1. Introduction

1. INTRODUCTION

M/s Rasik Industries (Prop. Indian Securities Limited) is already manufacturing TMT Bars, Angles, flats etc., at Behind Uttam Steel Mills Talwara Road, Mandi Gobindgarh, District Fatehgarh Sahib Punjab. They now want to increase the capacity of their unit by adding four numbers Induction Furnace of 8 TPH capacity each. The existing capacity of the unit is 100,000 MTA of TMT Bars, Angles, round etc. The capacity of the unit after expansion will be 1,20,000 MTA of Billets, Steel Ingots & Blooms and 100,000 MTA of TMT Bars, Angles, round. As per G.O.I Notification dated 14/09/2006 they have to submit Form No- I along with Pre-Feasibility Report and other relevant documents for getting Environmental Clearance. Further, the project site falls within the “Critically Polluted Areas” of Mandi Gobindgarh as notified by the Central Pollution Control Board, as such the project is to be treated as Category ‘A’ and thus the Environmental Clearance will be given by the Ministry of Environment and Forest, GOI, New Delhi. This Prefeasibility report has, therefore, been prepared to assess the likely impact of the proposed expansion on various factors which may be affected with the implementation of the programme and to suggest remedial / precautionary measures, if any. Key plan of the site is attached as Fig 1.1.

FIGURE – 1.1 KEY - PLAN

2. PROFILE OF THE PROMOTORS & COMPANY

M/s Rasik Industries (Prop. Indian Security Ltd.) is a Limited Company. The Director of the company are as under:

1. Sh. Ramesh Kumar Goyal 2. Sh. Rasik Goyal 3. Sh. Murli Dhar Mittal 4. Sh. Piyush Sharma 5. Sh. Naveen Mittal

All the promoters are well versed with the process involved & can handle the project efficiently.

3.0 DETAILS OF THE PROJECT

This is an existing unit for manufacturing of TMT Bars, Angles & Flats. Now it is proposed to increase the capacity of the unit by installing four numbers Induction furnace of capacity 08TPH each for manufacturing of Steel Ingots, Billets, Blooms at behind Uttam Steel Mill, Talwara Road, Mandi Gobindgarh, Dist- Fatehgarh Sahib, Punjab. It is about 5 Kms from Mandi Gobindgarh bus stand and about 50 km from Chandigarh and 45 km from Ludhiana on NH-44 highway. The existing area of the plot is about 7.5 Acres and about 5.5 Acres land will be acquired for expansion purpose. The capacity of the unit after expansion will be Billets, Steel Ingots & Blooms will be 400MTD and TMT bars, rounds, flats & angles will be 335MTD.

3.1 Raw Materials -The raw materials used in the manufacturing of steel Ingots / Billets are as under: i) MS/CI Scrap, Sponge / Pig Iron, Ferro Alloys:- These will be sourced from Domestic as well as International Markets. -The raw materials used in the manufacturing of structural sections are as under: ii) Steel Ingots and Billets: - These will be sourced from own unit.

3.2 Power

The existing power of the unit is 2500KW. The proposed power requirement of the unit will be 14000KW. After expansion power demand will be 16500KW. This demand will be met by sourcing the power from Punjab State Power Corporation limited from nearby Sub-station.

3.3 Water

Water consumption for the unit will be small as the requirements are only for cooling system where water will be re-circulated in a closed circuit. The existing requirement of the fresh water is about 15 KLD which include 10 KLD for makeup water is required for meeting the evaporation losses in the cooling circuit and 5 KLD for domestic purpose. After expansion total fresh water required will be 37 KLD which would be met from ground water through a tube-well already existing within the premises. Water balance of the project has been shown in Fig. 3.1

Figure: 3.1

WATER BALANCE FLOW DIAGRAM

(KLD) Supply Water over head Tank

Domestic Water Cooling Tower Supply Tank (1200) (12)

Consumption ( 2 )

Cooling for STP furnace

(10)

Evaporation (25)

For Irrigation Clear Water Tank purpose for (1175) Plantation

3.4 Manpower

The requirement of personnel for the proposed plant has been made keeping in view of the following:

Technical concept of plant, including process control and instrumentation. Smooth and efficient operation of the plant. Effective co-ordination between the various departments within the plant. Optimum organization will well defined and judicious job distribution Optimum utilization of different grades of workmen and supervisory staff and Maximum capacity of the facilities.

In all there are about 100 persons working in the unit out of which no persons will stay in the factory except watchman. After expansion about 250 persons will be working in the unit.

