Purulia Metal Casting (P) Ltd

PffuG PURULTATETAL CASTtl{c (P} LTD. (Piglron Division) Date : L9 .O7.2077

To TheDirector and Member Secretary ExpertAppraisal Committee (lndustry-l) l.A.Division Ministryof Environment,Forest and Climate Change Governmentof India IndiraParyavaran Bhawan JorBagh, Ali Ganj NewDelhi - 110003

Project ProposedProject of Pig lron Production59,310 TPA by Mini BlastFurnace (5Sm3) and SinterPlant (tZ m2)Village : Bongabari,P.O. : Vivekanandanagar, District: Purulia,Pin:.723147, West Bengal. F.No. l-llotLl236l20L6-lA.ll(l! of Ministryof Environment,Forest and climate Change(1.A. Division), Govt. of India,New Delhi. Reference The Twentieth meeting of the ExpertAppraisal Committee (EAC)for Industry-l Sector as per the provisionsof the EIA Notification, 2005 for Environmental Appraisalof Industry-lSector Projectswas held on 10th - 12th July2Ol7 in the Ministryof Environment,Forest and ClimateChange.

DearSir,

In referenceto the Minutesof the Meetingof the abovementioned Meeting, enclosed please find the AdditionalInformation as desiredby EAC,MoEF&CC for your readyreference and necessaryaction.

Kindlydo the needfulin this regard. Thankingyou. Yoursfaithfully,

( BhabaniPrasad Mukherjee) Director PuruliaMetal Casting(P) Ltd. (Piglron Division)

Encl.as statedabove.

An ISO9001:2008 Gompany HeadOffice : 4D/1& 4Dl2,4hFloor, 31, Ganesh Chandna Avenue, Kolkata - 700 013, West Bengal TradeEnquiries : +91 33 4067 3041, Customer Care : +917797601500 E-mail: pmc.46,[email protected] ; Website : www. prestigetmt.com Additional Information

Proposed Project

Pig Iron Production : 59,310 TPA [ By 1 X 65 m3 Mini Blast Furnace and 1 X 12 m2 Sinter Plant ]

MoEF&CC File No. J-11011/236/2016-IA.II (I)

Purulia Metal Casting (P) Ltd. (Pig Iron Division)

HEAD OFFICE PROPOSED PROJECT SITE 4D/1 & 4D/2, 4th Floor Village : Bongabari 31, Ganesh Chandra Avenue P.O. : Vivekanandanagar Kolkata - 700 013 District : Purulia West Bengal Pin : 723147 Ph: +91 33 4067 3041, +91 77976 01500 West Bengal Email : [email protected] Website : www.prestigetmt.com

Consultant

Envirotech East (P) Limited  An ISO 9001:2008, 14001:2004 & OHSAS:18001:2007  Company Laboratory recognised by Ministry of Environment & Forests, Govt. of India  NABET Accreditation List June 5, 2017  Page No. 43 ; Sl. No. 52, Sector No. 8 Metallurgical Industries (ferrous & non-ferrous) - both primary & secondary, Category-A Bengal Ambuja Commercial Complex UN F13, 1050/1, Survey Park, Kolkata 700 075, West Bengal, India Ph - (033) 2418 8127/8128/8601 ; Email - [email protected] Website : www.envirotecheast.com

July 2017 Environmental Impact Assessment for the Proposed Project of Pig Iron 3 2 Purulia Metal Casting (P) Ltd. Production : 59,310 TPA by Mini Blast Furnace (65 m ) and Sinter Plant (12 m ). (Pig Iron Division) Additional Information

CONTENTS

Issue No. Issues Raised by Hon’ble EAC Committee (Industry-1), MoEF&CC Page No.

I. Revised action plan for compliance of issues raised during the 2 public hearing.

II. Revised Entrepreneur Social Commitment plan in the form of 2 project for addressing the issues of public hearing. The fund allocated for ESC shall be used as CAPEX only.

