Bharat Alloys - Cfo & Hwa Ver. Rep

ANDHRA PRADESH POLLUTION CONTROL BOARD Regional Office, 1st Floor, Shankar Shopping Complex,Krishna Nagar Main Road, Kurnool – 518 002

K. RAVI KUMAR ., Environmental Engineer.

Phone No. 08518 - 235800. Fax No. 08518 – 233619 E-mail: [email protected]

Lr. No. 32-R-1125/PCB/RO/KNL/CFO & HWA/2008 To The Senior Environmental Engineer(CFO) A.P.Pollution Control Board, Board Office, Hyderabad

Date:

-05-2008

The Joint Chief Environmental Scientist(HWM) A.P.Pollution Control Board, Board Office, Hyderabad

Sir , Sub:

PCB – RO – KNL – CDCC - CFO application of M/s Bharat Alloys & Energy Limited, Dinnedevarapadu Village, Kurnool Mandal & District. – Verification report – Regarding.

Ref:

1)

CFO Order No. APPCB/KNL/KNL/40/A/2006 – 289, dt: 02-05-2007 2) HW Authorisation No. APPCB/KNL/KNL/467/HWM, dt: 02-05-2007 3) Industry’s application received on 16-05-2008

The details of the industry and inspection report are submitted as below: General Details: 1 Name and Address of the industry

M/s Bharat Alloys & Energy Limited, Dinnedevarapadu Village, Kurnool (M & Dist.) 08518 – 237845 / 46 / 47 / 48

With Tel. No, 2

3.

[email protected]

E-mail. Status of Consent and HWA. I

Fresh / Renewal CFO - Renewal Valid upto 31-12-2007 (Copy of CFE / CFO and HWA orders shall be enclosed). HWA - Renewal Valid upto 31-12-2007

II

Date of receipt of application Additional information if any.

III

Details of Consent Fee paid.

/

During the earlier renewal of CFO the industry has paid consent fee for the period (Period upto) of 2years i.e., valid upto 31-03-2008. But the Board office has issued consent order upto 31-12-2007 only. Now, the industry has applied for renewal of CFO duly paying consent fee of Rs. 1,80,000/- for the period of 3years i.e., valid upto 31-03-2011. Project cost. A certificate of chartered accountant is (including modification / expansion without submitted for fixed assets as Rs. depreciation, as per balance sheet) 12,41,44,157/excluding the value of revaluation. But the gross block of fixed assets is Rs.50,86,77,382/- as on 31-032007. The issue may be examined. Total investment on pollution control Rs. 1.12 Crores measures and recurring cost and percentage. Latitude & Longitude

N15046’54.3

N15046’52.2

E078001’57.9”

E078002’03.7”

Total Area of the plant:

34.0 acres

Extent of Greenbelt

8.0 acres

Surroundings of the Industry

4.

Date of commissioning.

5

Status of E.C I II

East West

: Vacant land & New colony : Vacant land followed by Railway line & NH-7 North : Vacant land South : Approach road followed by vacant land Sick unit commissioned on January 2004

Line of Activity as per EIA Notification. N.A < 50 Crores Environmental Clearance order No. --and date (Copy shall be enclosed).

6

III

Violations of EIA Notification, If any.

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I

Inspection conducted by

E.E & A.E.E-I

II

Representative of Industry present

III

Date of Inspection

Sri Ravi, President Sri K.Philip Jayaraju, General Manager 17-05-2008

CFO Details 7 Raw materials / Fuels required for production at Consented capacity per Day / Month. Note : Should not be mentioned as “ enclosed with the application “ S.No Name of the Major Raw material / (Per / Month ) for each product material used in the Activity

8

Quartz

90 TPD

2

Charcoal

80 TPD

3

Iron Ore / Mill scale

20 TPD

4

Electrode paste

2.5 TPD

Products & By Products manufactured / Storage capacity of Petroleum products / Mining capacity etc per Day / Month. S.No Products / Line of Activity Consented capacity Applied as per CFE order (as per the dt. 02-05-2007 application) 1

9

1

Ferro silicon

Water consumption. I Source of water supply (River / Bore wells / Public supply) S. Purpose no 1. Process 2. Washings 3. Boiler Feed 4 Industrial Cooling (Makeup) Humidification / Water spraying). 5 Gardening / Irrigation. 6 Others (to be specified) 7 Domestic Total: II. Status of Functioning of Water Meters

25 TPD

50 TPD

Tungabhadra river Quantity in KLD ------/ 100 KLD 5.0 KLD --5.0 KLD 110.0 KLD The industry had provided water meter before softner and it is under working condition.

