sinter write up

Richardson & Cruddas (1972) Ltd. II-1

CHAPTER – I

INTRODUCTION

1.1 Preamble

The growth of steel industry significantly contribute towards economic

progress of the country. However, any steel industry progress brings along

with it a number of environmental problems. Many of these problems can be

avoided, if adequate environmental control considerations are thought of

during conceptual stage of the project. Once the industry is set up, it

becomes very costly to install pollution control equipment and implement

other environmental control measures, if the same are not considered in the

conceptual stage.

Any industry exerts both positive and negative environmental impacts.

Negative impact cause environmental degradation. It is the responsibility of

Planners, Scientists and Environmentalists to document these impacts

separately so that these can be identified, quantified and attempts may be

made to minimize negative impacts and maximize the positive impacts for

better development with least environmental degradation.

1.2 Background of M/s. BMM Ispat ltd

M/s BMM Ispat Ltd. (BMMI) is a company promoted by Mr. Dinesh Kumar Singhi,

proprietor of Singhi Group of companies in Bellary District, Karnataka State.

The Singhi group is a well known business group in the field of mining of iron

ore and the group is also operating a mini steel plant producing sponge iron,

TMT bars and electric power. The Group has sales turnover exceeding Rs 442

crore and has its mining operations in Bellary-Hospet-Sandur belt and mini

steel plant at Danapur, Hospet Taluk in Bellary district of Karnataka State.

The companies belonging to Singhi Group are

1) BMM Ispat Ltd., Danapur

2) HKT Mining Pvt Ltd., Danapur

3) Bharat Mines and Minerals, Bellary


These companies are growth centres in the field of iron ore mining and

manufacture of TMT bars and pellets.

Mining

BMM group is in the Business of mining of iron ore and exporting

approximately 2.50 Mt/yr of iron ore. BMM Group is working in three Iron

ore lease areas in Sandur Taluk, Bellary District having all statuary clearance

to produce totally 3.6 mt/yr of iron ore. They have applied for lease for

mining in additional area and the acquiring process is in progress. All the

existing mines are well connected by rail to steel plants, ports etc.

HKT Mining Pvt. Ltd

The promoters of BMM Group are the promoters of HKT Mining Pvt. Ltd. HKT

have set up sponge iron plant, induction furnaces and rolling mill and as on

date are running the plant with all statuary clearances.

BMM Ispat Ltd

BMM Ispat Ltd. have established pellet plant, power plant and beneficiation

plant adjacent to the above HKT plant near Hospet and are running these

plants with all statuary clearances.

Overseas Venture

In addition, BMM group have acquired coal mine deposits over 3696.57 Ha in

Tanah Groqet province in Indonesia.

BMMI intend to put up a 2.0 Mt/yr integrated steel plant to produce rolled

steel products and BF slag based cement. The power requirement for the

steel plant will be met by captive power plant.


1.3 Present Project Proposal

Manufacturing Units Unit Capacity

Iron ore beneficiation plant Mt/year 3.4

Pelletization Plant Mt/year 1.20

DRI Plant Mt/year 0.7

Coke ovens Mt/year 0.8

Sinter plant Mt/year 2.5

Blast furnace Mt/year 1.7

EAF & BOF steel making Mt/year 2.3

Continuous casting machines • Slab Caster • Billet caster

Mt/year 1.10 1.10

Rolling Mills • Hot strip mill • Structural / wire rods

Mt/year

1.00 1.00

Oxygen Plant t/year 2x500

Calcining kilns t/year 1080

Cement Plant Mt/year 1.4

Power Plant MW 230

Estimated Investment : Rs. 6151.3 Crores

Project Completion Target : September 2012

1.4 Importance of the Proposed Project

Steel is the material of choice for industrial applications due to its high

specific strength and relatively low cost per unit weight. Present per capita

steel consumption in India is around 39 kg as compared to per capita steel

consumption of around 500 kg to 700 kg in countries like Japan, EU

Countries, South Korea, USA etc. Even Brazil, Mexico and China have per

capita consumption of around 110 kg to 150 kg and the world average is

about 150 kg.


Steel is made through Blast Furnace/Basic Oxygen Furnace Route (BF-BOF-

CC) or Sponge Iron/Electric Arc Furnace Route (DR-EAF-CC). Principal raw

material in BF route is iron ore lumps/sinter and in DR route iron ore

lumps/pellets. Depletion of high grade iron ore reserves and metallurgical

coal reserves, environmental concerns in coke making, sinter plant and blast

furnace have forced the industry to look into steel making through EAF

route. Shortages, quality and price fluctuations of steel scrap and

availability of huge quantities of non coking coal have led to increase in DRI

capacity.

Domestic Steel Demand Projection

In India, apparent consumption of steel increased from 14.8 million tonnes

in 1991-92 to 43.5 million tonnes in 2006-07.

Production of steel

As per the National Steel Policy - 2005 of Govt. of India, the demand-supply

scenario for steel upto 2020 is as given below:

National Steel Policy of Government of India have considered growth rate of

7.3% per annum. The actual growth of consumption during 2005-2006,

according to Steel Ministry, was 13.88%. Even if we assume a lower growth

rate of 10% per annum, the demand for the year 2014-15, it will be 97.67

million tons.

In terms of crude steel, the demand works out 105.5 million tons for 2015.

Production of crude steel during 2005-06 was 42.1 million tonnes. It can be

seen from the above that demand is likely to be more than double in the

next ten years.

Though a number of green field steel plants have been announced, because

of various constraints, there is likely to be delay in creation of new

capacities. Thus the supply side may not meet the growth in domestic

demand.


Based on the assessment of steel market (considering the boom in

construction sector and industrial applications) and the resources available

to the promoters, it is recommended to set up a 2.0 Mt/yr integrated steel

plant with flat (hot rolled coils and plates) and non flat products (TMT/wire

rods and Structural) in equal amount.

Demand for cement

Boom in the construction activities and infrastructure development have

lead to increased demand for cement. It is also in great demand in the

neighbouring countries like those in the gulf region and Far East. Hence, it is

proposed to convert the entire blast furnace slag into cement and produce

about 1.4 million ton per annum of cement.

Thus the proposed steel plant will facilitate in catalyzing the development

of small-scale industries around it. These may be spares and metal based.

These will be complimented by the service units. The project is also

expected to serve as center of significant small-scale industrial economy

around it. This is expected to play a major role in the future economic and

social development of this area.

1.5 Rationale for choice of Mariammanahalli hobli for Location of BMM

Ispat Complex

The Karnataka state Govt. have recommended for approval to establish

2.0 MT/YEAR integrated steal and Power plant in the State High Level

Clearance Meeting ( SHLCC ) Held on 21.08.2008 ( given in Annexure-I –

Sanction and Approvals).

Raw material availability at competitive price around the proposed

project.

Nearer to the allotted mine to BMM Ispat (25–30 Km from the proposed

industry).

Port facilities at Chennai, Krishnappattanam, Mangalore and Goa which is

well connected by rail route.


Tungabhadra river water availability (within 5 km)

Railway facilities within 1 km .

Availability of sufficient land to cater to all needs of integrated steel

industry.

Availability of skilled man power.

Mega industries/projects are eligible for exemption from entry tax (for

machinery and equipment during the project implementation).

Reduction of stamp duty and registration charges.

KPTCL, Kalyan steels, Kirloskar, JSW Steel & other Thermal power plants

near to the proposed site of BMM ISPAT LTD.

CBSE/ICSE schools, Engineering Colleges, Training Institutions, Hospitals,

etc. are at 12 – 15 km radius of the BMM Ispat.

1.6 Environmental Clearance

Environmental Impact Assessment (EIA) and Environmental Management

Plan (EMP) have been considered as the most important tools / documents

which can be utilized by the project proponent and Government Regulating

Agencies and Public to clearly understand the environmental implications of

the proposed project with respect to the overall developmental plan and to

take decisions in the interest of environment and the national economy. It

also helps to analyze the techno-environmental feasibility of the proposed

project. The corporate policy of BMM Ispat Ltd. requires Environmental Impact

Assessment (EIA) to be carried out for all new projects. This is primarily to

ascertain, beforehand the potential impact areas of the proposed project and

initiate necessary corrective actions at the design stage itself as well as the

appraise the environmental protection regulating authorities for issuing

Environmental Clearance for the project, as required under the relevant

provisions of Environment Protection Act, 1986, Rules and EIA Notification 2006.


1.7 Scope of the study

The present EIA and EMP report for BMM Ispat Ltd., Bellary has been

prepared based on the following TOR provided by MoEF and the existing

guidelines of CPCB and Generic structure of Environmental Impact

Assessment Document as per EIA Notification 2006.

1. Present land use should be prepared based on satellite imagery.

2. Location of national parks / wildlife sanctuary within 10 km. radius

should specifically be mentioned.

3. Permission and recommendations of the State Forest Department

regarding impact of proposed expansion on the surrounding reserve

forests viz. Hospet RF (4 Km), Nandibanda RF (4 Km) and Sandur RF (4

Km) should be included.

4. Permission from the Railway Department, if any, should be included.

5. Actual land requirement, classification of land, acquisition status,

rehabilitation and resettlement, if any, as per the policy of the Govt. of

Karnataka should be incorporated.

6. Status of environmental clearance for the captive mines and copies of

the letters should be included.

7. Clearance from the Railway Department regarding location of the

project should also be included.

8. Site-specific micro-meteorological data using temperature, relative

humidity, hourly wind speed and direction and rainfall should be

collected.

9. A list of industries containing name and type in 25 km radius should be

incorporated.

10. Residential colony should be located in upwind direction.


11. List of raw material required and source should be included.

12. Fuel analysis, quantity of fuel required, its source and transportation.

13. Manufacturing process details for all the plants proposed should be

included.

14. A chapter on type and details of coke oven plant including pollution

control methods should be included.

15. Type of coke oven and full details and justification for installing non-

recovery type of coke oven should be included.

16. One season ambient air quality data (except monsoon) at 8 locations

within the study area of 10 km., aerial coverage from project site with

one AAQMS in downwind direction should be carried out. The monitoring

stations should take into account the pre-dominant wind direction,

population zone and sensitive receptors including reserved forests.

17. Coordinates of the plant site as well as ash pond with topo-sheet.

18. Details of all kind of fuel to be used and its impact on the ambient air

environment should be included.

19. The suspended particulate matter present in the ambient air must be

analysed for the presence of poly-aromatic hydrocarbons (PAH), i.e.

Benzene soluble fraction. Chemical characterization of RSPM and for

incorporating of RSPM data.

20. Impact of the transport of raw material and finished product on the

transport system should be assessed and provided.

21. Determination of atmospheric inversion level at the project site and

assessment of ground level concentration of pollutants from the stack

emission based on site-specific meteorological features. Air quality

modeling for steel and cement plant for specific pollutants needs to be

done.


22. Plant-wise air pollution control measures proposed for the control of

gaseous emissions from all the sources should be incorporated.

23. A note on control of fugitive and secondary emissions from as per CPCB

guidelines from all the sources should be incorporated.

24. One season data for gaseous emissions during winter season is necessary.

25. Impact of the transport of the raw materials and end products on the

surrounding environment should be assessed and provided.

26. Alternate modes of transportation of coal for the project should be

examined and their relative merits and demerits in terms of

environmental impacts should be provided.

27. Permission for the drawl of 3,850 m3/day water from Tungbhadra Dam

and ground water sources from the concerned department and water

balance data including quantity of effluent generated, recycled and

reused and discharged should be provided. Methods adopted/to be

adopted for the water conservation.

28. Surface water quality of nearby rivers and dam (60 m upstream and

downstream) and other surface drains at eight locations must be

ascertained.

29. Ground water monitoring minimum at 8 locations and near solid waste

dump zone, Geological features and Geo-hydrological status of the study

area are essential as also. Ecological status (Terrestrial and Aquatic) is

vital.

30. A note on treatment of wastewater from different plants including coke

oven plant, recycle and reuse for different purposes should be included.

31. Action plan for solid/hazardous waste generation, storage, utilization

and disposal particularly tailings, slag, char and fly ash. Assurance that

100 % char will be used in the FBC boiler and copies of MOU regarding

utilization of ash should be included.


32. A write up on use of high calorific hazardous wastes in the kiln should be

included.

33. Detailed plan of ash utilization / management, evacuation of ash, ash

pond impermeability and whether it would be lined, if so, details of the

lining etc. and MOU signed with the Cement manufacturers for utilizing

granulated BF slag should be included.

34. Generation and utilization of waste/fuel gases from BF plant and their

utilization in the CPP have to be set out.

35. Risk assessment and damage control needs to be addressed.

36. Occupational health of the workers needs elaboration.

37. Green belt development plan in 33 % area and a scheme for rainwater

harvesting have to be put in place.

38. Socio-economic development activities need to be elaborated upon.

39. A note on identification and implementation of Carbon Credit project

should be included.

40. An Action Plan for the implementation of the recommendations made for

the Steel and Cement Plants in the CREP guidelines must be prepared.

41. Total capital cost and recurring cost/annum for environmental pollution

control measures should also be included.

42. A tabular chart for the issues raised and addressed during public

hearing/public consultation should be provided.

43. Any litigation / court case pending against the proposal should also be

included.

1.8 Report Format

The project report covers

Introduction

Project Description

Description of the environment


Anticipated Environmental Impacts and Mitigation measures.

Environmental monitoring programme.

Additional studies

Project benefits

Environmental impact statement

Environment management plan.

Summary and Conclusion

Consultant Credentials


CHAPTER II

PROJECT DESCRIPTION

2.1 Preamble

BMMI are intending to install a 2.0 Mt/yr integrated steel plant, of which

1.0 Mt/yr will be hot rolled coils and the balance will be non flat products

like TMT/wire rods and structural. The former will be produced in a hot

strip mill and the latter in light structural mill/ bar and rod mills.

BMMI are also intending to install a cement plant to use the granulated blast

furnace slag. A power plant will be set up to utilize the waste heat in the

DRI kiln off gases.

2.2 Location of the proposed plant and accessibility

The proposed plant is located in Mariammanahalli hobli, Bellary (Dist.),

Karnataka. (The latitude and longitude of the project site is 15°5’ - 15°10’N

and 76°22’ – 76°27’E respectively in the Topo sheet no 57A/8. The proposed

plant area is surrounded by various industrial Units and iron ore mines. The

location map is shown in Fig 1.1 & Fig 1.2. The accessibility and

surroundings of the project site are as follows:

Nearest State Highway : Bellary – Hospet (1.2 km) Nearest Habitation : Dhanapura village (2.0 km) Nearest major Railway Station: Hospet (15.0 km) Nearest Industry : i) HKT Mining

ii) BMM spat Archaeological Importance : None within 10 km radius Environmental Sensitive Area: None within 10 km radius Nearest Surface Water Body : i) TB Dam (5 km)

ii) Danayanakere (1 km) iii) Gunda Kere (1/2 Km)

Altitude 1180 feet above MSL Max. day Temperature 44oC Min. day Temperature 18oC Max. Relative Humidity 86% Min. Relative Humidity 41% Annual Rainfall 760mm (Avg. 10 years) Topography Undulated Historical places None within 10Km radius


2.3 Environmental Sensitivity

Sl. No. Areas Name

Aerial Distance

from (in km) 1. National Park Nil —

2. *Sanctuary / Tiger Reserve/ Elephant / any other Reserve

1. Gunda Reserve Forest 2. Nandibanda Reserve Forest 3. Ramgad Reserve Forest

4 km 7 km 4 km

3. Core Zone of Biosphere Reserve Nil —

4. Habitat for Migratory Birds Nil —

5. Archaeological Sites (i) Notified (ii) Others

Nil —

6. Water Bodies TB Dam 5.00

7. Defense Installation Nil —

8. Industries / Thermal Power Plants / Mines

Industries

Kirloskar Ferroys Ltd. Kalyani Steel Ltd. Hospet Steel Ltd. Ultratech Cements

10.0 9.0 10.0 10.0

Mines MSPL S.P. Minerals Other Mines (10 Nos.)

