EXECUTIVE SUMMARY

_______________________________________________________________

For

PROPOSED FERRO ALLOY PLANT

(INSTALLATION OF 2 x 6.5 MVA SUBMERGED ELECTRIC ARC FURNACE)

Proposed By

M/s. BALAJI ELECTRO SMELTERS LIMITED

Sy. No: 15/E, Fouzpur Village, Taroda (B) Grampanchayat, Jainath Mandal, Adilabad District, Andhra Pradesh

Prepared By
______________________________________________________________________________________

M/s. GLOBAL ENVIRO LABS

(Recognised by Govt. of India, MoEF, New Delhi Vide Gazette Notification No. S.O. 773 (E))

Tilaknagar X Roads, Bagh Amberpet,Hyderabad 500 013. Ph.: 040 65582886; Telefax:040 27407969 E.Mail: globalelabs@rediffmail.com

EXECUTIVE SUMMARY
1.0 INTRODUCTION M/s. BALAJI ELECTRO SMELTERS LIMITED is focusing on installation of 2 x 6.5 MVA Submerged Arc Furnace for manufacturing of 28,000 TPA of Ferro Manganese, 19,000 TPA of Silico Manganese and 9300 TPA of Ferro Silicon at Sy. No: 15/E, Fouzpur Village, Taroda (B) Grampanchayat, Jainath Mandal, Adilabad District of Andhra Pradesh. The total cost of the project is 24.00 Crores. As per EIA notification, 14th September 2006, the proponent has to be obtain Environmental Clearance from the Ministry of Environment & Forestry (MoEF), New Delhi and CFE (NOC) from APPCB for this proposed Project. Accordingly the proponent has appointed M/s. Global Enviro Labs, Hyderabad to carry out the Rapid Environmental Impact Assessment (REIA) study to suggest mitigative measures for potentially adverse environmental impacts that will be arise due to the proposed Project. 2.0 DETAILS ABOUT THE PROJECT SITE 1. The proposed project site is located as a Longitude of 78o3333 and latitude of 19o4410 N. 2. The site is located at 3.0 km away from National Highway 7, which connects Hyderabad to Adilabad. 3. The nearest railway facilities are available at Adilabad, which is at about 8.5 Kms. from the posed project site. 4. Taroda village is the near by habitation to the proposed project site located at a distance of 1.12 km. 5. The topography of the site is without many undulations. 6. The average annual rainfall in the area is 720 mm. 7. The major crops in the study area are cotton, paddy, sunflower, groundnut etc., 8. No habitations exist in the proposed project site. Hence displacement and rehabilitation of people is not involved. 9. No forest land is involved in the proposed site.

10. The following industries are situated with in 10 km radius of the proposed site A. M/s. GMR Spintex Limited 11. Yapalguda Reserved Forest is located at a distance of 6.0 km in SE and Hattighat Forest is located at a distance of 8.51 km in NW directions of the proposed project site. 2.1 PRODUCTION CAPACITIES AT PROPOSED PROJECT M/s. Balaji Electro Smelters Limited is proposed to produce 28,000 TPA of Ferro Manganese, 19,000 TPA of Silico Manganese and 9300 TPA of Ferro Silicon by installing the 2 x 6.5 MVA capacity of Submerged Electric Arc Furnace.

2.2 RAW MATERIALS REQUIREMENT FOR THE PROPOSED PROJECT Raw materials those are required in the proposed project and its average consumption in tonnes per annum is as follows: RAW MATERIAL CONSUMPTIONS FOR FERRO MANGANESE S No. 1 2 3 4 5 RAW MATERIALS Manganese Ore Pearl Coke Indian Coal Dolomite Electrode Paste Total QUANITTY (TPA) 64878.8 14617.6 4310.6 11088 503.5 95398.5

RAW MATERIAL CONSUMPTIONS FOR SILICO MANGANESE S No. 1 2 3 4 5 6 7 RAW MATERIALS Mn.Ore Fe.Mn. Slag Pearl Coke Indian Coal Quartz Dolomite Electrode Paste Total QUANTITY (TPA) 28538 14344.1 10107.2 5111.6 7865.7 4122.5 379.33 70468.4

RAW MATERIAL CONSUMPTIONS FOR FERRO SILICON

S No. 1 2 3 4

RAW MATERIALS Quartz Indian Coal Mill Scale Total

QUANTITY (TPA) 23250 13950 3720 40920

2.3 MANUFACTURING PROCESS Most of the alloys e.g., Ferro Manganese, Silico Manganese, and Ferro Silicon etc are produced by smelting process. Smelting of the charge materials are carried out in electrical arc furnace equipped with transformer of proper ratings.

