regularly operating and maintaining its APCD and ensuring that the emissions are adequately collected and concentration of air pollutants in its emissions conforms to the emission standards laid down by the board.
6.0 Cost of the Project
The total project cost is Rs 150.0 Crores (after addition of proposed machinery).Proposed Employment Generation from proposed project will be around 600 persons out of which 500 persons will be having direct employment and 100 persons will have indirect employment.
7.0 Site Selection
M M/S Mahalakshmi Profiles Pvt. Ltd. is situated at village Kallakal village, Manoharabad Mandal, Medak District in Telangana state , Latitude 17° 41' 54.3408"N and Longitude g
78°29'4.8192"E. The project falls under the Manoharabad Mandal. The land area of the plant is 19 Acres and 17 Guntas (78,610.256 sq m) out of which 13.675 acres is being used for the Industrial processes and 5.75(33.0% )Acres has been allocated for green belt. No National Parks/ Wildlife Sanctuaries/ Biosphere Reserves exist within 5 km radius of project site. Nearby water body is at Meenjipeta 5.5 km(North East) from the unit. 7.1 Land ownership and Related Details
The project land is owned by the proponent Mahalakshmi Profiles Pvt. Ltd. It is an Orange category industry that comes under the Industrial area of Manoharabad, The project falls under the Manoharabad Mandal. Non agriculture waste Land has been converted for industrial purpose. Land conversion documents has been enclosed at the end of the report The existing industry is with a Shed and two 12 tons per hour (TPH) Induction furnace and a Re- rolling mill. To increase the production The industry is now proposing addition of 6more 12 TPH additional induction furnace in the same premises.
8.0 Baseline of the Environment
8.1 Regional Meteorology
The study area has a severe summer season during the month of May with temperature shooting up to 47oC. The Normal means minimum temperature is 13.70C and means maximum is 39.90C. The onsite of the monsoon in the area is from June and tapers off during October. The average annual rainfall of the area is 644 mm. The area in general has dry climate with low humidity. The predominant wind direction during this period was from SE to NW sector accounting to about 45.83 % of the total time with calm winds of less than 1.0 kmph. During some of the times the wind speed was recorded more than 11 kmph. The monitoring period is from March to May 2019.
8.2 Ambient air quality
Ambient air quality of the study area has been assessed in and around the project. PM10 th 3 monitored in the Plant area showed 98 percentile value of 91.0 g/m with PM 2.5 of 39.0 µg/m3. 98th percentile values of Sulphur dioxide and Oxides of Nitrogen in the Plant area from the monitored data were 11.0 g/m3 and 25.0 µg/m3 respectively. CO concentration at all the locations was found to be 1.47 µg/m3 .
8.3 Air Quality in Buffer Zone
The maximum monitored value of Air pollutants at site and in the buffer zone at selected h
location is given below:
Name of the PM10 PM2.5 NOX SO2 CO Station µg/m3 µg/m3 µg/m3 µg/m3 Project Area 92 40 25 12 1.61 Banda Mailaram 98 36 23 15 1.66 Baswapur 98 38 22 17 1.74 Rawalkole 99 37 19 13 1.59 Medchal 97 38 20 12 1.69 Nuthankal 99 38 20 12 1.70 Sikindlapur 98 38 22 12 1.65 Koochavaram 99 39 24 14 1.66 Source : Primary monitoring
8.4 Water Quality
Assessment of water quality in the study area includes the quality assessment of parameters as per the Indian standard IS 10500 for Ground Water. Water characteristics are as follows:
Parameters Results mg/l TDS 478 - 2448 Hardness 240 - 1628 mg/l Chlorides 35 - 1079 mg/l Sulphates 24 - 278 mg/l Calcium 64 - 477 mg/l Magnesium 14 - 135 mg/l Iron 0.03 - 0.16 mg/l Heavy metals Zn, Pb, Cu and Al BDL Source :Primary monitoring The analyzed values are found within the permissible/desirable limits of IS: 10500.