4.0 4.0

10 km radius

9 Airports M/s. Jindal Southwest 25

10 **Railway Lines Hospet – Swamihalli (Iron ore loading station only) 0.03

11 National / State Highways NH – 13 1.0

* Three Reserved Forest are situated within 10 Km radius of the proposed site and the permission and recommendations obtained from the State Forest Department for setting up of integrated steel plant is given in Annexure 1– Sanctions and approvals.

** The permission obtained from Railway department is given in

Annexure 1 – Sanctions and approvals.


Fig.II.1 Location Map Bellary District


Fig. II.2 Location Map of Project Site


2.4 Resources / Infrastructure Requirements

2.4.1 Raw Materials

The Bellary district is well known for its availability of its low and high

grade iron ore. BMM Ispat group is having iron ore mines with a production

capacity of 250 MT/year. The environmental clearance obtained for the

above capacity is given in Annexure I - Sanctions and approvals. BMM have

already applied for lease for mining in additional area and acquiring

process is in progress. The raw materials required are given in Table 2.1.

Table – 2.1 List of Raw Materials

Raw material Quantity Mt/year Source

Low grade iron ore fines 4.4 Captive mines and from indigenous sources

Iron ore pellets 0.43 Indigenous source Bentonite 0.008 Indigenous source Non coking coal 1.243 Imported Coking coal 0.92 Imported Limestone 0.53 Indigenous source Dolomite 0.34 Indigenous source Quartzite 0.13 Indigenous source Clinker 0.73 Indigenous source Gypsum 0.04 Indigenous source

• While coking coal and non coking coal will be imported, all other materials are available indigenously.

2.4.2 Water requirement

The total water requirement will be about 3881 m3/hr. The Government of

Karnataka has already allotted 22 MGD of water from downstream of TB dam

and Almatti dam for the proposed project. The permission obtained for

drawl of the required quantity of fresh water is given in Annexure 1-

Sanctions and approvals. The quantities of water required for various units

of integrated steel plant and effluent generated are presented in Table 2.2.


TABLE 2.2 Water requirement and Effluent generation Unit :

m3/hour

Plant unit Total water

Re-circulated water Make-up water Process loss Blow down

Iron ore beneficiation plant 7300 7123 177 171 6 Iron ore pelletising plant 1800 1747 53 45 8 DR plant 4610 4372 238 233 5 Coke plant 2200 2067 133 120 13 Iron ore sintering plant 6950 6822 128 128 0 BF plant 8880 8370 510 452 58 Steel melting shop 3870 3676 194 150 44 Continuous casting machines shop 800 718 82 66 16 Calcination plant & oxygen plant 5130 4976 154 139 15 Rolling mill 27520 26687 833 719 114 Power plant 51500 50350 1150 830 320 Cement plant 300 291 9 8 1 Drinking & sanitation 100 100 100 Evaporation & other losses 120 120 120 0 Total 121080 117199 3881 3281 600 Blow down water use Green belt maintenance 400 Dust control in raw materials yard 200


Total 600


2.4.3 Land requirement

The government of Karnataka has already allotted 3530 acres of land in

Danapura, Nagalapura, Danayana kere and Garaga villages in Hospet Taluk in

Bellary district and acquisition of land is in progress. The details of land

required for each unit is furnished in Table 2.3. The Lay-out plan is given in

Figure II.3.

TABLE 2.3 LAND-USE IN CORE ZONE

Sl. No Land description

Area in Hectare

% of Land requirement

1 Factory

Raw materials Storage Yard

• Lime stone • Dolomite • Coal • Iron Ore

1.00 3.00 10.0 3.0

Beneficiation plant

12.0

Pellet plant

12.0

Sinter Plant

10.0

DRI Plant

10.0

Blast Furnace

40.0 16.50

SMS

6.0

Calcination Plant

2.0

Oxygen plant

1.0

Rolling mill

20.0


Power plant

4.0

Cement Plant & Grinding unit

18.0

Coke oven plant

26.0

Admin. Complex & Health Centers

2.0

Repair shop & Central stores

2.0

Landscaping, Garden and Tree curtains

54.0

2 Housing Colony 40 2.80 3 Water storage area 350 24.50 4 Roads & Railway station 121 8.50 5 Dump Yard 210 14.70 6 Green Belt 472 33.00 Total 1429 100.0


Fig. II.3 Layout plan


2.4.4 Power requirement

The energy requirement for various units is given in Table 2.4.

TABLE - 2.4 ENERGY REQUIREMENT

Manufacturing Units Power Consumption (MW)

Ore Beneficiation plant 7.5

Pelletising Plant 7.5

DR Plant 11.4

Coke ovens 4.8

Sinter plant 9.6

Blast furnace 28.9

Steel Making (EAF,BOF&LRF) 73.3


5.6

Rolling Mills • Hot strip mill • Structural/ wire rods

37.0

Auxiliaries ( Oxygen Plant, Calcining kilns etc.)

12.0

Cement Plant 11.4

Power Plant 21.0

Total 230

The annual electrical energy consumption in the plant is estimated to be

about 1740 million units. The average demand of the plant is estimated to be

230 MW. It is proposed to meet the entire requirement of electric power from

captive sources taking the support of State Electricity grid for stability. Power

generation will be effected by recovering the heat from waste gases from the

DR kilns and non recovery coke ovens and by firing coal and char from the kiln

discharge in suitable boilers. The purchased/ generated power will be

stepped down to 6.6 kV. The 6.6kV Switchgear will distribute power to the

6.6 kV motors and also to the LT substations located at load centers.

Provision will be made to sell the surplus power if any through the grid.

2.4.5 Fuel requirement


The fuel requirement and sources of availability are as follows.

Production unit Fuel Quality Quantity

Pelletising plant Non coking coal Ash < 12%, VM 25 – 30%, Sulphur < 0.6%

0.048 Mt/year

DR plant Non coking coal Same as above 0.55 Mt/year

Sinter plant Coke breeze Ash < 15%, VM < 1%, Sulphur < 0.6%

0.137 Mt/year

BF coke Ash < 12%, VM < 1%, Sulphur < 0.6%

0.686 Mt/year

BF plant Non coking coal Same as that for

pelletising plant 0.257 Mt/year

Power plant Non coking coal Same as that for pelletising plant

0.3 Mt/year

Rolling mills Furnace oil Sulphur 3% (max) 100,000 kl/yr

Calcining units Furnace oil Sulphur 3% (max) 30 kl/yr

The source and mode of transportation of the fuels is indicated below:

Fuel Source Mode of transportation

Non coking coal Imported By sea to Indian port and by rail thereafter

BF coke Coke plant By conveyor

Coke breeze Coke plant By conveyor

Furnace oil From Indian public sector oil companies

By road


2.4.6 Manpower requirement

The manpower required for the proposed integrated steel plant, cement

plant and Captive power plant are indicated below. A residential colony

with 500 quarters will be set up in the up wind direction of the plant site.

Adequate treated drinking water supply and sewage treatment system will

be established.

S.No Category Nos.

1 Managerial 340

2 Supervisory 1070

3 Skilled 2680

4 Unskilled 510

Total 4600

2.4.7 Construction materials requirement The details of chief construction materials are given below.

Sl.No. Materials 2 MT/YEAR

1 Coarse Aggregates (m3) 138,000

2 Sand (m3) 67500

3 Reinforcement 0-015 MT

7 Cement 0-06 MT

2.5 Details of Manufacturing Units

It is proposed to provide a iron ore beneficiation which can convert low

grade iron ore into a high grade concentrate to feed the pellet plant and

sinter plant. Depending on the characterization of the ore gravity and

magnetic separation methods will be employed to beneficiate the ore. Non

recovery type coke ovens plant will be installed to supply coke to blast

furnaces and coke breeze to sintering plant. The sensible heat in the coke

ovens gas will be used for power generation. A 230 MW captive power

generation using coke oven gases, DRI kiln gases and coal is proposed. A

pellet plant is proposed to manufacture pellets, which would be used to


feed DR plant and replace lump iron ore in the blast furnace burden. Sinter

plant will supply fluxed sinter to the blast furnace and will aid in achieving

high productivity. Sinter plant will be supplied with high grade iron ore

concentrate from the beneficiation plant. Liquid iron or hot metal, as it is

known in steel industry, will be produced in highly energy efficient blast

furnaces, where coal dust injection will be practiced to reduce the

requirement of metallurgical coke.

Two options are available for steel making, electric steel making and oxygen

blown steel making. The former is electrical energy intensive and needs

solid charge at least partially while the latter can accept wholly liquid

charge and widely employed in large capacity integrated steel plants. Both

the process routes are considered to produce liquid steel and feed the

continuous casting machines. The feed to the hot strip mill will be slabs and

to non flat rolling mills, it will be billets. These will be produced in

universally accepted continuous casting machines to reduce casting losses

and for automated production as against ingot casting. The rolling mill will

be designed to produce both flat and non flat products utilizing the state of

the art technology. Granulated slag from Blast furnace, clinker, gypsum and

coal are used for manufacturing of Portland cement. A schematic process

flow diagram of integrated steel complex is presented in Fig II.4.


Fig. II.4 Schematic process flow diagram – Integrated Steel Plant


2.5.1 Iron Ore beneficiation plant

The route adopted for beneficiation in the proposed plant is a combination

of gravity separation in spirals and magnetic separation in low intensity

magnetic separator and high gradient magnetic system.

Iron ore fines of minus 10 mm size will be ground to the liberation size in

grinding mills and pressure rolls. The ground ore will be stored as slurry in a

buffer tank.

The ground ore will be subjected to low and high intensity magnetic

separation to recover the magnetite and hematite part of the ore. The size

of the ore fed to high intensity magnetic separation will be restricted to

below 45 microns by screening and regrinding.

The concentrate from magnetic separation will then be dewatered in filters

to ensure that the moisture in the product will be low enough for

pelletising. The water reclaimed will be clean enough to be recycled back to

plant directly.

The tailings will be first dewatered in hydro cyclones and then treated in

thickeners for water recovery. The thickener sludge will be filtered to

recover water and the solid waste will be transported in trucks to the dump

area. The beneficiation plant will treat about 4.4 Mt/yr (dry) of iron ore and

produce 3.2 Mt/yr of concentrate and 1.2 Mt/yr of tailings.

The schematic flow sheet of beneficiation plant is given in Fig. II.5.


Fig. II.5. Bbeneficiation plant - Schematic flow sheet


2.5.2 Pellet Plant

There are two principal process steps for the production of pellets. The first

step is the formation of green balls. Fine grained iron ores having adequate

size distribution are rolled with a binder and wetting agent in suitable

devices such as discs. In this way, wet balls are formed. These are called

green pellets. During ball formation, a binder like bentonite is used.

Additives like limestone may be added for changing the metallurgical

properties of the indurated pellets.

In the second step, the green pellets are dried and indurated to obtain the

typical features of pellets. This is achieved, in most cases, by careful

heating under oxidizing atmosphere to just below the softening point of the

ore used. During heating, not only the crystalline structure is changed, but

also other bonds appear such as reaction between slag forming constituents

– both between each other and with iron oxides. The hot pellets are

carefully cooled in order to maintain as far as possible the resulting

crystalline and other bonds as well to avoid tension cracks.

It is proposed to adopt the grate - kiln process in the pelletising plant. The

plant is rated to produce 1.2 Mt/yr of pellets.

The induration or heat hardening process for the pellets can be divided into

four distinct stages – Drying, Preheating, Firing and Cooling. In the grate kiln

process, these stages are separate and will be carried out in three separate

machines - drying and preheating on the traveling grate, firing in rotary kiln

and cooling in annular cooler.

Each unit is designed to withstand mechanical and thermal stresses imposed

by activities to be carried out in the unit. At the end of the grate machine,

the pellets will be sufficiently hardened to withstand the impact of fall from

grate machine into the kiln. The hot air from the cooler will go through

ducts into grate machine for drying and preheating.

The pre heated pellets will drop into the rotary kiln. The pellets will move

through the rotary kiln towards the discharge end where coal fired burner


will be provided. Hot air from annular cooler will be sent to the kiln and

grate. Pulverized coal will be injected into the kiln together with hot air

from cooler. In the kiln, the temperature of the preheated pellets will be

raised to about 1300°C. The fired pellets will be discharged through a

bunker onto the cooler.

The pellets will be cooled in an annular cooler. The pellets are cooled to

less than 100°C. The cooled pellets will be collected on a heat resistant belt

conveyor and transported to product storage.

Coal pulverizing unit will receive coal from the storage yard and store in a

bunker upstream of the coal pulverise. Ground coal will be stored in a bin

and from there injected into the kiln.

Since iron ore concentrate is the feed to the proposed pellet plant, the

plant proper will start from iron ore concentrate storage.

The hourly material balance for the pelletising plant is indicated below:

Input, t Output, t Iron ore concentrate 157.5 Iron ore pellets 150.0 Bentonite 1.1 Process losses 5.3 Coal 6.0 Dust recycled 9.2 Dust loss 0.1

Total 164.6 Total 164.6

The schematic process flow chart of Pellet plant is given in Fig.II.6.


Fig. II.6 Schematic Process Flow sheet – Pellet plant

Proportioning and Mixing

Iron ore Concentrate

Dust

Balling & Sizing

Drying & Prehealing

Firing

CoolingHot Air

Pellets To Storage

Water

Under Size Pellets

Over size Pellets

Green Balls

Gas Exhaust ESP

Dust

Stack

Grinding

Hot Air

Coal


2.5.3 DRI

Sponge iron is the product of solid state reduction of iron ore. It is also

known as directly reduced iron or DRI. The process of manufacturing sponge

iron or DRI is known as DR process. These processes can use gaseous or solid

fuels for supply of heat and reducing gases. Coal based direct reduction

process using rotary kiln for reduction is proposed for this project.

One of the advantages in coal based DR processes is that it uses abundantly

available non coking coal and the heat in the flue gases from the reduction

kiln can be used for generation of electric power.

In the Coal based direct reduction process, a refractory lined rotary kiln is

used for reduction of iron ore in solid state. The size depends on the

production capacity of kiln. The kiln is mounted with a slope of 2.5%

downwards from the feed end to the discharge end. A central burner

located at the discharge end is used for initial heating of the kiln. Sized iron

ore is continuously fed into the kiln along with coal. Small quantities of

limestone/dolomite are added to absorb sulphur from the coal. A number of

air tubes are provided along the length of the kiln. Air is introduced through

these tubes axially in the free space over charge. The desired temperature

profile is maintained by controlling the volume of combustion air through

these tubes. The rotary kiln is broadly divided into two zones namely, the

pre-heating zone and the reduction zone. The pre-heating zone extends

over 40 to 50 percent of the length of the kiln. In this zone, the moisture in

the charge is driven off, and the volatile matter in the coal, liberating over

a temperature range of 600° C to 800° C, is burnt with the combustion air

supplied through the air tubes in the free space above the charge. Heat

from the combustion raises the temperature of the lining and the bed

surface. As the kiln rotates, the lining transfers the heat to the charge.