III. Revised water balance diagram. 4

IV. Revised material balance diagram. 5

V. Pollution control devises with capacities shall be included in 6 Process flow diagram.

VI. Plan for segregation of storm water and industrial processed water 9 shall be submitted.

VII. Blast Furnace Gas utilisation and associated calculations shall be 10 submitted.

VIII. The details of source of water shall be clearly submitted. 11

IX. Bag house shall be designed for 150% of the rated flow and filter 12 bags shall be PTFT dipped PPS type.

X. Electrical Load list shall be submitted. 12

XI. Revised plot plan incorporating drainage (storm water and process, 13 material storage, road, gate, assembly point, parking, plantation, firefighting system and plant).

XII. SOX and NOX emission estimation for maximum load operations 14 and mitigation measures.

XIII. Hazardous waste disposal protocol and agreement with RAMKY (as 15 proposed by PP).

XIV. Kitchen waste digester for the canteen waste and organic waste. 15

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 1

Environmental Impact Assessment for the Proposed Project of Pig Iron 3 2 Purulia Metal Casting (P) Ltd. Production : 59,310 TPA by Mini Blast Furnace (65 m ) and Sinter Plant (12 m ). (Pig Iron Division) Additional Information i. Revised action plan for compliance of issues raised during the public hearing.

Sl. No. Name Issued Raised Compliance 1. Sri Pranab Welcomed the proposed project 80% of the total manpower requirement Salui, and requested for job opportunity in (permanent : 60 & additional unskilled resident of the upcoming project. labour on contract basis : 80) shall be Hatara. fulfilled from local people as committed by the Project Proponent. 2. Sri Bidhan Welcomed the proposed project  The best available air pollution control Mahato, and requested the project systems like Dust Cather, Dust Cyclone resident of proponent to state the measures and Bag Filter will be provided for Bongabari. taken to minimize the effect of source and secondary emissions with pollution, both air and water, to be stack of adequate height for Mini Blast generated from the project. Furnace and Sinter Plant to control stack emissions within stipulated norms.  No process effluent will be discharged from the proposed project. There will be re-circulation system to reduce the make-up water consumption. 3. Mr. ldris Questioned the project proponent Same as point no. 2. Ansari, regarding the discharge quality of resident of effluent from the project. Kapoorbag an. 4. Sri Ashok Requested the project proponent to Same as point no. 1. Dutta, provide employment to the local resident of people in the area. Hatara. 5. Sri Requested the project proponent to Road development (3 km) will be done in Jaladhar take necessary steps to improve the each of the three villages namely, Singh condition of the local roads in the Bongabari, Shyampur and Hatuara. Sardar, area. resident of Hatara. ii. Revised Entrepreneur Social Commitment plan in the form of project for addressing the issues of public hearing. The fund allocated for ESC shall be used as CAPEX only.  Project Cost : Rs. 25.50 Crores  ESC Budget = 2.5 % of 25.50 Crores = Rs. 63.75 Lakhs  ESC commitment by Project Proponent = = Rs. 70.74 Lakhs

Entrepreneur Social Commitment (ESC) Sl. No. Description Rs. in Lakhs 1. Construction of W/C/Toilet (2) each for 3 schools (Bongabari Girls High School ; 18.72 Shyampur Primary School & Hatuara Primary School). 2. Public drinking water supply system for 3 villages (Bongabari ; Shyampur & 6.18 Hatuara). 3. Construction of metal consolidation road (3 km.) for each villages (Bongabari ; 45.84 Shyampur & Hatuara). Total 70.74

The fund allocated for ESC will be used as CAPEX only and will be completed within 18 months.

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 2

Entrepreneur Social Commitment (ESC)

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 3

All values are in KLD

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 4

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 5

Environmental Impact Assessment for the Proposed Project of Pig Iron 3 2 Purulia Metal Casting (P) Ltd. Production : 59,310 TPA by Mini Blast Furnace (65 m ) and Sinter Plant (12 m ). (Pig Iron Division) Additional Information v. Pollution Control Devices With Capacities shall be Included in Process Flow Diagram.