3.5 Manufacturing Process Steel Ingots/Billets: 1) By Induction furnace MS Scrap is put into the Electric furnace pot through magnetic conveying system, where it is heated to 1700 0C. Scrap is melted and is heated for about 90-100 minute. In the molten steel some Ferro alloys are added according to the carbon contents in the scrap. The molten steel is then put in moulds with the help of hydraulic crucible where, after cooling, the steel Ingots are taken out from the moulds and the same is ready for dispatch. In order to keep the temperature of the furnace within the desired limits, water is circulated around the furnace coils and make-up water is added daily.

TMT Bars and other Structural Steel Section:

These are produced by heating the Ingots & Billets received from the manufacturing process to about 1150– 12000C so that they can be converted into the desired sections through rolling. They are then cooled and cut into proper sizes for dispatch.

3.6 OTHER FEATURES: The plant would incorporate the most modern control system using the latest microprocessor based Dust Control System. Cooling water circuit is close circuited, thereby ensuring no generation of waste water. The process, selected envisages re-cycling all the material collected in the pollution control equipment whereby ensuring no generation of solid waste. The plant lay out is so arranged that the major production units are laid in a straight line whereby minimizing/ avoiding the various transfer points.

4. BASELINE ENVIRONMENTAL SETTINGS

4.1 The State

Punjab is one of the progressive States in the Northern part of India. It derives its name from five rivers which used to flow through the State before partition of the Country in 1947 viz Satluj, Beas, Ravi, Chenab, and Jehlam. After partition two of the rivers i.e. Chenab and Jehlam went to Pakistan Punjab and the other three remained in Indian Punjab. The economy of the State is dependent mainly on Agriculture. Punjab has over 2.04 lakh small and medium industries and about 600 large scale industries. It leads in the manufacture of machine and hand tools; printing and paper cutting machinery; auto parts and electrical switch gear. The State also provides more than 75% of the country's requirement for bicycles, sewing machines, hosiery and sports goods. It has also made big strides towards industrialization. A number of Industrial areas have been developed by the State. Ludhiana, Jallandhar, Amritsar and Mohali are famous for Large and Medium scale industrial units.

4.2 Fatehgarh Sahib District

The historic and pious district of Fatehgarh Sahib came into existence with effect from 13th April, 1992, Baisakhi Day deriving its name from Sahibzada Fateh Singh, the youngest son of Guru Gobind Singh. It is bounded by Distt of Ropar in the North, Patiala in the South, Mohali and Part of Patiala in the East Ludhiana in the West it is about 20 Kms towards the west of Chandigarh, the capital of Punjab.

The economy of the district depends mainly on agriculture and allied activities. The main towns are Sirhind, Bassi Pathana, Amloh, Khamano & Mandi Gobindgarh. The last is also known as the 'Steel Town of India' having a good number of steel rolling mills. Besides, numerous industrial units are engaged in the manufacturing of sewing machine parts, centrifugal pumps, bus/truck body building and mining machinery.

4.3 Project Site

The project is located at behind Uttam Steel Mill, Talwara Road, Mandi Gobindgarh of Fatehgarh Sahib Dist of Punjab on Delhi-Ludhiana Highway, NH-44, It lies near Long 76o-19’ and Lat: 30o-39’ and is at an Altitude of about 266m above mean sea level. All the places are connected with Mandi Gobindgarh and Fatehgarh Sahib

11 through well maintained metalled road. It is about 07 K.M. from Fatehgarh Sahib, and about 5 K.M from Mandi Gobindgarh Bus Stand. Chandigarh is at a distance of about 50 K.M. by road The nearest rail head is Mandi Gobindgarh on Delhi - Ludhiana railway line, which is at a distance of about 02 K.M. Location plan showing other features is given in Fig. 4.1 & 4.2 and Layout Plan of the unit is given in Fig. 4.3

Fig 4.1 LOCATION PLAN

Fig 4.2 Location on Google Image

Fig 4.3 SITE PLAN

4.4 Climate:

There is a meteorological observatory at Chandigarh which is at a distance of about 50 km from the site. Its data is fairly representative of the conditions in the District in general. The climate of the district is generally dry except in the brief monsoon season and is very hot in summer and cold in winter. The cold season is from middle of November to early part of March. Succeeding period up-to the end of June is hot season. July, August and September are the South West monsoon season.

4.5 Temperatures

The area is fairly plain. December and January are the coldest months whereas in May and June the heat is quite intense. The temperature varies from 5oC minimum to 41oC maximum during the year.

4.6 Rainfall

The rainfall in the Zone is caused by the South-West monsoon. It starts in the month of July and extends up-to the end of September. During this period the monsoon rain-fall contributes about 70 to 80% of the total annual rainfall. The average annual rain fall is in the range of 660

mm. The annual numbers of rainy days on an average are about 34 in a year, out of which about 20 falls in the monsoon period of July to September.