8.5 Nature of Soil
Soil samples were analyzed in and around the project site. The following are the highlights of soil quality in the study area. Summary of Soil Quality In plant Area pH of the all soil sample was 7.21. Texture of soil sample is found to be clay with sand 36%, silt 16% and Clay 48%. Phosphorus values in the soil sample collected was found to be 28 kg/ha. Nitrate of the soil sample collected was found to be 186 kg/ ha.
Summary of Soil Quality in Study Area pH of the all soil samples were found to be 7.16-7.86.
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Texture of soil samples is found to be Clay and sandy Clay with sand % in the range between 16-36%, silt between 16-48 % and Clay 34-54%. Phosphorus values in the soil samples collected were in the range of 28-64 kg/ha Nitrate of the soil samples collected were in the range of 186-282 kg/ha. 8.6 Ambient Noise
Noise monitoring was conducted in and around the project site. The values were below the respective statutory norms as applicable. 1st Feb to 30th April
8.7 Forests
The period of monsoon is very short lived in this area, which has a significant bearing apart from other biotic pressures, on the floristic composition of the forests. These are open forests in which thorny and usually hard wood species predominate. Rangipalli ,Manoharabad, Minajipet ,Kanukunta ,Munurabad and Dabilpur Reserve forest falls within 10 km radius around the site, with forest wealth such as Teak wood, Bamboo, Tamarind, Rosa grass, Beedi leaves, Neem seeds, medicinal plants etc., Bamboo fetches maximum revenue along with Beedi leaves ranging from 50 lakh to one crore per annum.
8.8 Flora
The study area does not habitat any thick vegetal cover. There is usually a thin grass growth which may appear during the short rainy season in most of the study area, but more or less the soil is barren and devoid of any grass growth. 8.9 Fauna Some of the animals which you would find here are Indian Giant Squirrel, Rhesus Monkey, Jackal, Red vented bulbul, Indian cuckoo, Common House Rats, Indian Fox, Indian Palm Squirrel, Wild Boar, House Sparrow, Common Myna, Common kingfisher, Common Peafowl, Common Pigeon, Goose Greylag, Grey Heron, House Crow, Indian Courser and Indian Pond Heron. No endangered fauna species are found in the area.
8.10 Socio-economic Status
Basic Socio-economic conditions are as follows: There are 60 villages and many hamlets in the study area. As per the 2011 census data, the population in the study area is 60,000. Density of population is 313 persons per sq. km. Literacy status of the area is found to be moderate with a total of 61.42 % of the population. Male and Female literacy is about 71.43 % and 51.37% respectively. Occupational status in the study area is in agriculture. 50 % of total population of the study area falls under main workers category. j
Agricultural activities are mainly in monsoon season. Major crops in the area are Jowar, Maize, groundnut, Ragi, Onion, Vegetables etc Medical facilities are inadequate, only few villages have the primary health care centers. For any major health care, the populace of the area has to go to Medchal /Manoharabad, which are major towns located at a distance of about 8.0 Km from the proposed site. Educational facilities are adequate. Higher educational center is Medchal at a distance of 8.0 km. This region is well connected by road. Many villages are adequately provided with protected water supply.
9.0 Identification of Hazards & Risks
Based on the type of operations, the possible Hazards and Emergencies are identified and appropriate mitigation measures are proposed. Safety hazards relating to Induction Furnace and Rolling Mill can be classified into 3 categories: Thermal hazards Electrical hazards Physical hazards S.No. Plant Possible Deviation from Likely Causes Consequences normal operation Area 1 Furnace Re-circulating and cooling Leakage of water Explosion under water coming in contact with from the walls extreme cases the molten iron or slag Spurting of metal/ slag Presence of Oil & Grease and Fire Sudden catches other Impurities in raw fire & flames materials 2 High Oil temperature being very Varying room Sudden flashing Power high. Temperatures of fire or Transforme bursting. r 3 High Heavy sparking at the pot Loose joints, cable Sparks in the Tension heads and the joints. cut, burning of beginning, Electrical fuses, short devastating fire Installation circuits etc. if neglected.