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 6

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 7

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 8

Environmental Impact Assessment for the Proposed Project of Pig Iron 3 2 Purulia Metal Casting (P) Ltd. Production : 59,310 TPA by Mini Blast Furnace (65 m ) and Sinter Plant (12 m ). (Pig Iron Division) Additional Information vi. Plan For Segregation of Stormwater and Industrial Process Water shall be Submitted.

The surface area of the proposed plant is undulation of max. RL. 100.50m. and minimum RL. 93.45m. i.e nearly about 7m. level difference. It is considered that the top level of adjacent highway (RL-99.00m.) had been fixed based on the maximum high flood level of the local area. Considering the adjacent road level, it is proposed that Finished Ground Level (F.G.L) of the main plant area has been considered as 99.500m to avoid the overflow of the plant during heavy rainy season. Considering Process water to be taken from rain water harvesting pond - 35 KLD.

To meet the above water requirement from rain water harvesting, suitable storage pond of required size is essential and to be placed in such area so that all rain/storm water from the whole plant is collected in the above pond by the good network of storm water drain (Refer attached Drainage Scheme). This storm water may consist of small leaves, iron ore particle, silt etc. To arrest the above, suitable size of screen of mesh size 3mmsq. is proposed to the inlet point of storage pond. From time to time the arrested particles near inlet to be cleaned by scraping or any suitable method. During any critical rainfall, if excess storm water is obtained than that of the pond capacity, overflow arrangement by MS controlled gate is proposed at the outlet point to dispose it to the nearest existing canal named Jamuna Jore of RL about 90.50m (Bed level).

Size of storage pond has been calculated based on the storage capacity required for 90 days rain period. From calculation, size of pond is approximately 40m x 30m x 3m (3600 cum). Water requirement for process is to meet by suitable pumping arrangement near storage pond with suitable pipe network to the used point of the respective plant.

CALCULATION OF RAIN HARVESTING POND CAPACITY The pond capacity has been calculated from the following parameter: (1) Process water to be taken during rainy Season 35 KLD (2)Total rainy day considered 90 Days. (3) Total capacity required(V) 3150 KL i.e 3150 Cum. (4) Considering length of pond(L)= 40 m. (5) Width of pond(B)= 30 m. (6) Depth required(D)= 2.6 m. Taking the effect of evaporation loss etc. provide overall depth=3.0m. POND SIZE : 40 m. x 30 m. x 3 m. 3600 cum.

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 8

Proposed Drainage Scheme

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 9

Environmental Impact Assessment for the Proposed Project of Pig Iron 3 2 Purulia Metal Casting (P) Ltd. Production : 59,310 TPA by Mini Blast Furnace (65 m ) and Sinter Plant (12 m ). (Pig Iron Division) Additional Information vii. Blast Furnace Gas Utilisation and Associated Calculations should be submitted.

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 10

BLAST FURNACE GAS UTILIZATION DIAGRAM

3 3 22,158 Nm /hr. 22,158 Nm /hr. BLAST FURNACE DUST CATCHER CYCLONE 23790 Nm3/hr. Blast furnace gas

/hr. 3

22,158

3 12,275 Nm /hr. 12,275 Nm3/hr. CHIMNEY STOVE BAG FILTER

Burnt gas Clean BF gas

/hr. 3

2,500 Nm3/hr. 9,883 SINTER PLANT

/hr. 3

7,383

LADLE PRE HEATER AND OTHER HEATING PURPOSE

viii. The details of Source of Water shall be clearly submitted.

Source of Make-up Water Source Throughout the Year During Rainy Season except Rainy Season 3 Months (90 days) Supply Water from 245 KLD 210 KLD Purulia Municipality Ground Water from 100 KLD 100 KLD 2 Bore-wells Rainwater Harvesting - 35 KLD Pond Total 345 KLD 345 KLD 35 KL X 90 Days = 3,150 KL 3 Rainwater Harvesting Pond Capacity : 40 m X 30 m X 3 m = 3,600 m

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 11

ix. Bag House shall be designed for 150% of the total flow and filter bags shall be PTFT dipped PPS type.

Bag House has been designed for 150% of the total flow (details have been given in point no. v ) and filter bags will be PTFT dipped PPS type. x. Electrical Load List shall be submitted.