4.7 Humidity

In summer months of April, May and June, which is the driest part of the year, the afternoon humidity comes down to 22% while the relative humidity during monsoon months goes upto about 80%.

4.8 Cloudiness

During monsoon season skies are over cast with moderate to heavy clouds. During rest of the year, the sky is mostly clear. It is lightly clouded occasionally during winter season.

4.9 Winds

The Wind direction in the area is mostly from North-West to South-East. During January to May the winds are quite strong while July to October is calm months. The general trends of various meteorological data from meteorological observatory at Chandigarh and field observations are used to draw Wind Rose Diagram. The Wind rose diagram is shown in Figure-4.4

FIGURE-4.4 WIND-ROSE DIAGRAM

4.10 Drainage The area is generally plain and has good slope from North- East to South-West. The area is well drained and takes the entire rain water flows to Sirhind Choe which ultimately joins river Ghaggar near Haryana boundary.

4.11 Land Use The total area of the District is 1180 sq km. 89% is net sown area and 11% is under non-agricultural use. Agriculture is mostly dependent on tube-wells. Rice and wheat are the main crops in the area.

4.12 Forest There is no reserved forest near the project site. The area under forest is hardly about 2000 Ha. The company also proposes to plant about 200 trees and shrubs within the project area.

4.13 Flora And Fauna Ecological system consists of varieties of interrelationship between both biotic and abiotic components. Biotic components comprise of both plant and animal communities, which interact not only within and between them but also within the abiotic physical. Animal plant communities in their natural habitat exist in a well

organized manner. The project does not disturb any natural setting and is coming up in an already existing Industrial area. Flora in the area generally consists of Dalbergia, Prosopis, Albizzia, Ficus, Azolla, Hydrilla, Nelumbo, Typha, Phragmites, Zizyphus Mauritiana, Syzgium cumini, Ipomoea aquatica, Cyprus and Grasses. Animals like Smooth Indian Otter, Hog Deer, Wild Boar, Flying Fox, Wildcat, Squirrel, Fruit bat, and Common

Mongoose are found in the area.

4.14 Ambient Air Quality The Status of Ambient Air Quality in the study area will be determined by monitoring air quality in the Area at different locations after issuing Terms of Reference. The study area is a mix of rural, urban and industrial area and the various sources of pollution are dust arising from agricultural activities, vehicular traffic and industries.

4.15 Water Quality Water quality of ground as well as surface resources in the study area will be studied for assessing the water environment and to evaluate the anticipated impact of the project on environment after issuing of Terms of Reference.

4.16 Ambient Noise Quality

Noise is defined as unwanted sound due to any operation. Presently there are no noise creating machinery nor any such has been added, except DG Sets which will be noise less.

4.17 Soil

Soil is generally sandy loam almost all over the District and soil depth is generally shallow except in areas having good vegetative cover. It is generally dry, shallow and deficient in organic matters. The study area comprises mostly of alluvial deposits of Quaternary age. The geological formations in the area comprise of sandstone largely micacous and form major features. The top zone of this stage consists of maroon clays and buff clays alternating one by one.

4.18 Demography And Socio-Economic Scenario

Large scale Industrial development has taken place in and around Mandi Gobindgarh. The socio-economic profile has been studied through random sample primary surveys and secondary data. The significant demographic and socio economic statistics of the district are summarized and given in Table- 4.1

TABLE-4.1 Summary of Key Demographic Statistics

PUNJAB DIST. FATEHGARH SAHIB Particulars 2011 2011

Male Population 1,46,34,819 3,20,603

Female Population 1,30,69,417 2,79,211

Total Population 2,77,04,236 5,99,814

Sex Ratio 893/1000 886

Density of 550 508 Population/Km2 Literacy Rate: Total 76.68 % 80.30%

Male 81.48% 84.50%

Female 71.34% 75.50%

Source: Google

5.0 ENVIRONMENTAL IMPACT ASSESSMENT:

5.1 Present Environment: Various Environment factors as existing in the project area which possibly are liable to be affected by the activities have been assessed & identified as below: (i) Ambient Air (ii) Water Quality (iii) Noise (iv) Land use pattern (v) Demography and socio-economic pattern.