10

Waste Water Generation: S.No 1.

Effluents

Quantity in KLD

Process & Washings

--

(specify stream wise i.e., LTDS, HTDS, High COD etc.--- brake up shall be given) 2

Boiler Blow Down -

---

3

Cooling Blow Down -

4

Softner regeneration

10.0 KLD (for recirculation) 5.0 KLD

5

Domestic

3.0 KLD Total: 18.5 KLD

11

Out let – as per CFE / CFO order dt.02-05-2007 Outlet No. 1 2

12.

Outlet Description Trade Effluents Domestic Effluents

Max Daily Discharge 10 3

Point of Disposal Recycling / Ash Quenching Septic tank followed by soak pit

a) ETP Details & Mode of Disposal:

I. Outlet No. 1 a. Stream Details: b. Treatment units details. c. Point of disposal

Trade effluent i.e., from cooling water blow down and softner regeneration. --Recycling / ash quenching / gardening

ii. Outlet No. 2 : a. Stream Details: b. Treatment units details. c. Point of disposal

-------

iii. For Domestic waste water:

Septic tank followed by soak pit

b) Standards as per CFO / CFE. N.A 13

Board Monitoring Data ---

Water Cess I

Returns filed upto (Month & Year)

31-03-2007

II

Assessment issued upto (Month & Year)

III

Assessment paid upto (Month & Year)

Assessment orders not issued by the Board Office after re-commissioning of the unit. Hence, the assessment orders may be issued on the above water consumption from Jan, 2004 ---

IV

Assessment amount due (In Rs.)

---

14

Air pollution:

S.No.

2

Source of Pollution ( Boiler / Furnace / Kiln / Cupola / Incinerator / Process emissions with Characteristics / Fugitive emissions with Characteristics / DG set ) Note: Capacity should be mentioned for each unit Submerged electric arc, semi opened type furnace of 16.5 MVA (3TPH) D.G set – 625 KVA

3 4

D.G set – 125 KVA D.G set – 75 KVA

1

Control equipment provided

Flow rate in m3/hr.

Stack height in Mts - above GL

Bag house

1,80,586

40mts

Nil

Nil

Nil (Kept as idle) 3mts 2.5 mts

Silencers Silencers

15. Emissions from chimneys – as per CFE / CFO order dt. 02-05-2007 Chimney No.

Description of Chimney

1

Stack Attached to 16.5 MVA (3 TPH) submerged Electric Arc Furnace Attached to 625 KVA + 75 KVA D.G sets

2

16

Quantity of Limiting Emissions Standard at peak flow

Board Monitoring Data

1,80,586

115 mg/Nm3

109.72 mg/Nm3

---

115 mg/Nm3

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Compliance of the industry on CFE (Schedule- A & B) Conditions for Fresh CFO / Schedule – B conditions for renewal. CFO Order No. APPCB/KNL/KNL/40/A/2006 – 289, DT: 02-05-2007

S. Condition Compliance No. The industry shall file the water cess : The industry is filing water cess 1 returns in Form-I as required under section returns in Form-I regularly. But the (5) of Water (P & CP) Cess Act, 1977 on or Board Office has not issued before the 5th of every calendar month, assessment orders. showing the quantity of water consumed in the previous month along with water meter readings. The industry shall remit water cess as per the assessment orders as and when issued by Board.

2

The industry shall take steps to reduce : The industry is restricting water water consumption to the extent possible consumption as per consent order. and consumption shall NOT exceed the quantities mentioned below: Sl.No. 1 2 3

Purpose Cooling Gardening / Irrigation Domestic Total :

Quantity 100 KLD 5 KLD 5 KLD 110 KLD

3

The emissions shall not contain : The stack emissions of electric arc constituents in excess of the prescribed furnace is within the prescribed limit limits mentioned below: as the industry is operating at 50% Chimney No. 1&2

4

Parameter SPM

Emissions Standards 115 mg/Nm3

load.