Charge material, preheated to about 1000°C enters the reduction zone.

Temperature of the order of 1050° C to 1100° C is maintained in the

reduction zone for reducing iron oxide to metallic iron.


The established kiln sizes for production of sponge iron are 100 t/d, 350 t/d

and 500 t/d. Four 500 t/d kilns will be employed to produce DRI.

The main production units of the DR plant are

• Coal and flux preparation unit

• Day bins building

• Kiln and cooler area

• Product separation unit

• Gas handling system

Iron ore pellets will be delivered to the day bins from the pellet plant by a

group of conveyors. Coal will be received in – 150 mm size from the coal

storage area. It will be screened in a primary screen to separate out – 50

mm fraction. The + 50 mm fraction will be sent to an impact crusher

working in closed circuit with the screen, for reducing the size to below 50

mm. The – 50 mm fraction will be ground to – 20 mm size in a double roll

crusher operating in closed circuit with a screen, for reducing the size to

below 20 mm. This coal will be conveyed to the day bins building where it

will be screened into three fractions, coal fines, coarse coal and feed coal.

There are two bins for feed coal and one each for coarse coal and coal fines

in each row.

Weigh feeders will be used to proportion ore, feed coal and dolomite

charged to the kiln from the feed end. Injection coal will be injected into

the kiln from the discharge end with the help of compressed air supplied by

the lobe compressor. There will be two rows of bins in day bins building,

each feeding two kilns.

The raw materials will be charged into the rotary kiln from the inlet end by

means of a feed tube. The rotary kiln is of 4.3 m in diameter and 72 m long

An AC step-less speed variable motor will rotate the kiln at 0.2 to 1.0 rpm.

Due to the inclination and the rotary motion of the kiln, the material will


move from the feed end of the kiln to the discharge end in approximately 10

to 12 hrs. The fine coal will be blown from the discharge end of the kiln to

maintain the required temperature and the carbon concentration in the

bed. The kiln has eight shell air fans mounted on the top which will blow air

in the respective zones to maintain the required temperature profile. The

material and the hot gasses move in the counter current direction; as a

result of which the iron ore gets pre-heated and gradually reduced by the

time it reaches the discharge end.

The hot material, after the reduction is complete, will be transferred to the

rotary cooler via the transfer chute. The cooler is 3.2 m in diameter and 44

m long. It will be rotated at 1.4 rpm. The water will be sprayed on the top

of the shell which will cool the material inside the cooler indirectly. The

material cooled to 80° C will discharge on a belt conveyor by a double

pendulum valve. This valve acts as the seal for the prevention of the

atmospheric air into the kiln cooler system. The total kiln cooler system is

kept under positive pressure of about 0.3–0.5 mbar. This prevents the

atmospheric air from getting into the system. The kiln has to be always

operated on positive pressure as any leakage into the system will cause the

re-oxidation of the sponge iron.

In the product separation building, double deck screen will separate the

cooler discharge into 0-3 mm and 3-20 mm and +20 mm size fractions. The

+20 mm fraction will be diverted to the sponge iron bin. The 0-3 mm sized

fraction will be fed to a drum type magnetic separator where the sponge

iron fines and the dolochar will get separated and will be fed to the

respective bins through the chutes and conveyor. The 3-20 mm fraction will

be similarly separated by another magnetic separator and fed to respective

bins. This magnetic fraction will be sponge iron lumps and the non-magnetic

will be char, which is the unburnt coal. This char will be used in the power

plant.

The gasses, which flow counter current to the material flow, will go to the

dust-settling chamber where the heavier particles settle down. These


particles are continuously removed by the wet scrapper system. The gases

then pass to the after burner chamber where the residual carbon or carbon

monoxide are burnt by the excess air available. The gases at high

temperature will be sent to waste heat recovery boiler. The gas, after it

looses heat in boiler unit, will be cooled and then cleaned in electrostatic

precipitators and let into the atmosphere at about 120 deg C through the

chimney. Alternatively the hot gases can bypass the boilers and get cooled

in gas conditioning towers before they are sent to the electro static

precipitator.

The gases from the DR kilns will be used to generate steam in waste heat

recovery boilers. Each kiln will have one boiler. The steam generated will be

used to drive a turbo-generator and supply power to the plant.

The hourly material balance for the DR plant is indicated below:

Input, t Output, t Iron ore pellets 137.7 DRI 95.0 Non coking coal 71.3 Process losses 76.3 Dolomite 2.9 Char 28.5 Dust recovered 12.0 Dust loss 0.06


The schematic process & flow chart of DRI plants are shown in Fig. II.7.


Fig.II.7 Schematic process flow chart - Sponge Iron Plant

GCT – Gas Conditioning Tower


2.5.4 Coke oven Plant ( Non recovery type )

Metallurgical coke is a strong, porous, carbonaceous material which is

produced by the destructive distillation of coking coals in refractory

chambers called coke ovens or carbonization chambers. Over 90 percent of

the world's oven coke production is used for the manufacture of liquid iron

by the blast furnace process.

Coke influences most the economy of iron making in a blast furnace. In

India, over sixty percent of the cost of producing hot metal is on account of

coke alone. The cost of coke is determined by the coking coal price and

conversion cost at the coke ovens. Coal prices have substantially gone up

recently and there is a strong need to economize on coke making

operations. In addition, the demands to produce better quality coke are

becoming greater, not with-standing the scarcity of premium quality coking

coals. In this context, the prime objectives of coke making are:

• To produce coke of the best possible quality with available coals

• To maximize throughput of coke

• To minimize conversion cost

• To produce byproducts of desired quality with little environmental

pollution

The two proven processes for manufacturing metallurgical coke are the

beehive process and the byproduct process. In the beehive process, air is

admitted to the coking chamber in controlled amounts for the purpose of

burning therein, the volatile products distilled from coal to generate heat

for further distillation. In the byproduct method, air is excluded from the

coking chambers, and the necessary heat for distillation is supplied from

external combustion of some of the gas recovered from the coking process,

or in some instances, cleaned blast furnace gas or a mixture of coke oven

and blast furnace gas. With modern byproduct ovens, properly operated, all

the volatile products liberated during coking are recovered as gas and coal

chemicals.


While the beehive process was the first leading method for manufacture of

coke, the byproduct process has gained wider acceptance and replaced

beehive units. Of late, a modification of the beehive technology, known as

non-recovery ovens, is gaining prominence especially as a low-capacity

economical coke producing unit.

During carbonization, a part of the initial charge of coal is evolved as mixed

gases and vapors. In non recovery type ovens, these are burnt to supply heat

to the process. Excess heat in flue gases is recovered in heat recovery

boilers and used to generate electric power. This process is considered for

the BMMI project.

Stamp charging is a process where the entire coal charge for coke making is

compressed and then pushed into the oven for coking. The stamping process

brings the coal particles into more intimate contact with each other, which

enhances the coking properties.

Non-recovery coke making produces a high quality blast furnace coke

without the generation of hazardous or toxic emissions, usually associated

with byproduct recovery coke ovens. In a non-recovery oven, all of the gas

generated is burnt in the process.

The ovens or carbonization chambers have a unique sole flue heating design

to equalize the coking rate from the top and bottom to produce a uniform

product. Because the chambers operate under negative pressure with a

horizontal design, it will be easier to comply with the requirements of the

emission regulations.

Primary air for combustion is introduced into the chamber above the charge

through ports located in the doors. The partially combusted flue gas exits

the chamber though down-comer passages in the wall to the sole flues.

The sole flue arrangement is divided into two sections, each with four

passes for combustion of the flue gas prior to exiting the heating system.

Thus, the coke side and the pusher side can be controlled independently for

uniform heating. An inlet air damper is installed at the turn from the first


pass to the second pass of the sole flue. This additional damper permits the

introduction of air to complete combustion of the flue gas while still in the

sole flue. Waste gas is conducted to a common collecting tunnel through

uptake passages in the oven wall.

The common waste heat tunnel is located at the top along the centre line of

the battery and extends the entire length of the battery. The number of

ovens per exhaust stack can be varied by changing the diameter of the

common tunnel. Each stack has a pneumatically-operated lid which permits

closing off the battery should it be necessary for operating reasons.

Because the coking chambers operate under negative pressure at all times,

there is a minimum fugitive emissions to the atmosphere. Pushing and

quenching emissions are controlled with state-of-the-art equipment similar

to that used in a byproduct plant.

When the coal is fully coked, the doors on each side of the oven are

removed and the coke is pushed. A large mechanically operated ram

attached to a pusher machine pushes the coke out of the oven and into a

railroad car called the quench car.

The quench car moves down the battery to a "quench tower" where the hot

coke is cooled with water. The quenched coke is then dumped onto the coke

wharf, from which it is conveyed to the screening station for sizing, and

then to the blast furnace.

The hourly material balance for the coke plant is indicated below:

Input, t Output, t

Coking coal 116.7 BF Coke 87.6

Coke breeze 19.4

Coke oven gas 8.3

Dust recycled 1.3

Dust loss 0.1


The process flow sheet of coal carbonization is shown in Fig. II.8.


Fig. II.8 – Process Flow sheet - Coke oven plant ( Non recovery )


The advantages of Non recovery plant

• Economy of the plant at the intended scale of production (2 X 0.4

Mt/yr)

• Power generation potential using the heat in the flue gases and

thereby reducing the requirement of coal firing in the power plant

and the consequent pollutants. (65 MW of power from gases from

coke plant and 130 MW by coal firing)

• Because the coking chambers are operated under negative pressure

at all times, there is a minimum of fugitive emissions to the

atmosphere.

2.5.5 Sinter Plant

Iron ore lumps were the only iron bearing material initially used in blast

furnace for production of hot metal. While mining iron ore, fines are also

generated and the quantity of fines depends on the characteristics of ore.

To gainfully utilize these fines, agglomeration technologies like sintering

and pelletising were developed.

The down draft sintering is presently the most important agglomeration

process. It differs from pelletising by various characteristics such as

• Feed of coarser grained ore particles

• Coke breeze as main energy source

• Heating up of the materials mix to slightly above the softening

temperature

• The final product consists of a spongy sinter cake, partly molten and

solidified, which by crushing and screening brought to the necessary

grain size.

The major advantages of using sinter in blast furnace are:

• Use of iron ore fines, coke breeze, metallurgical wastes in steel plant

like blast furnace flue dust & mill scale, limestone, dolomite for hot

metal production


• Better reducibility and other high temperature properties of burden

material

• Increased blast furnace productivity

• Improved quality of hot metal

• Reduction in coke rate in blast furnaces

The raw materials used for sintering are:

• Iron ore fines (-6 mm),

• Coke breeze (-3 mm),

• Limestone & dolomite fines (-3 mm)

and other metallurgical wastes like blast furnace flue dust, mill scale etc.

Originally the sintering process was used to sinter lead ores in up draft

sintering. Only in 1904, Dwight Lloyd developed straight line machine and

there after iron ore fines could be sintered. Initially, sinter plant was

proposed as a scavenging unit where all the metallurgical wastes are

recycled and charged into the blast furnace. Wastes are iron ore fines from

the mines, limestone and dolomite fines, coke breeze, mill scale, flue dust

from blast furnace, SMS sludge and mill scale from rolling mill. Now, straight

line sinter machines are available in varying sizes starting from 36 m2.

These are widely employed in integrated steel plants for feeding the blast

furnaces.

The entire requirement of sinter for blast furnaces will be met from straight

line machines. There will be two machines, each with 100 m2 sintering area

to produce around 2.5 million tons of sinter per annum.

The sinter plant will start from proportioning section which will have bins

for iron ore concentrate, coke and flux fines and lime. The above described

materials will be drawn in the proportion needed as per the calculation on

the blast furnace slag regime. The material will go to the primary mixing

drum wherein the mix will be homogenized and some amount of water will

be added. In the secondary mixing drum, steam will be added to the sinter


mix, the moisture addition will be based on optimum permeability of the

sinter mix. There will be two sinter machines in the plant. The

proportioning section and mixing and balling section will supply the sinter

mix to both the machines. The sinter mix from secondary mixing drum will

be conveyed to the top of the machine where there will be a charging

hopper. Below the hopper will be the charging drum with a segregation

plate. Sinter mix will roll down as per the size and the bigger particles of

ore and return sinter will roll to the bottom. Before the charging hopper,

there will be a hearth layer bunker, from which the hearth layer will be

spread to the grate and then the charging of sinter mix will be done. Due to

the vertical segregation, coke fines will continuously decrease from top to

bottom of the bed. Bed height of the sinter mix could be between 600-750

mm. The sinter mix top layer will be dried by recycling hot air from the

cooler. Also, there will be line burners which will burn small amount of BF

gas. The top of the sinter mix will be ignited. Below the ignition part, the

wind box will be closed by damper so that there is no suction. There after

the dampers will be open and continuously air will be sucked through sinter

mix. The sinter plant will have a high degree of instrumentation and

automation level 2. There will be specific models for return sinter control

and coke rate control and sinter machine speed control linked to burn raise

point of the sinter bed. There will be additional controls to regulate the

heat to ignition and moisture control based on permeability measure of the

sinter mix.

Sinter will be discharged at the end of the sintering machine on to a hot

sinter crusher. After the crushing, the sinter will be conveyed to the deep

bed, deep rail circular cooler is provided with a segregating arrangement

plates. The coarsest size sinter fractions will segregate to the bottom of the

cooler. The small size sinter which normally would fly away and create dust

pollution problem will segregate above the big pieces of sinter and on top of

the smaller pieces medium sized lumps of sinter will segregate. By doing

this, the air required for cooling can be optimized and the hot air so

recovered can be utilised for heating the top layer of sinter mix before

ignition. After the sinter is cooled, it will be screened on the cold screen


where return fines, hearth layer and product sinter will be separated. The

hearth layer will be sent to the hearth layer bunker. The return sinter will

be sent back to the sinter plant. Sinter will be conveyed to blast furnace by

conveyors. The tumbler index of the sinter will be more than 70% + 10mm.

The FeO in sinter is around 7%. The basicity of the sinter will depend on the

percentage of sinter in the burden and will vary between 1.6 and 1.8.

The hourly material balance for the sinter plant is indicated below:

Input, t Output, t

Iron ore fines 242.3 Sinter 288.9

Dolomite 34.6 Process losses 28.6

Lime 20.5 Dust recycled 4.7

Coke breeze 17.5 Dust loss 0.05

Quartzite 7.2


The process and flow sheet are shown in Fig. II.9 .


Fig. II.9 Process flow sheet - Sintering Plant


2.5.6 Blast Furnace

The blast furnace is one of the most ancient and most modern energy

efficient processing units. Metallic iron was produced by man almost four to

five thousand years ago. From that time, the basic principle of reducing iron

oxides using carbonaceous reducing agent at high temperatures has

remained unchanged. The main change has been an increase in the size of

the operation and improving fuel efficiency and environment control

measures. The change has been mainly due to improved understanding of

the process. Modern day big blast furnaces produce even 15,000-16,000 tons

hot metal/day/ furnace.