5.2 Probable Impact on Environment:

The above factors will be checked after the implementation of the project to cross check the probable impact discussed hereunder and remedial measures taken wherever necessary. Broadly the impacts may be classified in two categories as under:- i) Short term -during construction/development stage ii) Long term -during operational stage. Both these categories have been considered while predicting and evaluating the impacts as under:-

5.3 Development Stage: - (Short Term) This is a construction phase of the project and the impacts are temporary due to construction related activities are as under:- i) Air Environment:

There is no point source of air pollution. The only source will be the dust generation due to excavation, construction and plying of vehicles within unit. Some emission may be expected from vehicles plying in the area for transportation of material etc. Kerosene oil shall be provided to the labour so that they do not burn wood for cooking etc. Since the plant is an existing one and very few additions are to be made there is no likely hood of any significant effect on the overall air environment of the area.

ii) Water Environment :

Requirement of water during construction (Making foundation & Platform of furnace) will be about 1.0 m3/day and there will be no discharge as the same will be used completely. Labour during construction is not very large. Hardly about 10-15 persons may be working on an average that may be using water for drinking and bathing etc. Toilet facilities already exist at site which will be used by the labour.

In view of this there is no likely hood of any significant impact on the general environment of water in the area. iii) Noise Environment:

Some noise may be expected from the working of the machinery for construction purposes and movement of vehicles. Steps will be taken to reduce its effect by resorting to staggering of various operations Even otherwise since there will not be any large scale machinery, the activity is not likely to have any significant effect on the over all noise environment. iv) Land Environment:

The land at site is fairly level as such no leveling is required. Natural drainage will not be disturbed. Solid waste from construction activities will be used within the premises under roads & refilling. There will not be any significant impact on land in general.

v) Socio Economic:

It is an existing project and it does not involve any displacement of population or rehabilitation of any kind. Rather it will provide employment to local people and boost the economy of the area. It will have some positive impact, although not to a large extent.

5.4 Operational Stage: - (Long Term) After completion, when the additions start production, the operational impacts on the various parameters are discussed as under:-

i) Ambient Air Environment:

There are only two sources of likely pollution: a) SPM emission from the Induction furnaces b) Steel Rolling Mills & Reverbratory Furnace c) D.G. Sets. There is one number steel rolling mill of capacity 335 TPD. Now they want to enhance the capacity of unit by addition 4 numbers Induction furnaces of capacity 8 TPH each. There will be generation of emission containing SPM. All these processes are closed circuits as such emissions to the atmosphere will be minimum. However,

APCD like Bag filters will be provided at the exit point to arrest particulate matter for Induction furnace and gassifire on rolling mill. Whatever solid waste is arrested through APCD the same will be collected & disposed off at designated site. Flue gas from the DG Sets will pass through a chimney of adequate height and the final gas will be within permissible limits. Thus air environment is not likely to be affected significantly.

ii) Water Environment:

The total use of water after expansion will be about 37m3/day. The domestic waste water generated will be about 10m3/day, which will be treated through STP. The There will be no generation of industrial waste water after expansion. The entire cooling water will be recirculated. Thus water environment is not likely to be affected after expansion. Further, ground water will be balanced through recharge by rain water harvesting from the roof top through recharge wells. Thus pressure on underground water will be reduced.

iii) Land Environment:

It is an existing steel manufacturing unit. Now they want to enhance the capacity of unit in additional land. Thus there

will not be any significant adverse effect on the existing general land environment with the enhancement of the project. iv) Noise Environment:

There is no noise producing machinery or equipment except ID fans & Blower etc. which is placed in a room causing least disturbance in the area. There is no likelihood of any significant change in noise environment. The DG Sets are of noiseless type. v) Socio Economic Pattern

The project will provide extra employment to local people in the field of running plants and maintenance of APCDs and security etc. Thus it will have some positive effect on the employment potential in the area.

6.0 ENVIRONMENTAL MANAGEMENT PLAN:

6.1 General

Environment Management Plan (E.M.P) in a project is prepared to mitigate the possible adverse effect of various activities on the existing environmental factors, during construction as well as in operational stages, to avoid their deterioration, if any. It is desirable that necessary steps are taken right from the beginning of the project to be more effective. E.M.P. for this project has been prepared keeping in view the existing conditions and likely changes which may occur due to the proposed project.

6.2 Air Environment

During construction stage water will be sprinkled on the soil to avoid dust generation if any. The debris and unused construction malbas shall be removed immediately for recycling, if any, or for land fill. APCDs like Bag filters, shall be provided to arrest SPM from flue gases to keep it within permissible limits. All vehicles for service activities at the project site shall be checked for vehicular emission. The agencies will be asked to keep them within prescribed limits. They will also be asked to maintain them properly. A chimney of suitable

height has been provided for the D.G. Set to control the

G.L.C. of S.P.M., SO2, & Nox levels. Extensive tree plantation shall be resorted to for further improving the air environment in general and minimize noise levels.