The industry shall comply with Ambient air : The SPM concentrations are slightly quality standards of TSPM-200µg/m3, exceeding due to fugitive emissions RSPM-100µg/m3, SO2-80µg/m3, Noxgenerated while charging of fuels and 80µg/m3 tapping of the product. The industry Noise Levels : had also installed 50 HP electric motor Day time (6AM to 10PM)- 75dB(A) for effective extraction of fugitive Night time (10PM to 6AM)- 70dB(A)

emissions generated during tappings of the moulted metal and the blower outlet is connected to the inlet of ID fan. The industry has provided M.S.sheet

with a facility to roll on the angles on the front side of the canopy to avoid escaping of fumes during tapping operations. The SPM concentration was found to be 523.42µg/m3 as on 01-10-2007.

5

The industry shall not increase the : The industry is producing as per the capacity beyond the permitted capacity permitted capacity of consent order mentioned in this order, without obtaining and the production details are CFE / CFO of the Board. enclosed.

6

The industry shall operate the plant at 50% : Complied installed capacity i.e., 25 TPD only. The industry shall improve the dust : The industry has provided 3 tapping holes suppression / containment equipment to to the furnace, out of which the industry control fugitive emissions and shall report has closed the suction provided to the 3rd to E.E, PCB, Kurnool within a month tapping hole. The industry has provided M.S.sheet with a facility to roll on the angles on the front side of the canopy to avoid escaping of fumes during tapping operations. It was informed that they will operate 2 tapping holes only in future and hence the suction provided to the 3rd tapping hole has been closed to have effective suction. During the inspection it was informed that the industry has proposed to provide higher capacity blower for effective suction of fumes after re-commissioning. The industry shall comply with task force : The industry has provided heat directions exchanger as a augmentation of air

7

8 9

10

17 S. No.

pollution control equipment. The industry shall conduct stack and : The industry had submitted third party ambient air quality monitoring and submit analysis report in the month of the reports to Board office within one October 2006. month The applicant shall submit Environment : Complied statement in Form V before 30th September every year as per Rule No.14 of E(P) Rules, 1986 and amendments.

Compliance of the industry on EC Special conditions : N.A Condition

Compliance

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18

Compliance of the industry on Task Force Directions : 29-04-2008 The Board has issued stop production orders to the industry on 29-04-2008 and the compliance report submitted to the S.E.E(TF) on 17-05-2008 as follows:

S. No. 1.

2

3

19 S. No. 20

Condition Lot of fugitive emissions were observed during tapping operation of the furnace and the industry has not taken adequate measures to control the fugitive emissions The industry has made arrangement of semi-closed hood near the tap hole to suck the emissions generated during taping period. However, the suction was not effective and the emissions are drifting towards sides

Compliance :

The industry has provided 3 tapping holes to the furnace, out of which the industry has closed the suction provided to the 3rd tapping hole. The industry has provided M.S.sheet : with a facility to roll on the angles on the front side of the canopy to avoid escaping of fumes during tapping operations. It was informed that they will operate 2 tapping holes only in future and hence the suction provided to the 3rd tapping hole has been closed to have effective suction. It was informed that they have procured about 398 new bags to replace with damaged bags and replaced about 320Nos. of bags in the bag house. During the inspection it was informed that the industry has proposed to provide higher capacity blower for effective suction of fumes after re-commissioning. The industry has not provided closed shed : During inspection it was observed that the for storing fly ash / dust collected to avoid earlier fly ash collected in bags was carryover of dust into surroundings and not removed. It was informed that they have complied with the Board directions dated: sold out about 60 to 70 tonnes of silica dust 25-08-2007 to OSWAL MINERALS LTD, Bangalore. The industry is increasing the size of the closed shed for storage of silica dust to about 16mt x 16mt x 4mts height. It was informed that the construction of the shed will be completed within 10 days. During the inspection the R.G-I register of the industry was verified and observed that the industry has produced highest quantity in the month of July i.e., 753.06MT during year 2007 -08. The industry has to upgrade the suction blower to have effective suction during tapping operations. The industry shall provide water sprinkling system to suppress the silica dust near storage shed.