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 12

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 13

xii. SOx and NOx Emission Estimation for Maximum Load Operation and Mitigation Measure.

Estimation of SO Emission from Sinter Plant 2 Coke requirement is 3,762 TPA. Sulphur in Coke : 0.5% Sulphur in Sinter : 0.022%

Sulphur in Coke : Sulphur in Sinter : {(3,762 x 1,000) / (170 x 24)} x (0.5 /100) {(51,000 x 1,000) / (170 x 24)} x (0.022/100) = 4.61 kg/hr Sulphur = 2.75 kg/hr Sulphur = 1.28 gm/sec Sulphur = 0.764 gm/sec Sulphur Net Sulphur release through the stack from Sinter plant = (1.28 – 0.764) gm/sec = 0.516 gm/sec = 0.5 gm/sec (say) So, SO2 emission through stack = 0.5 x 2 = 1.0 gm/sec.

Estimation of SO2 Emission from Mini Blast Furnace

Coke requirement is 38,550 TPA. Sulphur in Coke : 0.5% Sulphur in BF Slag : 0.5%

Sulphur in Coke : Sulphur in Blast Furnace Slag : {(38,550 x 1,000) / (365 x 24)} x (0.5 /100) {(32,650 x 1,000) / (365 x 24)} x (0.5 /100) = 22 kg/hr Sulphur = 18.6 kg/hr Sulphur = 6.11 gm/sec Sulphur = 5.17 gm/sec Sulphur

Net Sulphur release through stack from MBF plant = (6.11 – 5.17) gm/sec = 0.94 gm/sec = 1.0 gm/sec (say) So, SO2 emission through stack = 1.0 x2 = 2.0 gm/sec

Estimation of NOx Emission from Mini Blast Furnace & Sinter Plant

In both the Plant the fuel is BF Gas. The flame temperature of BF Gas is low. Thus generation of NOx will be insignificant. NOX Emisssion from Sinter Plant = 0.76 gm/ sec NOX emission from Mini Blast Furnace = 0.08 gm/sec

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 14

Stack & Emission Characteristics Description Sinter Plant Mini Blast Furnace No. of Stacks 1 1 Stack Height (m) 34 36 Internal Diameter at Stack Top (m) 1.7 1.2 Exit Velocity of Flue Gas (m/s) 8.76 8.13 Temperature of Flue Gas (OC) 119 135 Temperature of Flue Gas (K) 392 408 Flue Gas Flow Rate (Nm3/hr) 49,871 22,158

SO2 Emission Rate (gm/sec) 0.97 2.07

NOx Emission Rate (gm/sec) 0.76 0.08

Predicted Maximum GLCs of SO2 & NOX NAAQS Pollutants Max. GLCs Direction Distance μg/m3 (μg/m3) (km)

SO2 2.39 SE 0.5 80

NOX 0.59 SE 0.5 80

Note:

Since predicted GLC of SO2 & NOX as found to be much less than the respective National Ambient Air Quality Standards (NAAQS), no pollution control / mitigation measures to control SO2 & NOX emission have been considered.

xiii. Hazardous Waste Disposal Protocol and Agreement with RAMKY (as proposed by PP).

Two types of Solid Wastes will be generated from the operation of Mini Blast Furnace and Sinter Plant.

1. Blast Furnace Slag which will be used by the nearby Cement Manufacturing Industries as raw material. 2. Dust accumulated from Dust Catcher, Dust Cyclone and Bag Filter which will be used in the process.

No Hazardous Waste will be generated from the proposed project so the Hazardous Waste Disposal Protocol and Agreement with RAMKY is not relevant. xiv. Kitchen Waste Digester for the Canteen Waste and Organic Waste.

Canteen waste digester system of proper capacity will be used. The waste after treatment will be used as manure for the plantation. Gas generated will be used as fuel for the canteen to the available extent.

Project Location : Village : Bongabari, P.O. : Vivekanandanagar, Envirotech East (P) Limited AI District : Purulia, Pin : 723147, West Bengal. 15