Basic Process Ferro-alloys are produced by reducing metals from their oxides contained in ores by using a suitable reduction under conditions created to ensure a high recovery of the valuable elements from the starting materials. Such reduction reactions are characterized by stability of an oxide at high temperatures. The stability of all oxides will become more stable with increasing temperature. An element which forms a stronger oxide can under appropriate conditions be used as reductant for a less strong oxide. The reaction will proceed successfully if the difference of oxygen involved with a small difference, favorable conditions should be formed to make the reaction proceed. The presence of iron or iron oxides can facilitate some reduction processes. Iron dissolves the reduced element, forms a compound with it, and thus lowers the melting point of an iron element alloy is lower than that of the pure element, e.g. in Ferro-manganese production, and therefore the reaction of reduction of the element can proceed at a lower temperature.

Ferro-Manganese Ferro Manganese is produced from manganese ores, which have the principle constituent of manganese mainly in the form of Oxides the balance usually being iron, aluminium,

magnesium oxides and silica. For making Ferro-manganese, coke is used as a reductant and fluxes like limestone or dolomite are added to the reaction mixture if the calculation of the slag composition demands such additions. Such reactions are carried out in submerged arc furnaces, which operate, as a rule, by continuous process. The electrodes in these furnaces are immersed into the solid charge. The furnace is recharged as the solid is being smelted and the alloy & slag are periodically removed. Smelting Procedure The charge for smelting Ferro-manganese is made up with the mixture of 2317 kg of Manganese ore, 676 kg of reductant and 396 kg of dolomite. The charge is loaded into the furnace from a charging apparatus which essentially is an electrically driven carriage moving on a monorail. The carriage has a loading chute. Coke breeze is first loaded from furnace bins to the charging apparatus, followed by ore. This sequence of charging ensures more thorough mixing of the charge and prevents sticking of moist ore fines to the walls of charging apparatus. In order to prevent separation of the charge into components, the entire batch is poured into a pile on the charge and a specific amount of dolomite is added to it. After that the piles are gathered into cones around the electrodes. The charging apparatus can deliver the charge only to the front side of electrodes. The materials are pushed to the rear side of electrodes by means of long rabbles and are partly thrown by shovels from piles prepared on the working stage at the rear corners of the furnace. Charging is continued as the materials settle down at the electrodes. A cone around an electrode should be 300-400 mm above the charge level. The electrodes are maintained at a depth of 1100-1400 mm with their ends being spaced 600-800 mm from the furnace bottom. Owing to deep placing of the electrodes, the high temperature zone is covered with a layer of charge 800-1000 mm thick. The spacing between the electrodes and furnace bottom prevents overheating of the metal and evaporation of manganese. Gases should evolve evenly over the whole surface of the furnace top. With fine materials used for smelting Ferro-manganese, gases tern to escape through blowholes they from near an electrode and therefore in that case it is especially important to maintain a high cone of charge at the electrodes and pierce the materials at the cone base.

When the charge is moist, hot charge may fall down or even be splashed together with slag from beneath the electrodes. This can occur owing to accumulation of gases in the melting zone with a poor gas permeability of the charge. Drying of manganese ore is an indispensable operation in the process. The use of dry ore and coke breeze ensures a higher productivity, lower consumption of electric energy, stable process conditions and better labour conditions. With a deficiency of reductant in the charge, manganese cannot be reduced fully and the content of manganese oxide in the slag and that of phosphorus in the metal increase. With a large excess of reductant the content of silicon in the metal increase the depth of electrode placing diminished, the high-temperature zone rises to a higher level and the heat and reducing ability of gases are utilized less efficiently. The position of electrodes in the furnace is controlled by giving manganese ore beneath them if a deeper immersion of an electrode is needed, or coke breeze, if an electrode should be raised higher. The metal and slag are tapped successively from all the two tap holes. The slag ratio in the smelting of Ferro-manganese by a flux less process is within 1.0 1.2. The slag is separated from metal during tapping by means of a skimmer arrangement. Moulds are arranged in a cascade under the spout; a partition is placed into the first mould, with its lower edge 60 70 mm below the pouring nose of the mould. Slag is retained by the partition and flows over into the ladle while. Silico-Manganese Silico-manganese an alloy of manganese with silicon and iron is a semi-product used for smelting of medium and low carbon Ferro-manganese. As mentioned earlier, Silicomanganese is also employed as a complex deoxidant in steel making and (upon melting together with aluminium) to produce a complex manganese-silicon-aluminium (M-K-A) deoxidant. The process for smelting Silico-manganese essentially consists in manganese and silicon being simultaneously reduced from manganese silicates, slag, ore and quartzite. The process relies on a higher temperature than that needed for smelting Ferro-manganese. The process is carried out continuously under slag having a ratio of 1:1.