Compliance of the industry on CREP Recommendations. N.A CREP Recommendations

Compliance

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Hazardous chemicals used and their storage facilities: Nil

21. HWA Details: i) Particulars of Authorisation obtained under APPCB/KNL/KNL/467/HWM, dt: 02-05-2007 HW(M&H) Rules, 2003 (No. & Validity date) ii) Authorization issued for Collection, reception, storage, (Transportation, reception, storage, treatment transport and disposal of and disposal) hazardous waste. *remarks shall be furnished if the industry is receiving Haz.Waste at the site and using as a raw material.

iii)

Process in which the industry is covered As follows (Please give Sl. No of process as per HW Rules)

iv)

Description of Hazardous waste with quantities and Stream No. as per HWM Rules, 2003

v)

vi)

As follows

Sl. No.

Name of the Hazardous waste

Stream

Quantity of Hazardous waste per annum 64 Nos. / 2 years

1.

Used lead acid batteries

22 of Schedule-IV

2

Process dust (Bag filter Dust)

13.1 of Schedule-1

4.0 MT/day

3

Waste oil / Waste Lubricant oils

5.1 of Schedule-I

1.6 Kl/yr

Mode of disposal

Return to manufacturers / dealers on buy back basis Disposed to authorized fly ash Brick manufacturing units Re-processing / Recycling units authorized by APPCB.

Particulars of on-site Secured Storage (Capacity 10 tonnes of hopper for storage of with dimensions) and mention period for which silica dust and also constructing a secured storage is sufficient. closed shed with a dimensions of about 16 x 16 x 4mt height for storage of silica dust. Quantity of Haz Waste stored on-site presently. --*Furnish specific remarks on the storage of Haz.waste for more than 90 days.

vii)

Quantity of Hazardous waste disposed for last six months as per the following break-up: Common TSDF – Common HW Incinerator – For recycle / reused -

viii) ix)

Silica dust, waste oil, lad acid batteries

Whether industry has submitted annual returns, No date of latest submission. Whether industry has installed incinerator or No sending to common HW Incinerator

x) xi)

Particular of own incinerator (if applicable) N.A Whether log books are maintained for incinerator. N.A (if applicable)

xii)

Whether industry has taken adequate steps to Yes prevent contaminated runoff from storage areas of Hazardous Waste.

xiii)

Steps taken by industry towards minimization and cleaner production.

waste Effective collection

xiv)

Future plan for waste minimization.

xv)

Facilities available characterization.

xvi)

Overall House Keeping within the factory premises.

Needs improvement

xviii)

Details of disposal of lead acid batteries along with nos and agencies to whom they are disposed

64 Nos. Are existing in the control room, but not disposed so far.

22

with,

industry

Not submitted for

waste ---

Compliance of the industry on previous Hazardous Waste Authorisation conditions. :

1

Industry shall give top priority for waste : Complied minimization and cleaner production practices

2

The industry shall submit the characteristics of : Not submitted flue gas dust (bag filter dust) within 15 days to the Regional Office, Kurnool with a copy marked to this office.

3

Industry has to improve house keeping at the : The industry had improved house storage area of the solid waste and send the keeping at the storage of solid waste. compliance report with in the 15 days. No compliance was submitted.

4

The industry shall not store hazardous waste for more than 90 days as per the HWM Rules, 2003.

5

The industry shall not dispose Waste oils / Non- : --ferrous metal scrap / Used lead acid batteries to the traders and the same shall be disposed off to the authorized agencies of APPCB.

6

Industry shall take necessary practical steps to prevention of oils spillages and carry over of oil from the premises

7

Industry shall maintain 6 copy manifest system : --for transportation of waste generated and a copy shall be submitted to Board Office and concerned Regional Office.

8

Industry shall dispose / sell the hazardous : Complied wastes to only industries / agencies authorized by State Pollution control Boards. They shall verify the authorization of the Board given to the party before disposing their wastes to the external party.

9

The industry shall submit the condition wise : Complied compliance report of the conditions stipulating in Schedule B and Schedule C of this order on half yearly basis to Board Office, Hyderabad and concerned Regional Office.

:

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: Complied

23

Inspection Officer’s Remarks:

The industry is having

the control equipment of

bag filters and heat exchanger as a augmentation of air pollution control equipment. The industry had also installed 50 HP electric motor for effective extraction of fugitive emissions generated during tappings of the moulted metal and the blower outlet is connected to the inlet of ID fan. The industry has provided M.S.sheet with a facility to roll on the angles on the front side of the canopy to avoid escaping of fumes during tapping operations.