Four 350 m3 blast furnaces are envisaged for producing hot metal. These

furnaces will have bell less top, high top pressure, coal dust injection, high

blast temperatures, oxygen enrichment etc.

The blast furnaces will use prepared burden such as sinter (75 - 85%) and

pellets (0-25%). Blast temperature will be 1050 – 1200 degree C. The blast

furnaces will have the latest in instrumentation and Computerization and

automation to achieve maximum production and fuel rate.

The blast furnace plant will consist of the following production units:

• Stock house

• Furnace charging system

• Furnace proper with cast house

• Hot blast stoves

• Cast house slag granulation unit and emergency slag pits

• Hot metal ladles and ladle repair shop

• Pig casting machine shop

• Dust catcher and dry gas cleaning system

• Water recirculation system

• Control rooms


Raw materials will be supplied to the stock house by conveyor systems.

Sinter and pellets will be delivered from the sintering plant and pelletising

plant respectively. Coke will be delivered from the coke plant. Quartzite

will be supplied from the raw materials storage yard. Separate dedusting

systems with bag filers will be provided to control the dust in materials

transfer points for stock house and cast house.

The hourly material balance for the BF plant is indicated below:

Input, t Output, t Sinter 272.4 Hot metal to SMS 202.4 Iron ore pellets 68.1 Cold pig iron 1.7 Coke 81.7 Granulated slag 73.6 Quartzite, t 8.0 BF gas 175.6 Injection coal, t 30.6 Flue dust 7.4 Dust loss 0.0 PCM skull loss 0.1


The process and flow sheet are shown in Fig. II.10.


Fig. II.10 Process Flow sheet – Blast Furnace

2.5.7 Steel Making plant and CCM

Two options are available for producing liquid steel.

• Basic oxygen furnace route

• Electric arc furnace route

Captive Power generation


Both the routes of steel making have been considered for this plant. Electric

steel making has been adopted so as to enable production alloy steel at a

future date. Basic oxygen furnace route is selected as it is less electrical

energy intensive and more suited for production of large tonnages. It is

proposed to produce about 0.95 Mt/yr of steel through electric route and

about 1.26 Mt/yr through basic oxygen route.

Electric arc furnace

Basic electric arc furnaces are used to produce practically all types of steel,

both for continuous casting and foundry purposes. Basic electric arc

furnaces employ a bottom consisting of burned magnesite brick. Side walls

are also magnesite lined. The furnace roofs are generally constructed with

high alumina refractory.

Two electric arc furnaces of 60 t heat size have been envisaged. The

furnace will be of AC electric arc type with ultra high power transformer.

Main features of the electric arc furnace include EBT, water cooled side

walls and roof, water spray cooling of electrodes, hot heel, foamy slag,

continuous charging of DRI etc.

The metallic charge of the furnace will consist of hot metal, DRI and steel

scrap. Hot metal will be charged through launder from the ladle. DRI will be

continuously charged from the storage bins. Scrap will be charged from

buckets. Additives will be charged through roof continuously.

Bins will be provided for storing DRI and additives from where weighed

quantities will be charged into the furnace. Hot heel and foamy slag

practice will be followed to hasten the process.

The steel making shop will have the furnace bay, charging bay, tapping bay.

Each bay will be provided with necessary electric over head travelling

cranes to handle hot metal, liquid steel and scrap.


The liquid steel from the electric arc furnace will be tapped into the casting

ladle placed on a ladle transfer car. The casting ladle will be moved to the

ladle furnace station for refining.

Basic oxygen furnace

This route is well established for steel making. The feed will be mainly

liquid iron from blast furnace. It will be refined by blowing high purity

oxygen into the liquid bath. The process is very fast and the production

capacity can be as high as 500 tons of steel in less than 45 minutes. The

basic oxygen furnace can be used to produce almost all grades of steel.

It is proposed to install two basic oxygen furnaces of 60 t capacity along

with f inclusions in the stream. Prior to start of casting, dummy bars will be

introduced into the moulds. The gaps between a dummy bar and mould

walls will be sealed and small pieces of steel scrap will be placed over the

dummy bar head for chilling of liquid steel.

Water supply to moulds, secondary cooling zone and machine cooling will be

commenced. In the liquid steel level in the tundish reaches a predetermined

level the nozzles of the tundish will be opened. The liquid steel stream from

tundish to mould will be protected by shroud system to ensure good quality

slabs/billets.

The partially solidified strands after leaving the moulds will pass through

the strand guide roller segments where intensive but controlled cooling of

the strands will be achieved by direct water spray with the help of water

nozzles. The solidified strands will be guided through withdrawal and

straightening unit before entering the gas cutting zone.

The dummy bars will be separated from the cast strands when dummy bars

reach beyond the withdrawal and straightening unit and will be stored in a

dummy bar storage device till their introduction is required for the next

cast.


The cast slabs/billets will be cut into predetermined length by automatic

oxy-acetylene gas cutting torches. The cut slabs/billets will be delivered to

cooling bed through run-out roller tables. Pusher will be provided for

pushing slabs/billets on the cooling bed where these slabs/billets will be

marked. The marked slabs/billets will be lifted by slab/billet handling

magnet crane for storage in the slab/billet storage bay.

The flowsheet for the steel making and continuous casting is given in

Fig. II.11.

The hourly material balance for the steel making shop is given below:

Input, t Output, t

Hot metal 202.4 Liquid steel 263.8

Scrap 14.8 SMS slag 30.5

DRI 78.1 SMS gas 2.1

Lime 15.4 Dust recycled 17.3

Calcined dolomite 3.0 Dust loss 0.017


The hourly material balance for the continuous casting plant is given below:

Input, t Output, t

Liquid steel 263.8 Slabs & billets 250.6

Recycled scrap 8.6

Scale & muck 4.6



Fig. II.11. Process flowsheet - steel making and continuous casting


2.5.8 Rolling Mill

The rolled products of an integrated steel plant fall into two categories,

flats and non flats. Sheets and plates belong to the first category.

Construction steel like angles, channels, I-beams, wide flange beams,

special sections such as zees and tees, wires, bars and rods belong to non

flat category.

Production of flat products

The hot strip mill is used to produce sheets and coils. The usual steel

composition is

C – 0.03 – 0.12%

P - 0.04 % max

S – 0.02% max.

This range of composition provides the best reliability. Such steels can be

produced in basic oxygen furnaces or electric arc furnaces working together

with ladle refining furnaces. Steels are usually killed, as slabs are cast in

continuous casting. Slabs can be thin slabs or thick slabs ranging from 80mm

– 250mm thick. The width could be 1200 – 2500 mm. The slabs must be

accurate enough in dimensions and sound enough in structure to permit

conversion rolling operations and their edges and surfaces should be free of

defects.

The slabs from the casting plant will be cooled, sheared to length,

inspected, edge defect eliminated, then charged to reheating furnaces and

then rolled in hot strip mill.

This method provides full flexibility of hot strip mill scheduling, permits

closer metallurgical control of steel rolling temperatures and minimizes

injurious steel surface defects resulting from defects in slab areas.

Slabs are heated in continuous reheating furnaces. The plant will consist of

roughing scale breaker and four 4-high roughing stands, finishing scale


breaker and six 4-high finishing stands, driven table rolls conveyor from

furnace to mill and also from stand to stand. If the mill is to produce strips

or sheets of greater width than the maximum width of slab available, the

first roughing stand is a broad side mill, in which the width of the slab is

increased in a single pass by cross rolling. In this case, turn tables for

manipulating the slabs must precede and follow the stand. A slab squeezer

also follows the broad side mill. The next three roughing stands are usually

provided with integral vertical edgers in front of each stand. Separating the

roughing train from finishing train is a holding cable while the finishing ends

is a closely grooved tandem train composed of finishing scale breaker and its

finishing stands.

High pressure, hydraulic sprays are located after the two scale breakers and

at several roughing stands to remove scale from the hot slab.

A flying shear is usually provided following the last finishing stand for

cutting the rolled product into lengths, if so desired. This is called the cut

to length sheets. As the steel proceeds from mill, it is carried over a long

table called the run-out table consisting of individually driven rollers. Two

or more coilers are located in this table. They operate to coil the strips

when continuous long lengths are required. When the coilers are in

operation and the steam passes over them on to a piler at the end of the

table. Additional tables may be installed parallel to the center run out table

with suitable transverse for moving material to them. This equipment if

used principally when heavier gauges are being rolled. The above desired

hot strip mill provides high rolling capacity and rapid steel travel with little

loss of heat but entitles a high installation cost and fixed number of passes

with some loss of flexibility in making rapid changes in the mill set up when

size of the product to be rolled is changed. Depending on the scheduling

alternate arrangement can be made to make the mill more flexible.

The first strip is taken, while rolling, to determine the proper grade of steel

and the size and surface quality of the slab, and then the scheduling is made


for a proper rolling sequence. The factors taken into consideration at this

stage are rolling width, gauge and steel consumption.

The next step is getting slabs heated to the correct rolling temperature. The

slab should have uniform “scale jacket” that will clean up readily in rolling.

The next step is to rough down the slab to a predetermined intermediate

thickness. As the slab leaves last roughing stand, it should be flat, straight,

free of furnace scale, true to width and after cross section, suitable for

further reduction at the finishing stands. The first rolling pass on the slab is

done on a scale breaker followed immediately with a high pressure hydraulic

spray to remove furnace scale. There are usually one or two more descaling

sprays following the second or third roughing stands and numerous steam

and air sprays provided to remove any further scale that may be loosened

during rolling or edging. Proper use of broadened mill slab squeezer and

three vertical edges normally guarantee the uniform width necessary.

The finishing stand is to be operated with careful regulation to obtain a

finished hot rolled product of fine quality. Various automatic control

elements have been incorporated to assist operators to produce strip to

uniformly high quality. Surface gauge width, finishing temperature and cross

sectional contour of the direction are all required to meet the given

standards. The final step in rolling on a strip mill is the disc position of the

hot rolled product and in some mills the product may be cut into required

lengths on a plain shear located at the exit end of the mill and sheared

pieces move along the rundown table to a hot piler. Greater portion of hot

rolled flat material is coiled by the hot coiling machine. This includes the

semi finished product designated as hot rolled break down, for subsequent

cold reduction as well as hot rolled sheets in coils which may be shipped as

such or transferred to the finishing department. The essential requirements

of the coiler are to receive the material at mill speeds, should coil it tightly

without excessive tension, telescoping, scratching or marking and finally

discharge finished coil quickly without damage.

About 1 million tons per annum of hot rolled coils will be produced.


Production of non flat products

Billets are rolled into non flat products in merchant mills and bar mills. Most

modern of all bar mill designs is the continuous mill with alternate

horizontal and vertical rolls, which obviate the need for twisting the bars

and the twist guides and eliminate the tendency to scratch bars. The stands

of the mill are spaced apart far enough so that a slight loop can be formed

between stands. Slight loop eliminates all push and pull between stands.

Flat thin material of narrow width can be produced on various types of bar

mills.

Continuous mills produce rods from 100 mm square billets. There are two

types of rod mills. In one type, a group of roughing or breaking down rolls is

provided and the rod is directly rolled from the billet. The draw back in this

method is that if the rolls are speeded up to correspond to elongated bar,

speed of the first roughing group is very slow. Long pieces are thus kept in

contact with cold rolls, resulting in cooling to a point where it becomes

difficult to finish. If the first roughing group is speeded up, then the piece

must be held ahead of the first intermediate and is cooled faster and more

unevenly than in the former instance. In some cases, solution to this has

been done by placing a heat retainer, a long narrow brick chamber heated

by gas, between roughing and intermediate groups of rolls. Best plan

involves use of reheating furnaces between two groups of rolls. Efficient

operation at the mill depends largely upon the skills of operating groups, for

best results roll diameter for different stands must be carefully selected and

maintained in proper proportions. The roll passes especially for the finishing

group of rolls must be skillfully adjusted and accurately tuned. The rolls and

guides must be carefully set in the housings and there after the draft must

be regulated through the mill screws to suit the conditions.

Uniform heating of the billet is also important. Modern rod mills employ

both continuous and looping features to get the best out of the mills. The

modern mills have a considerable number of stands arranged in a line

similar to continuous type rolls. However, instead of these stands being


driven by a single motor, the stands are arranged in units of 1, 2, 3 or more,

each unit driven by a separate variable speed motor. The length of this mill

is greater than that of continuous mill but shorter than the mills where

loops are used in spite of variable speed motors. These mills also employ 2-5

loops and the stands driven by variable speed motors to maintain short

loops.

The rebar mill will roll rebars, plain rounds, low alloy rounds and squares

from continuously cast billets. The mill will be of modern design and will

have the following features so that superior surface finish, good dimensional

tolerances and specified metallurgical properties of the final products are

ensured:

• Hot billet charging

• Billet weighing

• Mill floor level at +0.0 m

• Reheating furnace of walking beam type

• High pressure water jet de-scaling

• Billet welding

• Single strand high speed continuous H-V configured mill for twist-free rolling

• Housing- less stands for ease of maintenance and rigidity

• Quick roll change carpet in finishing stands

• Inter stand tension control rolling

• Convertible stands for slit rolling of smaller size re-rebars

• Online water quenching for production of TMT rebars in straight length

• Two Nos. 6-stand high speed finishing block for smaller rebar production

• High speed discharge facility at cooling bed entry side for rebars coming from 6-stand finishing block

• Automatic bundling and tying facilities for straight length rolled products.


Thus rolling mill complex envisaged for the plant will have a hot strip mill,

wire rod mill with a TMT section and light structural mill. The capacity of

the hot strip mill will be slightly higher and the other mills are of nearest

standard size. This is done to ensure flexibility in production of various

products to meet the market demand.

The hourly material balance for the rolling mills is given below:

Input, t Output, t

Slabs & billets 350.9 HR coils 166.7

Non flat products 166.7

Recycled scrap 8.8

Scale & muck 8.8


The process and flow sheet are shown in Fig. II.12 & II. 13.


Fig. II.12 Process Flow sheet - Rolling Mill

Reheating Furnace

Rolling Mills

Oil Firing

Rolled Products

Slabs / Billets

Steel Scrap

Combustion Gases to stack

Hot Billets / Slabs

To SMS To Sintering Plant

Mill Scale & Sludge


Fig. II.13 Process Flow diagram - Rolling Mill

Richardson & Cruddas (1972) Ltd. III-62

2.5.9 Calcining Plant

A calcination plant is envisaged to produce lime and calcined dolomite. There

will be two 500 t/d kilns for calcining limestone and one 80 t/d kiln for

calcining dolomite.

The calcining plant will consist of limestone/ dolomite storage bunkers, kiln

charging system, screens for calcined product and storage bins for calcined

materials from where they will be sent to the consumers. The plant will receive

screened limestone and dolomite from the raw materials storage yard. The

calcined product will be sent to the consumers in covered belt conveyors. The

process flow sheet is given in Fig. II.14.