Charging and furnace top maintenance are done essentially in the same way as in Ferromanganese. The metal and slag are tapped from the furnace every two hours. The thick slag at tapping entrains much of metal beads, which has a negative effect on manganese recovery. The slag can be made more fluid by adding raw dolomite. The metal and slag are tapped through same tap hole in a similar way to Ferro-manganese.

Ferro Silicon

Quartz, Iron Scrap and Charcoal are the main raw materials for the production of Ferro Silicon.

The Quartz is in the form of SiO2 and Iron Scrap is in the form of Fe. SiO2 is reduced to Si taking Carbon from Charcoal. The Fe comes from Iron Scrap and forms as Fe Si. This is a Slag less process since there are no other Oxides in the raw materials other than little Al2O3 and CaO. The liquid Ferro Silicon is tapped and collected in lined ladle and poured in dressed sand beds. After solidification the cakes are broken into required size and bagged for dispatch. 2.4 WATER REQUIREMENT & WASTEWATER GENERATION The proposed project will requires about 100 cum/day of water. The details of total water consumption, its breakup details are indicated below. WATER REQUIREMENT (m3/day)

S.N 1. 2. 3 4

Description For Cooling Dust Suppression Greenbelt Domestic & applications Total

Consumption Remarks in M3/Day 75 Evaporation losses 05 10 Misc. 10 100 Evaporation losses Gardening Losses Domestic & Other losses

The total water requirement is 100 KLD for the plant operations, which will be met by ground water through bore wells located within the plant premises Wastewater Generation: There is no generation of wastewater from the proposed Ferro Manganese, Silico Manganese and Ferro Silicon manufacturing process. Cooling tower water is continuously re-circulated in the cooling water circuits, heat exchangers and discharged to the sump or holding tank through cooling towers where evaporation losses, drift losses and spillages are encountered. Only 6 m3/day of Domestic effluent will be generated from the proposed project and this effluent will be sent to septic tank followed by soak pit. 3 ENVIRONMENTAL SETTING OF THE PROPOSED PROJECT a) The proposed project site is located in Sy. No: 15/E, Fouzpur Village, Taroda (B) Grampanchayat, Jainath Mandal, Adilabad District of Andhra Pradesh. b) Transpiration, Communication facilities and Public Health facilities are satisfactory c) There are no environmentally sensitive areas with in the study zone. 4.0 COLLECTION OF BASELINE DATA Initially baseline data was collected to know the existing quality of ambient air, surface water, ground water, soil characteristics, flora & fauna, noise levels and socio economic details of the people living in the study area during October 2010 to December 2010

4.1 AIR ENVIRONMENT In order to assess the existing ambient air quality in the study area of 10 km radius of the project, a network of 9 ambient air quality stations were selected and samples were collected to analyze for various parameters like PM2.5, PM10, SO2, NOx and CO & PAH (Poly-Aromatic Hydrocarbons) concentrations. The sampling stations were selected based on the Topography/ Terrain of the study area, Populated areas, Residential areas etc. The values of ambient air quality of all the monitoring stations for various parameters during the study period (October 2010 to December 2010) will be as following.

The maximum value of PM2.5 in the proposed project area is 19 g/m3., PM10 is 39.0 g/m3, SO2 is 3.1 g/m3, NOx is 4.3 g/m3 and CO levels are less than 1 ppm and PAH value is 1.3 ng/m3. The average value of PM2.5 in the buffer zone in the range of 19 25.2 g/m3, PM10 in the range of 41.2 51.3 g/m3, SO2 in the range of 3.7 5.83 g/m3, NOx in the range of 5.4 8.0 g/m3 and CO levels are less than 1 ppm and PAH values are 1.7 5.1 ng/m3. The concentrations of various parameters in the air quality of the study area were found to be well within the norms prescribed by NAAQ. 4.2 NOISE ENVIRONMENT In order o know the baseline noise levels, in and around the project site, Noise levels were measured at the project area and also at 8 villages in the study area. The day-night noise levels were monitored at all locations and the Day-night equivalent noise levels ranging from 46.0 dB (A) to 55.9 dB (A) The noise levels recorded at all the stations were found to be less than the standards prescribed. 4.3 WATER ENVIRONMENT In order to assess the water quality of the study area seven nos. of Surface water samples were collected and these samples were analyzed for various physical ad chemical and bacteriological parameters to know the contamination levels. Eight nos. of ground water samples were collected from bore wells from the near by villages and plant site to assess ground water quality impacts. All the water samples collected shows compliance of all parameters with the drinking water standard of IS 10500