During inspection it was observed that the earlier fly ash collected in bags was

removed. It was informed that they have sold out about 60 to 70 tonnes of silica dust to OSWAL MINERALS LTD, Bangalore. The industry is increasing the size of the closed shed for storage of silica dust to about 16mt x 16mt x 4mts height. It was informed that the construction of the shed will be completed within 10 days.

I

Maintenance of ETP / APC : Satisfactory

II

Records Maintained •

ETP Log Book. : N.A

•

Stack Monitoring Report.: Monitored by third party in the month of Sept. 2006

•

Ambient Air Quality Monitoring report. : Monitored by third party in the month of Sept. 2006

•

Energy consumption records : Maintained

•

Water meter readings : Maintained

(Signature of the Inspecting Officer) 24 I

Regional Officer’s Remarks: Compliance of the industry with reference to Notifications under E(P) Act & Rules. a) Fly Ash Notification.

The industry is generating about 4 TPD of silica dust from bag filter and it is being stored in a shed which is under construction. About 60 to 70T is disposed to OSWAL Minerals, Bangalore.

b) PLI Act Policy.

N.A

c) Environmental Statement in Submitted Form – V. d) Other if any.

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II

Complaint / Legal action taken against the industry. A complaint was received on 23-05-2007 & 05-10-2007 from the residents of Maruthi & Shilpa townships and Dinnedevarapadu (V) regarding creating of air pollution in the surrounding area. The Task Force, Hyderabad had issued directions to the industry on 25-08-2007. the Task Force committee inspected the unit on 18-02-2008. A legal hearing was held on 2504-2008 and issued stop production orders on 29-04-2008.

III. Mitigation Measures (Where significant adverse effects are identified, description of the measures to be taken to avoid, reduce or remedy those effects).

The industry had installed bag filters as a air pollution control equipment but due to inadequacy to handle the entire air emissions the industry has provided heat exchanger as a augmentation of air pollution control equipment to drop the temperature of flue gases. The industry had also installed 50 HP electrical motor blower for suction of the fugitive emissions, it was observed that the suction is not effective and fugitive emission were observed during the taping operations. Monitoring was conducted on 01-10-2007 and SPM values are recorded as Stack – 109.72mg/Nm3 and Ambient - 523.42 µg/m3 which indicates that the ambient air levels are exceeding the standards prescribed by the Board. During inspection on 17-05-2008 it was observed that the industry was not under operation as stop production were issued by the Board on 29-04-2008, it was informed that they have started production from 01-05-2008 after receipt of the orders from the Board Office and the same was verified with R.G-I register. During inspection, it was observed that the industry has closed the suction provided to the 3rd tapping hole of furnace. The industry has provided M.S.sheet with a facility to roll on the angles on the front side of the canopy to avoid escaping of fumes during tapping operations. It was informed that they will operate 2 tapping holes only in future and hence the suction provided to the 3rd tapping hole has been closed to have effective suction. It was informed that they have procured about 398 new bags to replace with damaged bags and replaced about 320Nos. of bags in the bag house of air pollution control equipment. During the inspection it was informed that the industry has proposed to provide higher capacity blower for effective suction of fumes after recommissioning. During inspection it was observed that the earlier fly ash collected in bags was removed. It was informed that they have sold out about 60 to 70 tonnes of silica dust to OSWAL MINERALS LTD, Bangalore. The industry is increasing the size of the closed shed for storage of silica dust to about 16mt x 16mt x 4mts height. It was informed that the construction of the shed will be completed within 10 days. During the inspection the R.G-I register of the industry was verified and observed that the industry has produced highest quantity in the month of July i.e., 753.06MT during year 2007 -08. The industry has to upgrade the suction blower to have effective suction during tapping operations. The industry shall provide water sprinkling system to suppress the silica dust near storage shed.

25

Recommendation (Specific comment whether to issue consent or not). The industry was issued stop production order on 29-04-2008 and compliance report was submitted to SEE(TF). The copy of the orders and reports is enclosed. The issue of CFO may be considered for a period of one year after revocation of stop production orders.

This is submitted for favour of kind information and taking necessary action. Yours faithfully, ENVIRONMENTAL ENGINEER -

Copy submitted to the JCEE (Cess & Planning) APPCB, Board Office, Hyderabad for favour of kind information and for taking necessary action.