ANDHRA PRADESH POLLUTION CONTROL BOARD

Regional Office, 1st Floor, Shankar Shopping Complex,Krishna Nagar Main Road, Kurnool – 518 002

K. RAVI KUMAR ., Phone No. 08518 - 235800.

Environmental Engineer. Fax No. 08518 – 233619
E-mail: ro_knl@yahoo.com

Lr. No. 32-R-1125/PCB/RO/KNL/CFO & HWA/2008 Date: -05-2008

To
The Senior Environmental Engineer(CFO) The Joint Chief Environmental Scientist(HWM)
A.P.Pollution Control Board, A.P.Pollution Control Board,
Board Office, Hyderabad 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,
Keopl@eth.net
E-mail.
2 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.
3. 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 31-03-
2007. The issue may be examined.
Total investment on pollution control Rs. 1.12 Crores
measures and recurring cost and
percentage.
Latitude & N15046’54.3 N15046’52.2
Longitude
E078001’57.9” E078002’03.7”
Total Area of the plant: 34.0 acres
Extent of Greenbelt 8.0 acres
 Surroundings of the Industry East : Vacant land & New colony
West : Vacant land followed by Railway line
& NH-7
North : Vacant land
South : Approach road followed by vacant
land
4. Date of commissioning. Sick unit commissioned on January 2004
5 Status of E.C
I Line of Activity as per EIA Notification. N.A < 50 Crores
II Environmental Clearance order No. ---
and date
(Copy shall be enclosed).
III Violations of EIA Notification, If any. ---
6 I Inspection conducted by E.E & A.E.E-I
II Representative of Industry present Sri Ravi, President
Sri K.Philip Jayaraju, General Manager
III Date of Inspection 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
1 Quartz 90 TPD
2 Charcoal 80 TPD
3 Iron Ore / Mill scale 20 TPD
4 Electrode paste 2.5 TPD

8 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 Ferro silicon 25 TPD 50 TPD

9 Water consumption.
I Source of water supply Tungabhadra river
(River / Bore wells / Public supply)
S. Purpose Quantity in KLD
no
1. Process ---
2. Washings ---
3. Boiler Feed ---
4 Industrial Cooling (Makeup) / 100 KLD
Humidification / Water spraying).
5 Gardening / Irrigation. 5.0 KLD
6 Others (to be specified) ---
7 Domestic 5.0 KLD
Total: 110.0 KLD
II. Status of Functioning of Water Meters The industry had provided water meter
before softner and it is under working
condition.
10 Waste Water Generation:

S.No Effluents Quantity in KLD

1. 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 - 10.0 KLD
(for recirculation)
4 Softner regeneration 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 Outlet Description Max Daily Point of Disposal

No. Discharge
1 Trade Effluents 10 Recycling / Ash Quenching
2 Domestic Effluents 3 Septic tank followed by soak pit

12. 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 / Board Monitoring Data

CFE.
N.A ---

13 Water Cess
I Returns filed upto (Month & Year) 31-03-2007
II Assessment issued upto (Month & Assessment orders not issued by the Board
Year) Office after re-commissioning of the unit.
Hence, the assessment orders may be
issued on the above water consumption
from Jan, 2004
III Assessment paid upto (Month & Year) ---
IV Assessment amount due (In Rs.) ---
14 Air pollution:

S.No. Source of Pollution Control Flow rate in Stack

( Boiler / Furnace / Kiln / equipment m3/hr. height in
Cupola / Incinerator / provided Mts - above
Process emissions with GL
Characteristics / Fugitive
emissions with
Characteristics / DG set )
Note:
Capacity should be
mentioned for each unit
1 Submerged electric arc, Bag house 1,80,586 40mts
semi opened type furnace
of 16.5 MVA (3TPH)
2 D.G set – 625 KVA Nil Nil Nil (Kept as
idle)
3 D.G set – 125 KVA Silencers 3mts
4 D.G set – 75 KVA Silencers 2.5 mts

15. Emissions from chimneys – as per CFE / CFO order dt. 02-05-2007

Chimney Description of Chimney Quantity of Limiting Board Monitoring

No. Emissions Standard Data
at peak flow

1 Stack Attached to 16.5 1,80,586 115 109.72 mg/Nm3

MVA (3 TPH) submerged mg/Nm3
Electric Arc Furnace
2 Attached to 625 KVA + 75 --- 115 ---
KVA D.G sets mg/Nm3

16 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.
1 The industry shall file the water cess : The industry is filing water cess
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. Purpose Quantity

1 Cooling 100 KLD
2 Gardening / Irrigation 5 KLD
3 Domestic 5 KLD
Total : 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 Parameter Emissions
load.
No. Standards
1&2 SPM 115 mg/Nm3

4 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, Nox- generated 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.
7 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.
8 The industry shall comply with task force : The industry has provided heat
directions exchanger as a augmentation of air
pollution control equipment.
9 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
10 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.

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

S.
Condition Compliance
No.
--- ---
 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.
Condition Compliance
No.
1. Lot of fugitive emissions were observed : The industry has provided 3 tapping holes
during tapping operation of the furnace to the furnace, out of which the industry has
and the industry has not taken adequate closed the suction provided to the 3rd tapping
measures to control the fugitive emissions hole. The industry has provided M.S.sheet
2 The industry has made arrangement of : with a facility to roll on the angles on the
semi-closed hood near the tap hole to suck front side of the canopy to avoid escaping of
the emissions generated during taping fumes during tapping operations. It was
period. However, the suction was not informed that they will operate 2 tapping
effective and the emissions are drifting holes only in future and hence the suction
towards sides 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.
3 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.

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

S.
CREP Recommendations Compliance
No.
--- ---

20 Hazardous chemicals used and their storage facilities: Nil

21. HWA Details:

i) Particulars of Authorisation obtained under APPCB/KNL/KNL/467/HWM, dt:
HW(M&H) Rules, 2003 (No. & Validity date) 02-05-2007
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 As follows

and Stream No. as per HWM Rules, 2003

Sl. Name of the Stream Quantity of Mode of disposal

No. Hazardous waste Hazardous
waste per
annum
1. Used lead acid 22 of Schedule-IV 64 Nos. / 2 Return to
batteries years manufacturers /
dealers on buy back
basis
2 Process dust (Bag 13.1 of Schedule-1 4.0 MT/day Disposed to
filter Dust) authorized fly ash
Brick manufacturing
units
3 Waste oil / Waste 5.1 of Schedule-I 1.6 Kl/yr Re-processing /
Lubricant oils Recycling units
authorized by
APPCB.

v) 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.
vi) 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 – Silica dust, waste oil, lad acid
For recycle / reused - batteries

viii) Whether industry has submitted annual returns, No

date of latest submission.
ix) Whether industry has installed incinerator or No
sending to common HW Incinerator

x) Particular of own incinerator (if applicable) N.A

xi) 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 waste Effective collection

minimization and cleaner production.
xiv) Future plan for waste minimization. Not submitted

xv) Facilities available with, industry for waste ---

characterization.

xvi) Overall House Keeping within the factory premises. Needs improvement

xviii) Details of disposal of lead acid batteries along with 64 Nos. Are existing in the control
nos and agencies to whom they are disposed room, but not disposed so far.

22 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 : Complied

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.
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 Regional Officer’s Remarks:

I Compliance of the industry with

reference to Notifications under
E(P) Act & Rules.
The industry is generating about 4 TPD of
a) Fly Ash Notification.
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.
---
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 25-
04-2008 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 re-
commissioning.

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.