Fig. II.14 Process flow sheet – Calcination Plant

Screening

Calcining Kiln

Oil Firing

Lime stone / Dolomite

Lumps

Calcined products

Screening

Lumps

TO SMS

GasesGas Cleaning

Dust

To Sintering Plant

Stack

Cleangas

Fines

Fines

To Sinter Plant

Dusty air

The hourly material balance for the calcination plant is given below:

Input, t Output, t Limestone/ dolomite 72.2 Calcined products 40.1 Process losses 30.4 Dust recycled 1.7 Dust loss 0.008


2.5.10 Cement Plant


Portland Slag Cement is manufactured either by intimately inter grinding a

mixture of Portland cement clinker and granulated slag with addition of

gypsum (natural or chemical) or calcium sulphate, or by an intimate and

uniform blending of Portland cement and finely ground granulated slag, so that

the resultant mixture would produce a cement capable of complying with

required specification. No material is added other than gypsum (natural or

chemical) or water or both. However, when gypsum is added it shall be in such

amounts that sulphur trioxide (SO3) in the cement produced does not exceed

the limits specified in Indian Standards. Besides, not more than one percent of

air-entraining agents or surfactants, which have proved not to be harmful, may

be added. The slag constituent shall be not less than 25 percent nor more than

65 percent of the Portland slag cement. The Portland slag cement should

confirm to Indian standard specification IS. 455-1976.

Portland slag cements (PSC) is a blended cement. SC, when used in

construction, will contribute to higher ultimate strength in concrete structures,

which can be constructed more economically than with ordinary Portland

cement. It can also be used in construction of dams where low heat of

hydration is needed. Cementitious material such as Blast furnace slag and

pozzolanic materials such as calcined pozzalana clay, fly ash, rice husk ash etc.

are used to blend with ordinary Portland cement clinker and appropriate

quantity of gypsum to produce blended cements such as PSC.

Grinding process

The three raw materials required for manufacture of Portland slag cement, as

per Bureau of Indian Standards are clinker, blast furnace slag and gypsum. Ash

collected in power plant is also used in the mix. Weighed quantities of these

materials are fed to the vertical roller mill through a set of material handling

equipments like weigh feeders, belt conveyors, bucket elevator to the inlet of

the vertical roller mill. The mixture is ground to desired fineness by regulating

the speed of the circuit classifier. The classifier separates coarser and finer


particles of cement. The finer particles are drawn out through vent, whereas

the coarser particles are returned to the mill for grinding. The fine cement is

collected by an ESP into a silo. This process is called inter grinding process.

Sometimes, instead of mixing ground granulated blast furnace slag (GGBS) with

clinker, it can also be traded separately.

The hourly material balance for the cement grinding plant is given below:

Input, t Output, t

BF slag 78.0 PS cement 176.1

Clinker 91.7 Exhaust gas 1.7

Gypsum 5.3 Dust recycled 1.6

Coal 4.4 Dust loss 0.002


The process flow sheet for cement plant is given in fig. II.15.


Fig. II.15 Process Flow Sheet – Cement Plant

Proportioning

Grinding

Purchased Clinker

Dusty Air

Bag Filter

Cement

Stack

CleanGas

GranulatedBF Slag

Gypsum

DryingDusty Gas Gas Cleaning

Dust

Hot Gas

Hot Air Generation

Coal

Ash to Dump

Ash from Power Plant


2.5.11 Power Plant

It is estimated that 230 MW of power shall be generated to meet the

requirement of the entire steel plant. Steam will be generated using the waste

heat in the flue gases from DR plant and coke plant and this is sufficient to

generate about 100 MW. To generate the balance power, coal fired,

atmospheric/ circulating fluidized bed combustion type boiler will be used. It is

possible to use char produced in the DR plant in this boiler.

The main units of the plant will be coal handling system, steam generator and

associated systems, steam turbine and associated systems and steam

condenser. The auxiliary systems include generator and electrical facilities,

control & instrumentation water treatment system, air conditioning system,

compressed air system, ventilation system and ash handling system.

It is proposed to use low ash imported coal. The coal will be supplied to the

power plant from the coal storage yard by a system of conveyors. Coal will be

sized and then fed to the boiler.

The steam generator system will produce superheated steam with desired

pressure and temperature. There will be two types of steam generators, waste

heat recovery type and fluidized bed combustion type. The former will be of

unfired, natural circulation, vertical tube, horizontal or vertical gas flow

multiple parallel pass type, ensuring uniform inlet gas flow distribution to all

the parallel processes. The latter will be of the natural circulation single drum

type and is a radiant, single reheat, balanced draft, semi-outdoor type system.

The flue gas from the boilers will be cleaned in electrostatic precipitators. The

dust collected from the flue gases from the coke plant ts recycled to the coke

making process. The dust collected from the flue gases from the DR plant is


sent to sintering plant. The fly ash will be collected in the hoppers and used in

cement grinding unit.

Two steam turbine generators, rated for 120/ 130MW maximum continuous

output at the generator terminals, have been proposed. The generator will be

a two/ three cylinder tandem compound, reheat, extraction and condensing

type system. The turbine generators will be complete with lube oil system,

control oil system, jacking oil system, seal steam system, turbine drain system,

HP/ LP bypass system, Instrumentation and control devices, Turbine

supervisory instruments, Automatic turbine run-up system and protection

system.

The steam condenser will be designed to handle the entire exhaust steam

including that of the HP/LP bypass system and all the drains and vents under

all modes of operation. The condenser will consist of a divided water box, a

hot well and vacuum pumps.

There will be condensate pumps, low pressure heaters, high pressure heaters,

deaerator, boiler feed pumps and gland steam condenser.

The pressure pneumatic type ash handling system has been envisaged for both

bed ash and fly ash removal. Ash silos will be used to store ash for use in

cement grinding unit.

The hourly material balance (coal firing) for the power plant is given below:

Input, t Output, t Coal 44.9 Exhaust gas 55.9 Char 27.6 Dust recycled Fly ash 13.2 Bottom ash 3.3 Dust loss 0.046



2.6 Statutory Regulatory Compliance

Air

Sl.No. Units Stack emission

1 Integrated Steel Units

<100 mg/Nm3

Combustion efficiency >99.9%

2 De-dusting units < 100 mg/Nm3

3 Fugitive emission < 2000 µg/m3

at a distance of 10.0m 4 Captive Power plant < 100 mg/Nm3 5 General Ambient air quality to be maintained at BMM

ISPAT LTD (Core zone) i. SPM ii. RPM iii. SO2 iv. NOx

< 500 µg/m3

< 150 µg/m3

< 120 µg/m3

< 120 µg/m3 6 General Ambient air quality to be maintained at

buffer zone v. SPM vi. RPM vii. SO2 viii. NOx

< 200 µg/m3

< 100 µg/m3

< 80 µg/m3

< 80 µg/m3

Waste water : General discharge Standards

Sl.No Parameter Inland surface

water Public sewers

Land for irrigation Marine/ coastal areas

(a) (b) (c) (d)


1 Suspended solids mg/l, max. < 100 600 200

(a) For process waste water (b) For cooling water effluent 10 per cent above total suspended matter of influent.

2 pH value 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0

3 Temperature shall not exceed 5oC above the receiving water temperature

shall not exceed 5oCabove the receiving water temperature

4 Oil and grease, mg/l max, 10 20 10 20

5

Chemical oxygen demand, mg/l, max.

250 - - 250

Noise

Noise Level [dB(A)] Standards at Industrial establishment

i) Day Time (6.00 AM – 10.00 PM) = < 75 dB(A)

ii) Night Time (10.00 PM – 6.00 AM) = < 70 dB(A)

Noise Level [ dB(A) ] Standards in buffer zones

i) Day Time (6.00 AM – 10.00 PM) = < 60 dB(A)

ii) Night Time (10.00 PM – 6.00 AM) = < 55 dB(A)

2.7 Charter on Corporate Responsibility for Environmental Protection (CREP): Integrated Iron & Steel Industry


Coke Oven Plant

The parameters like PLD (% leaking doors), PLL (%leaking lids), PLO (% leaking

off take) will be meet the notified standards under EPA. Industry will submit

time bound action plan and PERT Chart for the implementation of the same

after detailed engineering of the plant. The coke oven plant is expected to be

implemented with all latest technology and shall meet all guidelines given in

CREP

Steel Melting Shop

Controll of fugitive emissions by installation of secondary de-dusting facilities.

The primary fume extraction system and secondary dedusting facilties will be

installed.

Blast Furnace

The plant will be installed with latest available technology. Direct injection of

reducing agents will be provided.

Sponge Iron Plants

The draft guidelines of Central Pollution Control Board for the installation of

sponge iron plant will be followed and strictly amended

Solid Waste / Hazardous Waste Management

SMS slag will be initially dumped suitably and then will be used for road making

and ballast for railway track. BF slag will be granulated and it will be utilized in

captive cement plant.


Water Conservation / Water Pollution

Reducing specific water consumption to 5 m3/t for long products and 8 m3/t

for flat products. The effluent generated will be treated, if required and will

be reused for gardening and dust suppression. The zero discharge system will

be implemented.

Air Pollution Monitoring

Continuous stack monitoring system & its calibration in major stacks shall be

provided. 3 nos. of permanent AAQ monitoring stations around plant is also

envisaged. To operate the proposed pollution control equipment efficiently and

to keep proper record of run hours, failure time and efficiency with immediate

effect during operational phase. Compliance report will be submitted to CPCB

/ SPCB every three months. A best equipped Env.laboratory for analysis of air,

water and other pollutants in addition to on line monitoring of stacks. Training

for related employee will be given. The entire activity will be managed by an

independent Environmental Management Cell.

Clean technologies/ measures

Energy recovery from top Blast Furnace (BF) gas, Committed to adapt best

available technology. Tar-free runner linings will be used. Best available

indigenous materials will be used. Suppression of fugitive emissions using

nitrogen gas or other inert gas will be done as per the best available

technology. Reduction of Green House Gases by reduction in power

consumption by regular energy auditing.

Use of by-products gases for power generation


It is included in the project that flue gases from DRI plant & Coke plant will be

used for power Generation scheme, Plant will be one of the best example for

promotion of energy optimization technology

Resource Conservation such as Raw material, energy and water consumption to

match International Standards.

2.8 Implementation of Carbon Credit project

BMM intend to put up a 2.0 Mt/yr integrated steel plant to produce rolled steel

products and BF slag based cement. The power requirement for the steel plant

will be met by captive power plant. The total power requirement of the

integrated steel plant has been estimated as 230 MW. BMM could meet this

power requirement either by setting up a fossil fuel based power plant or by

importing the required power from the state grid. However both these

alternatives would have resulted in increased GHG emission due to fossil fuel

combustion. BMM realize that installation of a Waste Heat Recovery based

captive power generation facility is a step towards environmental sustainability

by saving exploitation and depletion of natural and non-renewable resource

like coal. The DR plant will have four kilns, each of 500 TPD capacity. The heat

in the flue gases from these kilns will support 60 MW power generation. The

heat in the flue gases from the coke making chambers is estimated to support

60 MW generation. Thus, 120 MW power can be generated using Waste Heat

Recovery boilers in the captive power plant. The balance 110 MW will be

generated by using coal.

There will be twelve Waste Heat Recovery boilers with different steam

generating capacity i.e., four no’s in the DR plant of each 60 TPH capacity and

eight no’s in coke plant of 30 TPH capacity. The boilers will be designed to

take care of the fluctuations in the volume and temperature of flue gases

exiting the DR kilns and batteries of coke making chambers.


The project activity is expected to generate around 808 million kWh of

electrical energy per year based on the heat energy recovered from the waste

gases. The auxiliary power consumption is estimated at about 10% of total

electricity generation.

The equipment for power generation will consist of waste heat recovery

boilers, bleed cum condensing turbo-generator, water treatment system,

condensate system, air cooled condenser system, auxiliary cooling water

system, compressed air system and electrical system consisting of switch gears,

low tension distribution panels, step-down transformer for meeting the in-

house power requirements of the power plant.

The waste gases generated in the sponge iron kilns, at temperatures of about

950°C, will be passed through heat recovery boilers and then passed through

electrostatic precipitator, before being released to the atmosphere. The flue

gases from the coke plant will be passed through heat recovery boilers and

then released to the atmosphere. In the heat recovery boilers, the heat energy

of the waste gases will convert the feed water into steam at 114 kg/cm2 and

540+5˚C. The steam so generated will be passed through the turbo generator

for power generation. A portion of the steam passing through the turbine is

bled-off and the remaining portion undergoes further expansion before being

exhausted to the air cooled condenser. The feed water to all the boilers is

heated to a temperature of 140°C in the deaerator which receives the steam

bled from the turbine. All equipments used in the project will be designed for

satisfactory operation for a lifetime of 30 years under specified site conditions.

In the absence of the aforesaid activity, the power requirement of the plant

would have been met by power generated from a more GHG intensive source

like a fossil fuel based captive power plant. The power generated from the

project activity would reduce the power generation from other fossil fuels

which are more GHG intensive.


Further, the use of iron ore concentrate obtained by beneficiation of low grade

iron ore reduces the requirement of coal for production of DRI and coke for the

production of hot metal in the blast furnaces. This also leads to less GHG

intensive production practices.

Hence, projects like this contribute to the global cause of control and

mitigation of climate change.

Since utilization of energy in the waste gases coming from the sponge iron kilns

and the coke plant result in real and measurable reduction in GHG emission,

the proposed activity can be considered as a potential Clean Development

Mechanism (CDM) project of United Nations Framework Convention on Climate

Change (UNFCCC) under its Kyoto Protocol. Ernst & Young Pvt. Ltd. has been

appointed as the CDM consultant to guide the company through the CDM

procedure to avail any possible benefits from emission reduction.

CHAPTER - III


DESCRIPTION OF ENVIRONMENT

The present environmental status of the proposed projects has been studied

covering 10 Km radius and presented in this chapter. It is necessary to know the

present quality of the environment with respect to the various aspects considered

under impact identification. These factors include air, water, noise, soil,

meteorology, land use, flora & fauna, socio-economic and demographic pattern.

For this purpose, a monitoring schedule covering three months of the year was

chalked out during December 2007 – February 2008 to generate baseline data on

ambient air quality, quality of ground water / surface water, soil, ambient noise

and meteorological parameters like temperature, humidity, wind speed and

direction, cloud cover etc. The baseline data on flora & fauna, socio-economic and

demographic factors, land use pattern, forests, geology, hydro-geology, soil and

agriculture, mineral resources etc. was carried out by field survey and secondary

data has been collected from the State Government authorities. The baseline

environmental data generation (air, water) were continued during summer season

(March – May 2008) and presented in this report.

3.1 Air Environment

Identification of different pollutants, which are expected to be released into the

atmosphere and having significant impact on the neighborhood, is an essential

component in impact assessment of the air environment. The ambient air quality

status of the study area of 10 km radial distance from the existing project will form

the baseline information. The predicted impacts due to the project will be

superimposed to find out the net (final) impacts (post-project scenario) on

environment.

If the final impacts due to the proposed project are known at the planning stage of the

project, a viable Environmental Management Plan (EMP) can be proposed to mitigate

and minimize adverse effects on the environment. The design of the ambient air

quality-monitoring network in the air quality surveillance programme is based on the

following considerations.


- Micro-meteorological conditions of the study area on synoptic scale

- Topography of the study area

- Representation of regional background levels

- Representation of core zone

- Representation of cross sectional distribution in the downwind directions

- Influences of the existing sources, if any.