4.4 LAND ENVIRONMENT 9 nos. of soil samples were collected and analyzed for Physical & Chemical parameters. 4.5 BIOLOGICAL ENVIORONMENT The details of flora and fauna present in the study area were described elaborately in the EIA report

4.6 SOICIO-ECONOMIC ENVIRONMENT The detailed description of the Socio-Economic Environment is presented in the EIA report. 5.0 ENVIRONMENTAL IMPACTS 5.1 AIR ENVIRONMENT BESL is installing 2 x 6.5 MVA Submerged Electric Arc Furnace for manufacturing of Ferro Manganese & Silico Manganese and Ferro Silicon in the process of implementation of proposed plant. For estimation of impacts both the furnaces, were considered. An attempt has been made to predict the incremental rise of various ground level concentrations above the baseline status in respect of air pollution due to proposed project. The Industrial Source Complex Short Term model (ISCST3) is a computerized air quality model, which was approved by United States Environmental Protection Agency for industrial applications is used for predicting the Ground Level Concentrations (GLC) due to the proposed plant. The emissions of concern are Suspended Particulate Matter (SPM) Sulphur dioxide (SO2) and Oxides of Nitrogen (NOx) The maximum ground level concentration of TPM is estimated to be about 1.42 g/m3 SO2 is 0.364 and NOx is 0.473 g/m3 within the project area. The net concentration of TPM SO2 & NOx (maximum baseline cone. + predicted conc.) in the project area are given below. OVERALL SCENARIO WITHIN PLANT AREA (g/m3) 24 Hourly Concentrations Baseline Scenario (Max) Predicted Ground Level Concentration due to proposed Ferro Alloy Plant (Max) Overall Scenario (worst case) Total Particulate Matter (TPM) 58 1.42 Sulphur Dioxide (SO2) 3.1 0.364 Oxides of Nitrogen (NOx) 4.3 0.473

59.42 (100)

3.46 (80)

4.77 (80)

The net concentrations of TPM, SO2 and NOx, are will with the National Ambient Air Quality Standards (NAAQS). Hence there will not be any adverse impact on air environment due to the proposed project activity. 5.2 WATER ENVIRONMENT The proposed project will requires 100 m3/day of water. Water is generally required for cooling, green belt, dust suppression and domestic purpose. The total water requirement will be met from the abundant available ground water sources. There is no generation of wastewater from the manufacturing process of ferro alloys. Cooling tower water is continuously re-circulated in the cooling water circuits, heat exchangers and discharged to the sump or holding tank through cooling towers where evaporation losses, drift losses and spillages are encountered. Only 6.0 m3/day Domestic effluent will be generated from the proposed project and this effluent will be sent to septic tank followed by soak pit. Rainwater harvesting structures have been proposed to recharge the ground water. Hence there will not be any adverse impact on water environment due to the proposed project. This indicates that there will not be any adverse impact on water environment due to the proposed project.

5.3 NOISE ENVIRONMENT The ambient noise levels in the proposed plant area will be with in stipulated standards. Hence, there will not be any adverse impact on noise environment due to the proposed project activity. 5.4 LAND ENVIRONMENT There is no generation and discharge of process effluents from this proposed plant. Hence there will not be any adverse impact on the land environment.

5.5 BIOLOGICAL ENVIRONMENT The biological environment will not be affected at all due to the proposed project

5.6 SOCIO-ECONOMIC ENVIRONMENT It will be obvious to assume that the activities of the plant operations have to be produced some improvements in the socio-economic levels in the study area. The proposed industrial activities will provide employment to local persons of different skills and trades. The employment potential ameliorated economic conditions of these families directly and provided employment to many other families indirectly who are involved in business and service oriented activities. This in-turn will improve the socioeconomic conditions of the area. 6.0 ENVIRONMENTAL MANAGEMENT PLAN The major objective and benefit of utilizing REIA in project planning stage itself is to prevent avoidable losses of environmental resources and values as a result of well-planned EMP. Environmental Management Plan includes protection/mitigation/enhancement measures as well as suggestions for the post project-monitoring programme to be implemented by the project proponent. 6.1 EMP DURING CONSTRUCTION PHASE The project proponent shall take appropriate steps to control pollution during construction phase. a) At the time of construction there will be substantial quantity of soil and debris generated and they can however be controlled by dust suppressant spraying. . b) Employees and labor working at the site shall be provided with water supply and proper sanitation facilities to maintain proper standards of hygiene. c) Some noise pollution can be anticipated due to the usage of concrete mixers and mechanical vibrators. Therefore it is advisable to provide earmuffs to the site workers. The vehicular traffic may also contribute to some nose level enhancement during construction phase. However its impact on the nearby settlement would be negligible. d) The solid wastes shall be collected and segregated and all the combustible wastes shall be burnt in a controlled manner. e) All the hazardous material such as LPG, diesel, painting materials etc, shall be stored as per International Safety Standards.

