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M/s. Star Metallics and Power Private Limited (SMPPL) is a joint venture
company formed as a Special Purposes Vehicle (SPV) by Euro Industrial
Enterprises Private Limited, India (EIEL) and Emirate Trading Agency (ETA) for
operating existing Ferro Alloy Plant located at Vyasankere, near Hospete,
Karnataka. SMPPL proposes to establish a 32 MW Coal based Captive Power
Plant within the existing premises to meet the power requirement for its ferro
alloy plant.
Euro Industrial Enterprises Private Limited, India (EIEL) had acquired the
established ferro alloy plant having 95 acres of plot area with all its appurtenances
and one 15 MVA submerged arc furnace along with its auxiliary equipments from
Sandur Manganese & Iron Ores Limited (SIMORE).
Emirate Trading Agency (ETA) had purchased two 20 MVA submerged arcfurnaces located in the existing ferro alloy plant at Vyasankere, near Hospete,
Karnataka from Sandur Manganese & Iron Ores Limited (SIMORE). It has
planned to dismantle and relocate one of the 20 MVA furnaces at Bahrain Ferro
Alloys limited, Manama, Bahrain. The other 20 MVA furnace is proposed to be
operated at its current location at Vyasankere along with one 15 MVA furnace
belonging to EIEL.
EIEL and ETA have formed a joint venture company as a Special Purpose vehicle
(SPV) by the name Star Metallics and Power Pvt. Ltd. (SMPPL) for operating
existing ferro alloy plant. SMPPL proposes to install a 32 MW Captive PowerPlant (CPP) within the existing unit premises to meet the power requirement of
existing Ferro alloy plant. Power from public utility grid is being utilized for Ferro
alloy plant and later it will source the power from the proposed 32 MW CPP.
2. NEED OF THE PROJECT
The existing Ferro alloy plant had been stopped since last ten years due to
unavailability of power. The capacity of plant for silicomanganese production
is 44,700 MT per year. Since the state grid power supply is economically
unviable in the long run and every effort to restart the ferro alloy plant using
power from other sources were unsuccessful, it was decided to install a 32MW Captive Power Plant to augment the power requirement. The proposed
32 MW captive power plant is coal based with fluidized bed combustion
technology. Power from the CPP will be used to run ferro alloy plant and the
surplus power will be exported to consumers.
3. PROJECT DETAILS:
3.1 LOCATION OF THE PROJECT:
The ferroalloy complex is situated at Vyasankere, 12 km from Hospet (in Bellary
district) on the National Highway 13 connecting Bangalore with New Delhi on a
95 acre plot. SMPPL’s proposed 32 MW Captive Power Plant will be locatedwithin the existing premises of the ferroalloy plant. Hospete (formerly Hospet) is
located at 15.27° N 76.4° E. It has an average elevation of 480 meters (1574 feet).
Project Proponent: M/s. Star Metallics & Power Pvt. Ltd: Page 2 of 13
Reptiles: The reptiles commonly observed are Pythons Cobra Rat-Snake Green
Snakes, common garden lizard, saw scaled viper chameleon.
4.9 SOCIO ECONOMIC DATA
As per the census the population of the district stood at 16.53 lakhs. Thegeographical area is 8447 sq.km. It has two revenue sub divisions viz., Bellary
Sub-Division and Hospet Sub-Division which have in all seven taluks. The
Bellary Sub- Division has 3 taluks while there are five taluks in Hospet Sub-
Division. There are 27 hoblies, two CMCs one Town Municipality, seven Town
Panchayat 542 Revenue villages, 436 and as/habitations. The rural populations
constitute 70%. The density of population is 196 per sq.km which is much lower
than the State average of 235 per sq.km. However the decimal growth rate for
1981-91 was 26.92 % which is higher than the State growth rate of 21.12 %.
The SC/ST population constitutes 28 % of the total population. The sex-ratio
was 965 which are slightly higher than the state average of 960.
4.10 LITERACY LEVELS: Literacy rate in study area is given below:
LITERACY HOSPETE
Year 1991 Census 2001Census
Literacy % 42.00 60.64
Male Literacy % 51.00 74.95
Female Literacy % 31.00 52.92
The study area (Hospete) experiences a considerably very moderate literacy rateof 60.64% (2001).
5.0 ENVIRONMENTAL IMPACTS AND MANAGEMENT PLAN
The following is the new unit proposed under expansion of the ferro alloy Plant
(a) Coal Based Captive Power Plant of 32 MW.