3.1.1 CLIMATE AND METEOROLOGY

Regional climate and meteorology:

The study area lies in sub-tropical region where climate is characterized by hot and

humid summer, moderate monsoon and mild winter seasons. Summer is typically from

March to June, when temperature ranges from a maximum of 44°C during daytime to a

minimum of 27°C at night. Winter from December to February, when the maximum

temperature during day time goes upto 38°C and minimum temperature 17°C at night.

The mean maximum and minimum temperatures of study area are presented in

table 3.1

TABLE - 3.1

MEAN MAXIMUM AND MINIMUM TEMPERATURES OF STUDY AREA

(DISTRICT CENSUS HAND BOOK, 2005)

Mean monthly maximum temperature °C

Mean monthly minimum temperature °C Sl.

No. Month 2002-03 2003-04 2004-05 2002-03 2003-04 2004-05

1. January 30.8 32.1 32.8 19 19.6 18.7 2. February 34.3 35.5 35.9 20.7 22.5 21.5 3. March 37.9 37.9 40 23.8 24.8 23 4. April 40.1 41.4 40.3 27.2 27.3 25.8 5. May 40 42.2 42.1 28.4 30.3 24.7 6. June 36.7 39.2 36.8 26.9 28.6 25.7 7. July 34.3 32.9 33.5 25.7 24.9 24.1 8. August 33.6 32.9 34.8 25.2 23.7 25.7 9. September 33.5 34.4 31.9 24.9 25.1 23.5 10. October 32.2 32.2 31.8 23.8 23.5 23.9 11. November 30.5 31.5 31.5 21.4 21.3 19.5 12. December 29.4 30.9 32.5 19.3 17.6 17.1


The area receives annual rainfall varying between 490 to 870 mm. The rains

predominantly occur between June to September due to south-west monsoon. Rains

also occur in the months of October to December due to north-east monsoon. Table3.2

presents month-wise average rainfall in (District census hand book, 2005).

TABLE - 3.2 MONTHLY RAINFALL (mm)

Month 2000- 01 2001- 02 2002- 03 2003- 04 2004- 05 January 4.9 5.0 0 0 0 February 2.2 0.6 0 0.8 2.7

March 5.5 0.3 9.5 10.3 3.4 April 17.2 9.0 3.9 24.6 19.1 May 46.4 49.6 0 136.1 36.2 June 76.8 14.9 68.4 20.9 20.9 July 94.9 60.1 31.1 175 138.2

August 249.8 94 43.8 89.8 10.4 September 58.9 185.8 57.1 123 169.2

October 111.75 404.4 174.9 236.1 64.4 November 22.0 25.2 27 3.4 30.1 December 35.0 16.6 0.9 3.1 0

Total 730.0 865.6 416.6 822.3 494.6

The pattern of rainfall is highly irregular and varies significantly from year to year.

Humidity is the percent water vapour content of the atmospheric air. Its content

changes the nature and characteristics of the pollutants. Fog provides surface area for

suspended particles to Coalesce and also enhance chemical reactions of the gaseous

pollutants. The monthly average of relative humidity recorded at 8.30 AM and 5.30 PM

is presented in Table 3.3.

TABLE - 3.3 RELATIVE HUMIDITY IN DIFFERENT MONTHS (2000 TO 2005) Relative humidity (%) Sl. No. Month

8.30 AM 5.30 PM 1. January 78.4 54.2 2. February 72.8 44.0 3. March 64.6 32.8 4. April 64 34.4 5. May 58 37.2 6. June 60.6 46.4 7. July 67.2 54.2 8. August 68.8 53.4 9. September 69.0 54.4 10. October 77.60 59.2 11. November 82.40 72.6


12. December 78.2 61.0

The following observations can be made from the secondary data.

• The morning relative humidity (RH) attains the maximum in the month of

November (82.4%) and minimum in the month of May (58.0%).

• The evening humidity attains the maximum in the month of November (72.6%)

and a minimum in the month of March (32.8%).

• The variations in the relative humidity throughout the year reflect the tropical

semi arid climate.

Wind speed and wind direction have a significant role on the dispersion of atmospheric

pollutants and therefore the air quality of area. Ground level concentrations for the

pollutants are inversely proportional to the wind speed in down wind direction while in

upwind direction no effect will be observed and in cross wind directions partial effect

due to the emission source is observed.

Micrometeorology at site

Prevailing micro-meteorological conditions at site regulate the dispersion (and hence

dilution) of air pollutants in the atmosphere. Therefore, study of meteorological

conditions is an integral part of environmental impact assessment studies.

Accordingly, a meteorological station was set up at project site. The following

parameters were recorded at hourly intervals during December`07 – February`08.

• Air temperature (°C)

• Relative humidity (%)

• Wind speed (m/s)

• Wind direction (eight quadrants)

The data collected on wind speed and wind direction was used for computation of

wind percentage frequencies in all the sixteen directions for wind speed in the range

of 1.0 -5.0, 5.1-11.0, 11.0-19.0 and 19-29 kmph. Wind speed <1.0 kmph was

considered as calm condition. Table 3.4 through 3.6 show the wind frequency pattern

of 06-17, 17-05 and 0-24 hours.


TABLE - 3.4

WIND FREQUENCY, DISTRIBUTION (06 -17 hrs)

Wind frequency (%) Direction of wind Calm 1-5

km/h 5-11 km/h

11-19 km/h

19-29 km/h Total

N - 0.27 0.09 - 0.36

NNE 0.64 1.01 - - 1.65

NE 2.02 7.33 1.28 - 10.63

ENE 4.12 13.83 2.11 - 20.06

E 1.56 4.95 0.82 - 7.33

ESE 4.85 12.09 4.76 - 21.70

SE 7.88 12.09 5.14 - 25.11

SSE 1.92 4.49 1.83 - 8.24

S 1.37 2.28 0.82 - 4.47

SSW - 0.18 - - 0.18

SW - - - - -

WSW 0.18 0.09 - - 0.27

W - - - - -

WNW - - - - -

NW - - - - -

NNW

-

- - - - -


TABLE - 3.5

WIND FREQUENCY, DISTRIBUTION (17-05 HRS)


km/h 5-11 km/h

11-19 km/h

19-29 km/h Total

N 0.09 0.27 - - 0.36

NNE 0.09 1.19 0.45 - 1.73

NE 1.56 6.41 1.55 - 9.52

ENE 3.95 10.35 4.40 - 18.70

E 1.10 3.40 1.28 - 5.78

ESE 7.78 10.07 4.58 - 22.43

SE 8.88 10.90 4.95 - 24.73

SSE 2.38 5.31 2.84 - 10.53

S 2.56 2.47 0.92 - 5.95

SSW - - - - -

SW - - - - -

WSW 0.09 - - - 0.09

W - - - - -

WNW - 0.09 - - 0.09

NW - - - - -

NNW

-

- 0.09 - - 0.09


TABLE – 3.6

WIND FREQUENCY, DISTRIBUTION (overall)


km/h 5-11 km/h

11-19 km/h

19-29 km/h Total

N 0.05 0.27 0.05 - 0.37

NNE 0.37 1.10 0.23 - 1.70

NE 1.79 6.87 1.42 - 10.08

ENE 4.02 12.08 3.25 - 19.35

E 1.32 4.17 1.05 - 6.54

ESE 6.32 11.08 4.67 - 22.07

SE 8.38 11.49 5.04 - 24.91

SSE 2.15 4.90 2.34 - 9.39

S 1.97 2.38 0.86 - 5.21

SSW - 0.09 - - 0.09

SW - - - - -

WSW 0.14 0.05 - - 0.19

W - - - - -

WNW - 0.05 - - 0.05

NW - - - - -

NNW

-

- 0.05 - - 0.05

Wind pattern during the season (Winter 2006- 2007) the summary of wind pattern is

given below:

The annual wind rose is given in Fig. III.1. The seasonal and shift-wise wind rose

diagrams are presented in Fig. III.2 and III.3.The abstract of micro-meteorological

status of the project site is furnished in Table 3.7. The micro-meteorological data are

given in Annexure II.


Fig. III.1


Fig. III.2


Fig. III.3


Table 3.7 Abstract of Micro-meteorological data

Wind speed KM/Hour

Temperature (°C)

Date Min Max Avg

Predominant Wind

direction Min. Max.

Mean Relative Humidity

(%)

Rainfall mm

Sky Appeara

nce

1.12.07 2.3 12.6 7.5 SE 18.5 25.5 67 0 Clear

2.12.07 2.1 11.3 6.1 SE 18.5 26.0 67.74 0 Clear

3.12.07 1.9 15.9 6.6 SE 19.0 27.0 65.0 0 Clear

3.12.07 1.6 9.5 5.8 SE 19.0 27.5 68.5 0 Clear

5.12.07 2.4 16.1 7.2 S 18.0 26.5 62.3 0 Clear

6.12.07 1.6 18.6 7.9 SE 17.5 27.0 61.8 0 Clear

7.12.07 1.6 9.2 4.5 SE 18.0 26.0 65.8 0 Clear

8.12.07 1.3 9.6 3.5 SE 18.0 27.0 70.5 0 Clear

9.12.07 1.3 14.5 5.3 SE 18.5 26.0 69.2 0 Clear

10.12.07 1.8 17.5 6.0 SE 18.0 27.5 68.0 0 Clear

1112.07 1.6 16.1 7.9 ESE 18.0 27.5 68.1 0 Clear

12.12.07 1.6 14.6 6.7 SE 17.0 27.0 71.8 0 Clear

13.12.07 3.8 15.5 8.3 SE 17.5 26.5 73.6 0 Clear

14.12.07 4.1 18.5 11.0 SAE 17.0 26.5 73.1 0 Clear

15.12.07 6.9 16.2 12.0 ESE 17.5 26.5 74.3 0 Clear

16.12.07 1.9 18.8 11.4 SE 17.0 26.0 77.2 0 Clear

17.12.07 5.4 18.6 12.6 SE 17.5 24.5 76.8 0 Clear

18.12.07 1.9 12.1 7.9 SE 16.5 22.5 78.9 3.0 Rainy

19.12.07 2.4 17.3 8.5 ESE 15.0 20.0 91.6 3.8 Rainy

20.12.07 3.9 14.8 9.6 SE 15.0 26.0 93.9 10.5 Rainy

21.12.07 1.3 17.9 10.2 SE 16.0 27.0 77.9 0 Clear

22.12.07 2.6 15.1 6.2 SE 18.0 26.0 74.8 0 Clear

23.12.07 1.3 7.7 4.0 SE 18.0 27.5 72.8 0 Clear

24.12.07 1.5 13.6 5.2 ESE 18.0 27.0 71.2 0 Clear

25.12.07 1.2 7.5 4.2 SE 18.5 26.5 70.9 0 Clear

26.12.07 1.7 11.7 5.1 ESE 19.0 27.5 71.0 0 Clear

27.12.07 1.3 12.1 5.9 SE 19.5 27.0 70.0 0 Clear

28.12.07 1.3 8.7 3.8 SE 19.5 27.5 69.8 0 Clear

29.12.07 1.4 5.4 3.4 SE 19.5 28.0 68.3 0 Clear

30.12.07 2.2 18.4 10.0 ESE 20.5 28.5 68.3 0 Clear

31.12.07 1.6 15.2 7.5 ESE 20.0 30.0 68.7 0 Clear


Table -3.7 Abstract of Micro-meteorological data (Contd.,)

Wind speed, KM/Hour Temperature

(°C) Date

Min Max Avg.

Predominant Wind direction

Min. Max.


(%)

Rainfall mm

Sky Appearance

1.01.08 3.3 15.8 8.7 ESE 18.5 28.0 70.3 0 Clear

2.01.08 4.6 15.6 8.4 ESE 19.0 27.0 74.4 0 Clear

3.01.08 3.1 14.5 8.7 ENE 17.0 26.0 74.0 0 Clear

3.01.08 3.1 15.3 9.3 SE 16.5 26.0 79.0 0 Clear

5.01.08 6.5 12.1 9.5 ESE 16.5 25.5 77.0 0 Clear

6.01.08 5.2 14.5 10.9 ESE 17.5 26.0 76.1 0 Clear

7.01.08 5.4 18.0 10.4 ESE 17.5 24.5 77.3 0 Clear

8.01.08 5.2 17.3 10.4 ESE 17.5 26.0 77.4 0 Clear

9.01.08 3.3 13.6 8.1 ENE 18.0 24.5 69.6 0 Clear

10.01.08 3.3 14.4 7.0 ENE 18.0 25.5 67.8 0 Clear

1112.07 5.9 15.4 10.7 ESE 18.5 25.5 65.3 0 Clear

12.01.08 5.9 13.4 10.0 ESE 17.5 25.5 67.1 0 Clear

13.01.08 4.0 13.6 8.8 ESE 18.5 26.0 68.5 0 Clear

14.01.08 4.4 13.6 10.1 ENE 18.5 25.5 67.0 0 Clear

15.01.08 4.1 14.6 9.1 ESE 19.0 26.5 65.3 0 Clear

16.01.08 3.6 13.0 7.8 ENE 19.0 26.5 68.0 0 Clear

17.01.08 2.2 11.2 6.7 ESE 18.5 26.0 68.3 0 Clear

18.01.08 2.9 12.7 7.9 ESE 18.5 25.5 66.6 0 Clear

19.01.08 2.7 13.3 7.6 ESE 19.0 27.5 62.8 0 Clear

20.01.08 2.5 10.0 7.2 ESE 19.0 27.5 61.0 0 Clear

21.01.08 2.3 10.4 5.9 ESE 19.0 28.0 61.7 0 Clear

22.01.08 2.5 10.8 5.2 ESE 19.5 28.5 59.0 0 Clear

23.01.08 1.3 9.6 4.6 SE 20.0 27.5 60.4 0 Clear

24.01.08 1.9 10.1 5.3 ESE 19.0 26.5 63.0 0 Clear

25.01.08 7.8 16.9 11.4 ESE 19.0 27.0 65.3 0 Clear

26.01.08 1.7 11.8 5.8 SE 19.0 27.0 63.4 0 Clear

27.01.08 1.4 9.8 5.0 SE 18.5 26.5 63.6 0 Clear

28.01.08 1.2 9.1 4.9 ESE 19.0 28.0 64.5 0 Clear

29.01.08 1.5 11.4 5.1 ESE 18.5 28.0 61.5 0 Clear

30.01.08 2.9 13.4 8.4 ESE 19.0 28.0 62.0 0 Clear

31.01.08 1.3 8.9 4.3 SE 18.5 26.0 62.8 0 Clear


Table - 3.7 : Abstract of Micro-meteorological data (Contd.,)

Wind speed KM/Hour

Temperature (°C) Date

Min Max Avg

Predominant Wind

direction Min. Max.