10.0 Likely Impact on Environment
10.1 Air Environment
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During construction water will be sprinkled on the soil to avoid dust generation if any. The debris and unused construction material shall be removed immediately for recycling, if any, or for land fill.
Bag filters & Cyclone shall be provided to arrest SPM from flue gases to keep it within permissible limits. All vehicles for service activities at the project site shall be checked for vehicular emission. The agencies will be asked to keep them within prescribed limits. They will also be asked to maintain them properly.
A chimney of suitable height is already provided for the D.G. set to control the G.L.C. of
S.P.M., SO2, & NOx levels. Extensive tree plantation shall be resorted to for further improving the air environment in general and minimize noise levels.
10.2 Water Environment
Water shall be drawn from a tube-well installed in the factory area and distributed through an Over Head Service Reservoir. This will all be a closed system. During construction existing toilet facilities shall be used by the labour. Finally waste water from the toilets shall be taken to septic tank. It will not be thrown outside either on land or in any water body. Roof top Rain Water shall be harvested and used for ground water recharge to minimize effect of withdrawal of water from the underground.
10.3 Land Environment
No additional land will be required for expansion. The requirements of sand and aggregates for the construction works like foundation etc. will be supplied by venders. The land use is thus so planned that there is minimum adverse impacts.
10.4 Solid/Hazardous Waste
The other solid/Hazardous wastes from the bag filters shall be stored in a dumping pit of R.C.C. Construction and sent for proper disposal. Slag from the manufacturing process shall be used for making roads or sent to cement plant for further use.
10.5 Green Belt
The main objective of the green belt is to provide a barrier between the source of pollution and the surrounding areas. The green belt helps to capture the fugitive emission and to attenuate the noise generated, apart from improving the aesthetics. Development of green belt and other forms of greenery shall also prevent soil erosion and washing away of topsoil besides helping in stabilizing the functional ecosystem and further, to make the climate more conducive and to
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restore water balance. It is planned that the selected plants will be grown as per normal horticultural (or forestry) practice and authorities responsible for plantation will also make sure that adequate provision for watering and protection of the saplings exists at site.
11.0 Emergency Preparedness Plan
Emergency planning is primary for the protection of plant personnel and people in nearby areas and the environment that could be affected by unplanned hazardous events. Use of proper personnel protective equipment, fire protection systems and continuous training of people working in the shop floor are the only measures which helps industries to avoid accidents.
12.0 Issues And Response During Public Hearing
It is a Draft report submitted to SPCB for grant of public hearing dates.
13.0 Corporate Environment Responsibility
Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure. Special emphasis on Financial and Social benefits will be given to the local people. Development of social amenities will be in the form of medical facilities, education to underprivileged and creation of self-help groups. The company has earmarked Rs 112 lakhs towards the Corporate Social Responsibility (CSR) Activities.
14.0 Occupational Health Measures
Conceptually when the healthy employees are placed on the jobs, they produce much better than what unhealthy employees produce. Larger the number of unhealthy employees, the greater is the loss to the steel plant in terms of low productivity, increasing healthcare cost, sickness absenteeism, and loss of production.
Project management is keenly protecting health of the employees by preventing and controlling occupational diseases and by eliminating occupational factors and conditions hazardous to the health of the employees at work place by promoting regular medical checkups and by building safe protecting environment at work sites.
15.0 Post Project Environmental Monitoring Program
A number of environmental aspects will be regularly monitored so as to ensure the implementation and effectiveness of various mitigative measures adopted. The implementation and monitoring of effectiveness of the environmental mitigation measures will be assigned to the Environmental Control Department. An Environmental Management Unit, comprising of m
senior management level officers will periodically assess and monitor the implementation of mitigation measures and environmental monitoring Program, and tackle the bottlenecks of the implementation of mitigation measures.
Budget for Implementation of Environmental Management Plan S. No Component Capital cost for the proposed expansion in Lakhs 1 Pollution equipment for Induction Furnace 75 2 Greenbelt development 5 3 Environmental management cell 25 4 CER 112 Total 217 Lakhs