The proposed coal based captive power plant may influence the environment in
two distinct phases:
a) During construction phase which is temporary and of short term
b) During operation phase which may have long term effects
5.1 Impacts during Construction Phase and control measures
The construction of proposed captive power plant would result in increase of SPM
concentrations due to fugitive dust. Frequent water sprinkling in the vicinity of the
construction sites would be undertaken and will be continued after the completion
of plant construction as there is scope for heavy truck mobility. It will be ensured
that both gasoline and diesel powered vehicles are properly maintained to comply
with exhaust emission requirements.
Project Proponent: M/s. Star Metallics & Power Pvt. Ltd: Page 6 of 13
The proposed CPP shall use low ash content (1% ash) imported Indonesian
Coal to reduce the generation of SPM and hence the fly ash. The industry
shall provide special high efficiency Electrostatic precipitator at boiler outlet
for extracting the dust pollutant from flue gas for achieving a dust
concentration at the outlet of chimney as low as 100 mg/Nm3.
An adequate chimney of 60 m AGL shall be provided to disperse the flue
gases over a wide area to keep the ambient air quality well within the
permissible limits.
5.2.1.3 DG sets: Two DG sets of adequate capacity shall be used as power
back up. The industry shall operate the same using low sulphur diesel.
Industry shall provide adequate chimneys and necessary noise control
measures for the same.
The dispersion of pollutants in the atmosphere for the proposed CPP is determinedusing Gaussian plume dispersion model. For the present study, this model is used for
the prediction of maximum ground level concentration (GLC).
Predicted ground level concentrations were superimposed on existing ambient air
quality to obtain the overall GLC’s once the CPP becomes operational. It is found
that, there will not be any significant adverse impact on ambient air quality.
5.2.1.4 Fugitive Emissions from Material handling from proposed CPP:
Raw material handling process is one of the main sources of dust generation. Coal
while being drawn from stockyard and ground in hoppers leads to generation of dust.Proper sprinkling & dust extraction shall be adopted to reduce the same.
5.2.2 NOISE ENVIRONMENT
The plant and equipment will be specified and designed with a view to
minimize noise pollution. The major noise producing equipment such as
turbo-generator & DG sets shall be provided with acoustic enclosures.
Pumps, fans, compressors etc., shall be run at speeds less than 1500 rpm.
Equipment shall be statically and dynamically balanced. Safety blow off
valves, discharge pipes, relief valves etc. shall be equipped with silencers.Pipe lines shall be liberally sized for low velocities. Proper encasement of
noise generating sources will be done to control the noise levels below 75 dB(A)
at plant boundary. A scientifically designed thick greenbelt shall be grown.
5.2.3 WATER ENVIRONMENT
The total water consumption of the ferro alloy plant at present is about 136 m3 /day.
With the installation of CPP of 32 MW, the water consumption of the complex shall
increase to 652 (136 + 516 ) m3 /day.
Project Proponent: M/s. Star Metallics & Power Pvt. Ltd: Page 8 of 13
addition to this, there would be provision for forced draft cooling and ventilation of
closed environment in the work zone.
Proper equipment design for control of noise at source, adopting proper
protective appliances and administrative control for rotation of manpower in
noisy areas would prevent exposure of workmen to high noise levels.
5.2.8 Occupational Safety & Health Management
Plant safety measures would form an integral part of the environmental
management plan of the proposed plant. Workers safety would be given
highest priority so as to avoid any form of personal injury or lost-time
accident. In-built safety features of the plant and machinery would help to
avoid hazardous events causing damage to the life and property.
SMPPL has provided all necessary provisions under Factory Act. In addition aSafety committee will be formed and manned by equal participants from
Management and Workers.
Safety shoes, helmet & uniform are issued to each worker. Other safety
equipments will be used according to the nature of job involved
SMPPL has established its own well equipped occupational health center headed
by experienced Doctors with a team of Nurses, /Compounders .
5.2.9 SOCIAL IMPACTS:
Population displacement is main culprit during the establishment of a thermal
power plant due to large area requirement. The proposed project shall be located
in the existing ferro alloy plant premises in an area of 25 acres (Existing area is 95
acres). Hence, there shall not be additional requirement of land. There shall be no
displacement of the population by the proposed project. The land transformation
shall be marginal.
5.3 Social Welfare
SMPPL shall employ an additional manpower of 45 people in the proposed CPP.plant. A total of about 100 persons will be given indirect employment during
construction and installation of the new unit. Preference will be given to the local
people.
This expansion project would aid in the overall social and economic development
of the region.
Project Proponent: M/s. Star Metallics & Power Pvt. Ltd: Page 12 of 13