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FORM V (See rule 14)

ENVIRONMENTAL STATEMENT FOR THE FINANCIAL YEAR ENDING THE 31ST MARCH-2015

BMM Stage II - 2 MTPA Integrated Steel Plant:

PART A

i. Name and address of the owner: Mr. B.K. Ganesh Occupier of the industry Director & Occupier, Operation or process BMM Ispat Ltd, Danapura Tq- Hospet, Dist- Bellary. ii. Industry category Primary - (STC Code) Secondary- (STC Code) iii. Production category Units - DRI Plant : 4 x 500 TPD) Beneficiation Plant : 1.3MTPA Pellet Plant : 1.2 MTPA

Captive Power Plant : 1X70MW Captive Power Plant : 2x70 MW iv. Year of establishment: Aug 2011 v. Date of the last environmental statement submitted. : 14.08.2014

PART B

Water and Raw Material Consumption: Production during 2014-15 (1st Aril 2014 to 31st March 2015)

i. Water consumption in m3/A

Process:

Sl. No.

Unit Water consumption

1 DRI Plant 4,23,883 m3/A 2 Power Plant (1X70MW) 2,64,317 m3/A 3 Iron Ore Beneficiation Plant 4,05,832 m3/A 4 Pellet Plant 3,27,619m3/A 5 Power Plant (2X70MW) 2,55,645m3/A

Cooling : (included in the above list) Domestic : 21600 m3/A

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Specific water consumption

Name of Products

Process water consumption per unit of products

During the current financial year (2013-

14)

During the current financial year (2014-15)

DRI Plant 1.41 m3/ton 0.996 m3/ton Power Plant-1X70MW 0.70 Ltrs/KWh 0.66 Ltrs/KWh Iron Ore Beneficiation Plant

0.565 m3/ton 0.422 m3/ton

Pellet Plant 0.328 m3/ton 0.592m3/ton Power Plant-2X70MW 0.373 Ltrs/KWh 0.259 Ltrs/KWh

ii. Raw material consumption Name of Product

Name of raw materials*

Consumption of raw material per unit of output

During the previous financial year (2013-14)


DRI (4X500TPD) Iron Ore Iron ore pellet Coal Limestone Dolomite

0.09 1.41 0.94

0.04

0.07 1.45 0.98

0.047

Power-70MW Flue Gas from Kiln Coal Dolochar Rice Husk Bed material

0.237Kg/Kwh 0.038 Kg/Kwh 0.0001 Kg/Kwh 0.0008 Kg/Kwh

0.40 Kg/Kwh 0.059Kg/Kwh 0.0003Kg/Kwh 0.0018Kg/Kwh

Iron Ore Beneficiation

Iron Ore

1.008 1.34

Pellet Iron Ore concentrate Bentonite Limestone Coal Dolamite Furnace oil Coke

1.17 0.006 0.018 0.038 0.014 0.01

0.0084

1.19 0.007 0.019 0.037 0.016 0.002 0.0069

Power -2X70MW Flue Gas from Kiln Coal Dolochar Rice Husk Bed material

0.26Kg/Kwh

0.036 Kg/Kwh 0.003 Kg/Kwh

0.60Kg/Kwh 0.093Kg/Kwh 0.0012Kg/Kwh

0.00026Kg/Kwh * Industry may use codes if disclosing details of raw material would violate contractual obligations, otherwise all industries have to name the raw materials used.

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PART.C

Pollution discharged to environment/unit of output (Parameter as specified in the consent issued) Pollutants

Quantity of Pollutants discharged (mass/day)

Kg/day

Concentration of Pollutants discharged

(mass/volume)

Percentage of variation from

prescribed standards with

reasons

a. Water Zero Discharge of waste water

b. Air SID- kiln 1&2 73.4 kg/day 75 mg/Nm3 56.34 % Below SID- kiln 3&4 78.7 kg/day 74 mg/Nm3 53.18% Below Power Plant (70MW: WHRB 40MW & FBC 30MW)

148.2 kg/day 65 mg/Nm3 48.55 % Below

Beneficiation Plant Nil Nil Nil Pellet Plant 237.9 kg/day 43 mg/Nm3 60.35 % Below Power plant( 2X70MW)

506.9 kg/day 45 mg/Nm3 12.00% Below

PART.D

HAZARDOUS WASTES (as specified under Hazardous Wastes (Management & Handling Rules, 1989)

Hazardous Wastes Total Quantity (Kg) During the previous

financial year (2013-14) During the current financial

year (2014-15) 1.From Process Used Oil:

a) Power Plant -1x70MW

b) DRI plant

c) Iron Ore Beneficiation Plant

d) Pellet Plant

e) Power plant-2x70MW

Resin from DM Plant

2. From Pollution Control Facilities

3900 Lts /annum

1330.5 Lts /annum

4489.6 Lts /annum

NIL

6000 Lts /annum

NIL

4800 Lts /annum

2320 Lts /annum

6850 Lts /annum

2450 Lts /annum

7550 Lts /annum

NIL

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PART- E

SOLID WASTES: Solid Wastes

Total Quantity

During the previous financial year (2013-14)


i) DRI plant a. From process

Fly Ash /dust :53990 TPA Coal dust : 15000 TPA Dolochar : 38990 TPA

b. From Pollution Control Facility

Fly Ash /dust : 47250 TPA Coal dust : 12000 TPA Dolochar : 35250TPA

c. 1) Quantity recycled or re- utilised within the unit

2) Sold 3) Disposed/Stored

All the Qty. of Coal dust is reused in process. All the dolochar produced was utilised in CFBC boiler for power generation