(%)

Rainfall mm

Sky Appearanc

e

1.02.08 3.9 13.5 8.7 ESE 19.5 28.5 63.1 0 Clear

2.02.08 5.7 14.8 9.0 ESE 19.0 28.0 63.1 0 Clear

3.02.08 3.1 12.9 7.4 ENE 19.0 28.5 60.8 0 Clear

3.02.08 1.9 15.1 8.8 SE 19.0 27.5 65.8 0 Clear

5.02.08 3.8 15.1 9.4 ESE 19.0 28.0 65.0 0 Clear

6.02.08 2.1 16.5 19.0 ESE 19.0 28.5 59.3 0 Clear

7.02.08 1.9 13.5 8.5 ESE 19.0 28.5 59.8 0 Clear

8.02.08 2.9 13.5 8.7 ESE 20.0 29.0 62.3 0 Clear

9.02.08 2.9 13.8 9.0 ENE 19.5 29.0 61.8 0 Clear

10.02.08 1.6 14.0 8.9 ENE 19.5 29.0 62.3 0 Clear

1112.07 2.6 13.1 8.5 ESE 19.5 29.0 61.0 0 Clear

12.02.08 1.6 10.3 8.5 ESE 19.5 29.5 62.0 0 Clear

13.02.08 1.9 12.6 7.7 ESE 19.5 12.6 59.9 0 Clear

14.02.08 1.6 11.6 7.7 ENE 20.0 29.5 60.1 0 Clear

15.02.08 2.9 14.9 8.6 ESE 19.5 29.5 61.5 0 Clear

16.02.08 2.9 13.5 7.1 ENE 20.0 29.0 61.0 0 Clear

17.02.08 2.4 12.6 8.6 ESE 20.0 30.0 60.3 0 Clear

18.02.08 3.2 15.4 8.8 ENE 20.0 30.0 60.8 0 Clear

19.02.08 1.9 14.5 8.1 ESE/ENE 20.5 29.5 57.7 0 Clear

20.02.08 1.6 10.6 6.9 ESE 20.0 30.0 58.8 0 Clear

21.02.08 2.6 14.9 8.1 ESE 20.0 30.0 61.6 0 Clear

22.02.08 1.6 16.5 7.8 WSW 19.5 30.0 59.4 0 Clear

23.02.08 2.6 13.8 7.3 WNW 20.0 30.0 56.9 0 Clear

24.02.08 1.6 12.6 6.5 WSW 21.0 30.0 59.1 0 Clear

25.02.08 1.6 13.5 8.8 WNW 21.0 30.5 58.0 0 Clear

26.02.08 2.8 11.6 7.4 WSW 20.5 30.5 59.0 0 Clear

27.02.08 1.9 11.9 7.2 WSW 20.0 30.0 58.2 0 Clear

28.02.08 1.8 11.5 7.1 WNW 21.0 30.5 56.7 0 Clear

29.02.08 2.1 11.6 6.2 WSW 21.0 30.5 57.4 0 Clear

Season 1.2 18.8 7.8 SE 15 30.5 66.7 17.3 Clear


Data Analysis

Meteorological data collected during the study reveals the following status.

Wind Direction: Predominant wind was from Northeast quadrant.

Wind Speed : Wind velocity readings were ranging from 1.2 to 18.8 Kmph.

Temperature : Temperature values were ranging from 15.0 °C to 30.5°C.

Relative Humidity: The mean relative humidity value was found to be 66.7%.

Cloud cover : Sky was clear during the study period.

Atm. pressure: The mean atmospheric pressure was found to be 752 mm of Hg.

Rainfall: A total rainfall of 17.3 mm was recorded during the study period.

3.1.2 Existing Ambient Air Quality

Methodology for Ambient Air Quality

The ambient air quality monitoring stations are shown in Fig. III.4 and given in Table 3.8.

Based on the project activities the parameters chosen for assessment of ambient air

quality were Suspended Particulate Matter (SPM), Respirable Particulate Matter (RPM),

Sulphur di-oxide (SO2), Oxides of Nitrogen (NOx) and Carbon Monoxide (CO). Random

sampling for Poly Aromatic Hydro-carbons (PAH) and Chemical characteristic of RSPM

at one location in core zone and four locations at buffer zone were carried out. A field

laboratory for the purpose of calibration of equipments and standardization of

analytical procedures was established and the samples were analyzed on the day of

sample collection. SPM were monitored on 24 hourly basis and all gaseous pollutants

(SO2, NOx & CO) were monitored on 8 hourly basis to meet the requirements of Central

Pollution Control Board (CPCB).


Fig. III.4


Table - 3.8 Ambient air quality monitoring stations (Distance & Bearing directions)

Sl.No Location name & code Distance in Km Direction

1 Project Site (A1) - -

2 Existing Plant (A2) - -

3 Dhanapura (A3) 2.5 NNW

4 Marimanhalli (A4) 3.0 NW

5 Nagalapura (A5) 3.0 SSW

6 Mugimavinahalli (A6) 9.5 SW

7 Haravanahalli (A7) 7.5 SW

8 Ramgad (A8) 6.0 E

9 Medarahalli (A9) 7.5 NE

10 Vysankari (A10) 9.5 NW

Data Analysis

Winter Season ( Dec06-Feb07)

The ambient air quality status is given in Table 3.9 and data are given in Annexure III.

At all location, the SPM and RPM values were ranging between 85 and 186 µg/m3 and

30 and 69 µg/m3 respectively. The SO2 and NOx values ere ranging between 5 and

16 µg/m3 and 6 and 30 µg/m3 respectively. Analysis report on PAH and chemical

characterization of RSPM are presented in Annexure III.The CO values were found to be

below the detectable limit of <114.5 µg/m3.

Summer Season ( March – May 2007)

The ambient air quality status is given in Table 3.10. At all location, the SPM and RPM

values were ranging between 102 and 185 µg/m3 and 32 and 69 µg/m3 respectively.

The SO2 and NOx values ere ranging between 5 and 16 µg/m3 and 7 and 25 µg/m3

respectively. The CO values were found to be below the detectable limit of

<114.5 µg/m3


Table 3.9 Ambient air quality status Unit : µg/m3

Location name & code Min 98th

Per. Max AM GM Std. dev

CPCB Limit

SPM

Project Site (A1) 136 170 176 153.21 152.8 10.1 500

Existing Plant (A2) 135 172 186 157.9 157.3 13.7 500

Dhanapura (A3) 110 142 146 123.4 123.1 9.7 200

Marimanhalli (A4) 108 135 145 123.8 123.6 8.5 200

Nagalapura (A5) 102 131 132 117.7 117.4 8.6 200

Mugimavinahalli (A6) 118 141 146 129.4 129.2 7.2 200

Haravanahalli (A7) 96 115 115 101.5 101.3 6.5 200

Ramgad (A8) 96 126 132 115.1 114.6 10.1 200

Medarahalli (A9) 95 126 134 107.6 107.2 9.1 200

Vysankari (A10) 85 102 112 96.8 96.6 5.9 200

RPM Project Site (A1) 32 62 63 52.8 52.4 6.5 150

Existing Plant (A2) 48 68 69 58.9 58.5 6.8 150

Dhanapura (A3) 42 57 58 46.9 46.8 3.7 100

Marimanhalli (A4) 36 47 48 43.2 43.1 2.7 100

Nagalapura (A5) 39 48 49 43.4 43.3 3.0 100


Haravanahalli (A7) 30 38 38 34.4 34.3 2.0 100

Ramgad (A8) 31 41 42 36.6 36.5 2.7 100

Medarahalli (A9) 30 38 38 34.8 34.7 2.1 100

Vysankari (A10) 31 40 41 36.0 35.9 2.8 100

SO2 Project Site (A1) 6 8 9 6.8 6.8 0.8 120

Existing Plant (A2) 8 16 16 12.0 11.8 2.2 120

Dhanapura (A3) 6 7 7 6.3 6.3 0.5 80

Marimanhalli (A4) 6 8 8 6.3 6.2 0.6 80

Nagalapura (A5) 6 7 7 6.2 6.2 0.4 80


Haravanahalli (A7) 6 7 7 6.2 6.2 0.4 80




CPCB Limit

Ramgad (A8) 5 8 8 6.7 6.6 1.0 80

Medarahalli (A9) 6 7 8 6.3 6.3 0.5 80

Vysankari (A10) 6 7 7 6.3 6.3 0.5 80 NOx

Project Site (A1) 8 18 18 13.7 13.4 2.4 120

Existing Plant (A2) 16 28 30 24.2 24.1 3.2 120

Dhanapura (A3) 6 10 10 8.4 8.2 1.7 80

Marimanhalli (A4) 10 18 18 14.2 14.1 2.1 80

Nagalapura (A5) 6 12 12 8.7 8.6 1.7 80


Haravanahalli (A7) 6 10 10 8.3 8.3 0.9 80

Ramgad (A8) 10 16 16 13.2 13.0 2.1 80

Medarahalli (A9) 8 12 14 10.8 10.7 1.4 80

Vysankari (A10) 8 10 12 9.0 9.0 1.1 80

Note : All CO values were found to be below the detectable limit of <114.5µg/m3 (0.1ppm)

Table 3.10 Ambient air quality status

Unit : µg/m3



CPCB Limit

SPM Project Site (A1) 142 182 184 158.4 153.8 11.2 500 Existing Plant (A2) 146 176 185 159.2 158.3 14.2 500 Dhanapura (A3) 120 145 152 132.4 131.8 10.2 200 Marimanhalli (A4) 108 151 151 126.4 124.6 9.5 200 Nagalapura (A5) 108 141 142 120.2 119.4 9.6 200 Mugimavinahalli (A6) 124 141 145 130.2 129.2 8.2 200

Haravanahalli (A7) 102 125 125 108.5 107.3 7.5 200 Ramgad (A8) 112 126 130 118.1 116.6 9.1 200 Medarahalli (A9) 110 125 134 117.2 115.2 9.4 200 Vysankari (A10) 110 112 114 106.5 104.2 6.2 200

RPM Project Site (A1) 36 64 65 52.8 51.6 6.2 150




CPCB Limit

Existing Plant (A2) 41 69 69 58.9 57.5 6.5 150 Dhanapura (A3) 40 55 58 46.9 45.2 3.8 100 Marimanhalli (A4) 36 50 52 43.2 43.1 2.8 100 Nagalapura (A5) 37 45 49 43.4 42.5 2.7 100 Mugimavinahalli (A6) 38 54 56 45.8 44.5 3.3 100

Haravanahalli (A7) 32 36 40 34.4 35.2 2.1 100 Ramgad (A8) 33 42 42 36.6 36.1 2.6 100 Medarahalli (A9) 34 37 39 34.8 33.2 2.2 100

Vysankari (A10) 32 42 43 36.0 35.2 2.5 100

SO2 Project Site (A1) 6 9 9 6.8 6.5 0.7 120 Existing Plant (A2) 7 15 16 12.0 11.8 2.3 120 Dhanapura (A3) 7 9 10 6.3 6.2 0.8 80 Marimanhalli (A4) 6 9 9 6.3 6.2 0.7 80 Nagalapura (A5) 6 8 8 6.2 6.2 0.5 80 Mugimavinahalli (A6) 6 8 8 7.2 7.1 1.2 80


NOx Project Site (A1) 8 16 18 13.7 13.4 2.9 120 Existing Plant (A2) 10 24 25 24.2 24.0 3.8 120 Dhanapura (A3) 7 12 13 8.4 8.0 1.8 80 Marimanhalli (A4) 9 14 15 14.2 13.8 2.4 80 Nagalapura (A5) 6 11 12 8.7 8.4 1.8 80 Mugimavinahalli (A6) 9 15 16 13.8 13.1 2.1 80


Note : All CO values were found to be below the detectable limit of <114.5µg/m3 (0.1ppm)


3.2 Noise Levels

Methodology

Noise levels were monitored at twelve locations within and outside the project

premises. Noise readings were taken for daytime as well as nighttime. CYGNET 100X data

logging Sound level meter was used for recording noise levels.

Data Analysis

The ambient noise level monitoring stations are shown in Fig. III.4. The noise level

abstract is given in Table 3.11.

The Day and night time Leq Noise levels were ranging from 42.1 dB(A) to 68.9 dB(A) and

34.8 dB(A) to 49.6 dB(A) respectively. It is observed that noise levels varied at different

sampling stations. The noise levels are found to be within the prescribed limits.

Table – 3.11 Noise Level status

Noise Level, dB(A) Day Time Night Time

S. No Location Name

Min Max Leq Min Max Leq 1 Project Site (N1) 49.7 54.7 52.4 40.8 47.6 43.3 2 Existing Plant (N2) 65.6 72.6 68.9 60.2 68.6 63.4 3 Dhanapura (N3) 46.5 53.8 49.1 38.3 44.8 41.6 4 Marimanhalli (N4) 55.6 65.4 60.1 38.1 44.5 41.3 5 Nagalapura (N5) 47.6 53.2 50.5 39.5 46.6 43.4 6 Mugimavinahalli (N6) 46.2 52.9 49.3 38.6 43.9 40.2 7 Haravanahalli (N7) 48.1 53.6 51.0 39.9 45.3 40.8 8 Ramgad (N8) 45.3 52.1 48.4 38.3 44.2 40.7 9 Medarahalli (N9) 45.1 50.8 48.3 36.5 42.4 38.4 10 Kalahalli (N10) 50.1 58.6 52.4 46.8 51.2 48.2 11 Ayinahalli (N11) 44.5 49.6 42.1 34.2 39.6 34.8 12 Devalapura (N12) 50.8 57.2 51.8 43.2 53.8 46.1

3.3 Water Environment

Reconnaissance survey was carried out based on the location of ground and surface

water bodies, which represent baseline condition. A total of 16 water samples Viz., 8

ground/drinking water samples (W1 – W8) and 8 surface water samples (W9–W16)


were collected and analyzed as per standard methods. The water quality monitoring

stations are shown in Fig. III.5 and Table 3.12. The ground and surface water quality

data are given Annexure IV.

Methodology

Seven no. of water samples and two no of surface water were collected during the

study period for Physico-chemical and Bacteriological parameters after taking suitable

precautions and analysed as per Standard methods. Samples were collected for

Chemical analysis as per procedure outlined in IS: 2488. Sterilised bottles were used for

collection of water samples for bacteriological analysis, stored in icebox and

transported to the laboratory for the analysis. Parameters like pH, Temperature, DO

etc. were measured in the field while collecting the samples. MPN index of coliforms

were determined in the laboratory as per Standard methods.


Fig. III.5


Table – 3.12 Water / Surface water quality monitoring stations

S.No. Location name Location Code

1 Borewell, Existing Plant W1

2 Borewell, Devalapura W2

3 Handpump, Mariyammanahalli Tanda W3

4 Handpump, Nagalapura W4

5 Borewell, Marimanhalli W5

6 Borewell, Mugimavinahalli W6

7 Handpump, Danapura W7

9 Borewell, Hanumanahalli W8

9 Pond, Dayanakhere W9

10 TB Dam W10

11 Pond, near Gunda W11

12 Pond, near Nagalapura W12

13 Tank water, Dhanapura W13

14 Tank water, Marimanhalli W14

15 Pond, near Nandipanda W15

16 Pond, near Vysankari W16

Data Analysis

Ground water

Winter : At all locations, pH values were in the range of 7.28 – 8.12 with agreeable

colour, taste and odour. Chloride and Sulphate values were in the range of 18 – 386

mg/l and 12 – 180 mg/l respectively. Hardness values were found to be in the range of

30 – 380 mg/l. Fluoride values were found to the maximum extend of 0.90 mg/l. At

all locations, oil and grease, phenolic compounds, cyanides, sulphides and insecticides

were found to be absent and all heavy metal except iron values were found to be

below the detection limit. Iron value was found to be a maximum extent of 0.16 mg/l.