6.3 Water Environment:

Water shall be drawn from existing tube-well installed in the factory area. During construction existing toilet facilities shall be used by the labour. Finally waste water from the toilets shall be taken to septic tank through underground delivery system and treated up to tertiary level. Treated water will be used for irrigation within the premises. It will not be thrown outside either on land or in any water body. Roof top Rain Water shall be harvested and used for ground water recharge to minimize effect of withdrawal of water from the underground.

6.4 Land Environment:

To avoid erosion of the top soil the development is planned in the shortest possible time and land-clearing activity shall be kept to the absolute minimum by working at the specific sites one by one where construction is to take place so as to increase detention and infiltration. The construction activity is within the shed area. Natural waterways/drainage pattern shall be maintained by

providing culverts where needed. The requirements of sand and aggregates for the construction works will be met through venders. The land use is thus so planned that there is minimum adverse impact.

6.5 Solid Waste

The other solid wastes from the bag filters shall be stored in a dumping pit of R.C.C. and disposed off in the designated land fill places. Slag from the manufacturing process shall be given to cement plant for further use.

6.6 Green Belt

The main objective of the green belt is to provide a barrier between the source of pollution and the surrounding areas. The green belt helps to capture the fugitive emission and to attenuate the noise generated, apart from improving the aesthetics. Development of green belt and other forms of greenery shall also prevent soil erosion and washing away of topsoil besides helping in stabilizing the functional ecosystem and further, to make the climate more conducive and to restore water balance. It is planned that the selected plants will be grown as per normal horticultural (or forestry) practice and authorities responsible for plantation will also make sure that adequate provision for watering and protection of the saplings exists at site.

6.7 Occupational Health and Safety of workers

The only health hazards expected are heat & dust. Following mitigation measures will be provided:-

1. HEAT:

Workers working near the furnace and handling moulds manually may be exposed to heat. Fans will be provided near such places and hot air shall be drawn through exhaust fans. All workers will be provided PPE like gloves, helmets, gum boots, goggles etc. Fresh water shall be available near the working area.

2. DUST:

• Exhaust fans have been provided for collection of dust laden air within the shed and its further disposal through bag filters. • Face masks and side covered glasses have been provided to all workers. • Frequent check-up of the workers will be done which shall include chest X-ray, ECG & vision testing. Necessary treatment shall be provided wherever required. • All check-ups will be documented and reviewed monthly for Occupational health and safety of the workers.

7.0 ENVIRONMENT MONITORING PROGRAMME

Regular monitoring of all significant environmental parameters is essential to check the compliance status vis-à-vis the environmental laws and regulation. The objectives of the monitoring will be as follows:  To verify the results of the impact assessment study with respect to the proposed projects.  To study the trend of concentrated values of the parameters, which have been identified as critical and then planning the mitigating measures.  To check and assess the efficacy of pollution control equipment.  To ensure that any additional parameters, other than those identified in the impact, do not turn critical after the commissioning of proposed project.

To implement the EMP, a structured Environment Management Cell (EMC) interwoven with the existing management system will be created. EMC will undertake regular monitoring of the environment and conduct yearly audit of the environmental performance during the construction of the project. It will also check that the stipulated measures are being satisfactorily implemented and operated. It shall also co-ordinate with local authorities to see that all environmental measures are well coordinated.

A comprehensive environmental monitoring program that has been prepared for the purpose of implementation in the proposed residential colony by the EMC is described below:

 The ambient Air quality shall be monitored at project site and two upward and downstream locations once

every quarter for PM2.5, PM10, NOx & SO2 and CO levels during the Construction Phase and Operational Phase. The Ambient Noise Levels shall also be monitored once every six months.

 The vehicles shall be checked for PUC once every quarter during the development period and records shall be maintained.

 Groundwater quality of the Tube-wells in site area will be regularly monitored preferably once in a quarter during the development period.

 Air Pollution Control System & ETP/STP shall be provided with a small Laboratory and weekly monitoring of the parameters shall be undertaken. In addition monitoring shall be got done from an independent agency as laid down by State Pollution Control Board. All the above observations will be complied and documented by the EMC to serve the following purposes.

 Identification of any environmental problems that are occurring in the area.

 Initiating or providing solution to those problems through designed channels and verification of the implementation status.

 Controlling activities inside the project, until the environmental problem has been corrected.

 Suitably responding to emergency situations.

7.1 Environment Management Cell: The Environment Management Cell shall include:  Representative of Management (Head of Environment Cell)  Process Incharge  Incharge Maintenance Department  A representative of Environmental Consultants