47250 TPA

All the Qty. of Coal dust is reused in process. All the dolochar produced was utilised in CFBC boiler for power generation

53990TPA

ii) Power Plant-1X70MW a. From process --- b. From Pollution Control Facility

Fly ash – 16,762 TPA Fly ash –34864.49TPA Bed ash –3873.83TPA

c. 1) Quantity of recycled or re-utilised within the unit 2) Sold 3) Disposed

5,400 TPA

30,000 TPA

NIL

NIL

34864.49TPA

3873.83TPA iii) Beneficiation Plant a. From process Tailing – 1,59,493TPA Tailing –1,92,090 TPA b. From Pollution Control Facility

- -

c. 1) Quantity of recycled or re-utilised within the unit 2) Sold 3) Disposed/stored

- -

Stored in a tailing ponds iv) Pellet Plant a. From process - b. From Pollution Control Facility

Ash/dust -481 TPA Ash/dust - 600TPA


All the waste is reused in BP process

All the waste is reused in BP process

V) Power Plant 2X70MW a. From process Bed ash-300 tons Bed ash-400 tons b. From Pollution Control Facility

Fly ash –75000 TPA Fly ash –1,25,000TPA

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NIL

All fly ash were Sold to cement plant in closed containers

NIL

NIL

All fly ash were Sold to cement plant in closed containers

Bed ash is used for road making

& land fill

PART. F

Please specify the characteristics (in terms of concentration and quantum) of hazardous as well as solid wastes and indicate disposal practice adopted for both these categories of wastes. The fly ash generated in the power plant is being sold to cement industries for cement making through closed containers. Also the fly ash is being used for brick making, for which 2 Nos of fly ash brick manufacturing plants are in operation. Waste Oil is the source of Hazardous waste generation. The waste oil is scientifically collected and stored in barrels. It is propose to mix with furnace oil & use it in furnace, as fuel / smear on metal surface to avoid corrosion. Coal based DRI plants do not handle any hazardous chemicals (as stipulated in Manufacture, Impact & Storage of Handling, Chemicals Rules) nor generate any hazardous waste (Stipulated in Hazardous Waste Management & handling Rules)

PART.G

Impact of the pollution control measures taken on conservation of natural resources and consequently on the cost of production. The industry has concerns for Environment; it has spent Rs. 82.39Lakhs towards Pollution Control/monitoring maintenance & Rs.42.00Lakhs towards CAAQMS Equipment etc., during 2013-14. The industry has spent Rs. 40.0 Lakhs towards Green Belt Development and planted 60,000nos. trees during 2014-2015. Also spent 1.5 crores on the EMS & OHSAS Implementation activities. With regards to handling of fly ash, we are happy to inform that we have commissioned two units of Eco friendly “Automated Bricks/Blocks manufacturing unit”. Ash bricks of 2000 to 4000 No.s and blocks of 1200 per day are being manufactured.

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Water Conservation is practised by recycling/reutilising water from slime ponds and treated DM back wash, seepage recovery from reservoirs. Quantity of recycled/reutilised water is 3,30,000 Cum. Rain Water harvesting 35,000 cum.

PART-H

Additional measures/investment proposal for environmental protection including abatement of pollution. Environmental protection measures adopted are as per norms approved by KSPCB.

PART-I

Any other particulars in respect of environmental protection and abatement of pollution

BMM Ispat Ltd is taking care of all aspects of environment, like air, water noise pollution control etc.,

Water pollution control measures:

1. It is followed zero discharge policy and there is generation of effluent water.

2. Installed 3 nos. STP’s to treat the domestic effluent, one more STP is under construction.

3. Reduced fresh water consumption by 330 million liters of water in the year 2014, in the form

of recycling, reusing and rainwater harvesting etc.,

Air pollution control measures:

1. Installed 12 nos. of ESP’s for various processes and 45 nos. of DE-dusting systems for abating

dust emissions.

2. Installed Dry fog system at transfer chutes & conveyor transfer points.

3. Installed more than 150 nos. of water sprinklers on dumps, on conveyors etc.,

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4. Coal is obtained by Rail way wagons. The industry has provided Wagon Tripler and Dry fog system to arrest fugitive dust.

5. The coal is transported to different users point in closed Conveyer system. Dry fog system / Sprinkler Systems are provided at dust generation sources.

6. The Industry has provided barricades for iron Ore Storage Area on three sides.

7. Regular water sprinkling on unpaved roads.

8. Installed online stack emission monitoring to ensure the emission within the norms.

9. Installed 2nos. of CAAQMS station at the boundaries of the plant to ensure dust levels are

within the permissible limits.

10. Regular air quality monitoring to ensure dust free the work place environment.

Green belt development:

1. Own nursery to cater the sapling needs

2. Yearly 50,000 saplings have been developed and planted in the factory premises.

3. Till date 2,70,000 samplings have been planted.

Implemented EMS & OHSAS management:

1. Taken all the necessary requirements and executed works to implement EMS system like,

providing coloured bins, segregation wastes and it’s disposal, constructed hazardous waste

storage areas, scrap storage areas etc.,

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Green Belt Developments Photographs

Own nursery for development of saplings

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DUST EXTRACTION BY TRUCK MOUNTED

VACUUM OPERATED EQUIPMENTS

VACCUME OPERATED ROAD SWEEPING

MACHINE

WATER SPRINKLING SYSTEM AT SPONGE IRON FOGGING TYPE DUST SUPRESSION SYSTEM

ON RAW MATERIAL HEAP

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