f) The construction of the project does not involve any rehabilitation of human settlements. 6.2 POST CONSTRUCTION PHASE 6.2.1 AIR ENVIRONMENT The main sources of dust pollution are 2 x 6.5 MVA Submerged Electric Arc Furnace and handling operations of raw materials & products and their transfer points. The Exhaust emissions of proposed 2 x 6.5 MVA Submerged Electric Arc Furnace will be dedusted in the 2 nos. of individual Bag filters, designed for an outlet concentration of less than 50 mg/Nm3 and the emissions from the proposed Submerged Electric Arc Furnace after treating in heat exchanger and FD cooler & Bag filters will be let out into the atmosphere through a common stack height of 33m. A separate dedusting system will be provided to control the dust from various material transfer points by means of suitable ducting connected to an Induced Draught fan. The dust that is drawn from various points will be passed through bag filters. Recommendations: a) The proposed air pollution control equipments should be installed prior to commissioning the plant. b) Online Continuous monitoring system for SPM should be provided. c) Pressure drop measuring system across the bag filters will be installed. d) All the internal roads shall be asphalted to reduce the fugitive dust to truck movement. 6.2.2 WATER ENVIRONMENT The wastewater generated from the proposed project will be Only 6.0 m3/day of Domestic effluent and this effluent will be sent to septic tank followed by soak pit. Rainwater harvesting structures have been proposed to recharge the ground water. Hence there will not be any discharge of effluent outside the premises. Hence there will not be any impact on ground water / surface water due to the proposed project.

6.2.3 SOLID WASTE The following are the solid wastes generated from the plant and disposal facilities.

Particulars
Ferro Manganese Slag Silico Manganese slag

Quantity (TPA) 27441.8 18049.2

Disposal Will be reused in the Silico Manganese production This Slag will be separated for metal contents in Gigging plant & remaining will be used in the manufacturing of paver blocks, designer tiles & hallow blocks, which are produced in the industrys own unit located in Yavatmal Will be used in the road formations & filling of low laying areas Reused in the Furnace

Ferro Silicon Slag

465

Dust from Bag Filters

6089.2

There is a lot of brick manufacturing activity within 30 km radius of the plant site. 6.2.4 NOISE ENVIRONMENT The major noise-generating sources in the plant are furnace and compressor, etc. All these machinery will be manufactured keeping in view the MOEF International Standards on noise levels. The major noise levels will be confined to the working zones of the proposed activity. The Leq of eight hours will be within the prescribed standards. Community noise levels are not likely to be effected due to the existing belt and attenuation due to the physical barriers. As the nearest habitation is about 1.12 km from the project site, there will not be any adverse impact on habitations due to the proposed activity. Recommendations: a) The impact can reduce by adopting shock absorbing techniques. b) Earplugs shall be provided to the workers and this shall be enforced strictly.

c) Increase the distance between source and receiver, by altering the relative orientation of receiver and the source.

6.2.5 LAND ENVIRONMENT The land acquired for the proposed project is 8.5 acres in this land allocated for greenbelt development is 2.8 acres. All the required Air pollution control systems will be provided in the proposed plant. The treated domestic effluent will be confirmed to the A.P. Pollution Control Boards standards. Hence there will not be any impact on land environment due to the proposed project. Recommendations a) Landscaping can be done around the administrative building. This will help in preserving the ecological conditions. b) The treated water shall be used for green belt development.

6.2.6 GREENBELT DEVELOPMENT 2.8 acres of extensive greenbelt will be developed in the acquired sit for the proposed plant. The greenbelt shall be developed simultaneously with the plant construction. This will further mitigate the pollution impacts.

7.3 POST PROJECT MONITORING STRATEGY The detailed Post Project Monitoring strategy is given in Chapter 6 of EIA report. 7.4. DISASTER MANAGEMENT PLAN The management is very much aware of their obligation to protect all persons at work and others in the neighborhood who may be affected by an unfortunate and unforeseen incidence occurring at the works. Any hazard either to employees or others arising from activities at the plant site shall, as far as possible, be handled by the personnel of the company and prevented from spreading any further.

The manufacturing of ferro alloys are very simple and risk of accident is minimum. However in the case of eventuality the Disaster Management plan adopted by the proponents is sufficient and may be able to control the situation.