The maximum total coliforms were found to be 8 MPN/100 ml. While comparing with

IS: 10500 – 1991 norms, all values except total coliforms were found to be well within

the limits.


Summer : At all locations, pH values were in the range of 7.13 – 8.42 with agreeable

colour, taste and odour. Chloride and Sulphate values were in the range of 22 – 408

mg/l and 18 – 215 mg/l respectively. Hardness values were found to be in the range of

38 – 396 mg/l. Fluoride values were found to the maximum extend of 0.98 mg/l. At

all locations, oil and grease, phenolic compounds, cyanides, sulphides and insecticides

were found to be absent and all heavy metal except iron values were found to be

below the detection limit. Iron value was found to be a maximum extent of 0.25 mg/l.

The maximum total coliforms were found to be 21 MPN/100 ml. While comparing with

IS: 10500 – 1991 norms, all values except total coliforms were found to be well within

the limits.

Surface water

pH values were found to be in the range of 8.1 – 8.24. At all locations Oil & Grease,

Phenols, Cyanides, Sulphides and insecticides were found to be absent and most of the

heavy metals values were found to be below the detectable limits. Also, low BOD/COD

values and good D.O. content at these locations indicate that the natural restoration

of water quality is maintained.

3.4 Soil Environment

In order to assess the baseline status of soil quality of the project site and

neighborhood, four sampling locations were selected. At each location, samples were

collected using augers and analyzed for nutrient and engineering parameters. The

location of Soil Sampling station is shown in III.5.The soil quality status is given in

Table No. 3.13.


Table 3.13 Soil quality status

Sl. No Parameters Project

Site (S1) Danapura

(S2) Gunda (S3)

Mariaman-halli (S4)

Nagalapura (S5)

1 pH 8.58 8.4 8.68 8.54 8.60

2 Electrical Conductivity (m-mhos/cm) 0.3 0.4 0.3 0.3 0.3

3 Nitrogen (Kg/ha) 102.0 110.4 124.0 104 114 4 Phosphorus (Kg/ha) 3.8 5.0 5.4 5.0 5.1 5 Potassium (Kg/ha) 140 168 170 155 162 6 Available Magnesium (%) 4.0 4.4 5.1 4.2 5.2 7 Organic Carbon (%) 1.02 1.0 1.4 0.9 1.6

8

Grain Size Distribution Gravel (%) Sand (%) Silt & Clay (%)

8.0 70.0 22.0

20.0 60.0 20.0

10.0 70.0 20.0

10.0 60.0 30.0

11.0 80.0 9.0

9 Textural Class Sandy Loam

Sandy Loam

Sandy Loam Sandy Loam Sandy Loam

10 Bulk Density (g/cc) 1.4 1.5 1.3 1.8 1.2 11 Liquid Limit (%) 16 14 18 15 16 12 Plastic Limit (%) 8.0 8.0 8.0 12.0 10.0 13 Infiltration Rate (cm/hr) 2.4 2.8 3.1 3.0 2.8 14 Field Capacity (%) 11.0 11.4 11.2 10.4 10.8 15 Wilting Co-efficient (%) 0.9 0.8 1.2 0.9 1.4

16 Available Water Storage Capacity (%) 10.1 10.6 10.4 9.5 9.8

At all locations, pH ranges from 8.4 to 8.68. The sand content of the soil ranged

between 60.0 and 80.0 %. Nitrogen, Potassium and Phosphorus are found to be in the

range of 102 – 124 Kg/Ha, 140 – 170 Kg/Ha and 3.8 – 5.4 Kg/Ha respectively. Organic

Carbon was found to be in the range of 0.9 – 1.4 %. Texture Class was found to be

Sandy Loam.


3.5 Land Environment

The area is a rugged and undulating terrain with an average elevation of 525 m above

MSL with the general slope towards north. In general the slope is moderate but steep

slopes are observed close to the Sandur hill ranges, which is the main topographic

feature in the area. The Sandur hills trend NW and are found east of the site forming a

spoon shaped hill range rising to a height of 1000 m above MSL. It is a doubly plunging

synform forming a structural basin broad in the south-eastern part and tapers in the

northwest. In the middle of the hill range a valley is found and hence it forms a spoon

shaped hill system. Isolated hillocks with sheet rocks or rocky knobs rising to a height

ranging from 75 to 100 m above the ground level and boulder outcrops are found

around the site as a result the area has an undulating topography.

Drainage and water bodies

The drainage system forms part of the Tungabadra river basin. The Tungabadra river

flows in the north-western part of the region and the construction of a dam west of

Hospet Town has formed a large reservoir with a water spread. The reservoir covers

much of the north western part of the area examined. The drainage pattern is

dendritic and the drainage density is moderate and is formed by the network of

several streams originating from the hillocks. Minor streams originating from the

Sandur hills, flows directly into the Tungabadra reservoir.

Lakes were formed by the construction of bunds across minor streams for storage of

water for irrigation. The Dhanayakana Kere is the largest and is located southeast of the

site. Several smaller lakes are found through out the area supplying water for irrigation.

However, most of the lakes go dry during summer which is fairly severe in this region.

Ground water in the region occurs in unconfined conditions in shallow weathered

portions and in semi confined conditions, in the fractured horizon. There are twenty

seven borewells, drilled within the existing industry area. Examination of the data

collected from these borewells indicate that the depth to water table varies from 6 to

10 m, the depth of borewell varies from 40 to 75 m and casing depth varies from 15 to

20 m. In these borewells water has been struck at depths of 25 m to 45 m. Yield of

borewell varies from 1 to 14 m3 per hour.


As per the Hydrogeological survey carried out for the area, it is noticed that “there is

ample scope for extracting Ground water in the premises of the Industrial Area.” The

depth of water table being very shallow there is a needed to depress the water table

to safer limit of 20 Mtr to prevent water logging conditions and create scope for

recharge.

Geology

The area is part of the Karnataka cratonic nuclei that exposes the oldest rocks of

Archaean age (4000 to 2.500 Ma (million years)). The Greenstone belts or schist belts

that are metamorphosed under varying grade occur as linear enclaves within grey

gneissic complex. These enclaves represent volcano-sedimentary sequences that were

formed in shallow seas that were existed during the Precambrian. They are linear belts

elongated in N-S and NNW-SSE directions and have been classified into three groups as

1) Ancient Supracrustals, 2) Auriferous Schist Belts and 3) Younger Schist Belts based

on the differences in age, metamorphism and mineralisation. The Ancient

Supracrustals are the oldest (>3000 Ma) and are metamorphosed under high grade

ranging from amphibolite to granulite facies. Occurrences of these schist belts are

found in the southern part of the state. Sargur, Krishnarajpet, Holenarasipur, Hadnur,

Nuggihalli, Kalyadi, Nagamangala, Ghattihosalli, Kunigal, Gundulupet and Gurgunta

belts. The mineralisations include Chromium, titanium, vanadium and tungsten. The

Auriferous Schist belts have formed during the time interval 3000 to 2500 Ma and hosts

the valuable gold deposits. They include the Kolar and Hutti-Maski, Pennar-Hagari,

Mangalur, Hungud-Kushtagi and Raichur-Deodurg schist belts. They are confined to the

eastern part of the state separated from the Younger schist belts by the Closepet

granite which forms a linear intrusion.

The younger schist belts also known as Dharwar type schist belts host bulk of the iron

ore deposits and include the Shimoga, Bhababudan, Kudremukh, Chitradurga and

Sandur schist belts. While volcanic rocks predominate in the other group of schist

belts, bulk of the younger schist belt are composed of metamorphosed sedimentary

rocks that were deposited in shallow basins. The volcano-sedimentary sequence is

deposited over the tonalitic-trondhjemitic gneisses that intruded the terrain after the

formation of the Ancient Supracrustals and Auriferous Greenstone belts.


The tonalitic – trondhjemitic gneisses hence form the basement for the Younger

Greenstone Belts. Intrusion of granites called as Closepet granite is an important event

in the evolution of the Dharwar craton and forms a linear intrusion extending in N-S

direction for nearly 500 km with an average width of 20 km almost parallel to the

alignment of the greenstone belts located in the region. The age of the granite is

inferred by radiometric dating methods as 2,528 ± 5 Ma.

The Sandur Schist Belt:

The Sandur schist belt is located in the eastern margin of the area and it contains

valuable iron and manganese deposits and has transformed the region into an

industrial belt. The Sandur schist belt is the smallest of the Younger Greenstone belts

covering an area of 960 sq. km. Its structure is highly disturbed by the regional

tectonics and the intrusion of the Closepet granite and has been squeezed out into two

parts. The eastern part known as Copper Mountain Range volumetrically is dominated

by mafic volcanic material and on the other hand the western part Sandur Belt

contains metasedimentary rocks in abundance. The metasedimentary rocks include

basal conglomerates, quartzites, manganiferous graywake, phyllite and numerous

bands of banded magnetite and haematite quartzites. The basin is known for its

richness in both iron and manganese ores.

The important deposits of iron ore in Sandur Belt are located in Donimalai, Devadari,

Kumaraswamy and Ramadurg ranges with proved reserves of over 500 million tonnes

with more than 62% Fe.

The area investigated comprise the rocks of the Sandur Schish belt forming the linear

hill ranges located in the eastern part of the area. The region west of the hill ranges

form the basement gneisses and the younger granites belonging to the Closepet

granite intrusion are found forming isolated hillocks and boulder outcrops in the

southern part of the area.

About the Site:

The area is covered by Clospet granite, greywacke and metabasalts, belonging to

Archean to lower Proterozoic. In particular the western part is covered by pink granite


and grey granite of Archean group and the eastern part is covered by argillites, Meta

volcanics of Chitradurga group. In geohydrological parallance the rocks are termed as

hard rock, which have been dissected by joint planes and have undergone weathering

and erosion. Granites in the area are medium to coarse grained, having pale pink and

grey color, rocks exposed in the area are bouldery in nature. They have two to three

sets of joints at places. Meta volcanics exposed outside the industry area are having

defined schistocity. It is generally NNW-SSE. (In the engineering geological context,

the rock formations are found out to serves as stable foundation).

Land-use Pattern

Remote sensing satellite Imageries were collected and interpreted for the 10 Km

radius study area with project site as center. Based on the satellite data land -use /

land cover maps have been prepared.

Land –use / Land cover classification system

The present land–use / land cover maps were prepared based on the classification

system of National standards. For explanation for each of the land –use category the

two references were used. Viz. 1.Manual of land use / land cover mapping satellite

imagery and 2. Manual procedures for waste land mapping. The details are given in

Table 3.14.

Table – 3.14 Land –use / Land cover classification system

Sl. No. Level 1 Level 2 1 Built up land Town / cities Villages 2 Agriculture land Crop land (Irrigated / rainfed) Plantations 3 Forest Evergreen / Semi evergreen Deciduous 4 Waste lands Saline / Sandy Marchy / Swampy 5 Water bodies Rivers / Stream Lake / Reservoir / Tanks 6 Others Shifting cultivation Grass land Salt pans Snow covered / glacial


Data requirement

IRS-1B Geo Coded False colour composite (FCC) products on 1:50000 scale of path 30

and row 45 with data were acquired from National Remote Sensing Agency, Hyderabad

and used for the mapping and interpretation. Besides other collateral data as available

in the form of maps, charts, census records other reports and especially topographical

survey of India maps on 1:50000 were used. In addition to this, ground truth survey

was also collected to verify and confirm the ground features.

Methodology

The methodology adopted for preparation of land use / land cover maps is

mono-scopic interpretation of geo-coded scenes of IRS -1B satellite, Sensor L2A2, L2B2

and field observations taken. The various steps involved in the study area are

preparatory fieldwork, field survey and post fieldwork.

Pre-field interpretation of Satellite details

The false colour Composite (FCC) of IRS-1B Satellite data at 1:50000 scale has been

used for pre-field interpretation work. Taking the help of topo sheets, geology, geo-

morphology and by using the image elements the features were identified and

delineated the boundaries roughly. Each feature is identified on image by their image

elements like tone, texture, colour, shape, size, pattern and association. A tentative

legend in terms and erosion was formulated. The sample areas for field check were

selected covering all the physio-graphic land-use / land cover features cum image

characteristics.

Ground Truth Collection

Ground truth field verification was conducted using both topo sheets and imagery.

Representative sample areas were traversed to observe the broad land–use features

and the sample areas were adjusted according to the field conditions. Detailed field

observations and investigations were carried out and land–use features on the imagery

were recorded.


Post field work

The base maps of the study area were prepared with the help of Survey of India Topo

sheet at 1:50000 scale. Preliminary interpreted land use and the land cover features

boundaries from IRS-1B FCC were modified in light of field information and the final

thematic details were transferred on to the base maps. The tentative legend during

the pre-field work were finalized. The final interpreted and classified thematic map

was prepared using standard colour coding and detailed description of features with

Standard symbols. All the classes are noted and marked by the standard legend on the

map. Visual interpretation of multi-sensor false colour imagery composite of the area

was prepared using LANDSAT satellite data (Fig. III.6).

Final output.

The final out put would be the land use / land cover on 1:50000 scale numerals are

given different colour code for each category as shown in map. Area estimation of all

the features of land –use / land cover categories are noted

Observations

The main interpreted Land use / land cover classes of the study area are presented in

Table 3.15

Table 3.15 Land-Use in buffer zone

Sl.No. Land use / Land cover Percentage of composition

1 Agricultural area 3.45 2 Forest 24.87 3 Scrubland (Open and Dense) 15.65 4 Fallow/Wetland 25.21 5 Built-up Area 4.58 6 Rocky Outcrop/Stony waste/Mining 2.50 7 Water body 6.10 8 Hilly tract 11.34 9 Proposed Industrial Plant 4.90 10 Existing Plant/dumping Yard 1.40


FIG. III.6 LANDUSE MAP

Please show the location of proposed colony in thia figure. As per TOR

NO.10 .


3.6 Biological Environment

Flora Analysis

The structure and composition of plant community depends on the factors like

location, temperature, water resource etc. A complete structure of plant community

could be obtained by studying both the terrestrial and aquatic flora of that particular

area. Since they are prone to be disturbed by the socio-economical status, it is

necessary to review or analysis their establishment.

Hence, the present study was carried out meticulously covering a distance of 10Sq.Km,

adopting the standard methodology of quadrant construction (Clements, 1898). It

includes laying down square sample plots or units for detailed analysis of vegetation.

Quadrants sizes of 1m × 1m, 5m × 5m and 100m × 100m were constructed for herbs,

shrubs and trees respectively, giving a replication of 10 numbers.

Data Analysis

Field survey was carried out at 9 locations in and around the plant site (10 Km radius)

Site – 1

Ramgad Reserve Forest

Herbs Abutilon indicum, G. Don. Abutilon neilghereinse, Munro. Acanthus sp. Achyranthus aspera, L. Achyranthus bidentata, Bl. Amaranthus viridis, L. Aristida depressa, Retz. Boerhaavia diffusa, L. Boerhaavia rependa, Willd Chloris barbata, Sw. Chloris bournei, Rang & Tad. Chloris polystachya, Roxb. Hyptis sp. Hyptis suaveolens, Poit. Indigofera tinctoria, L Justicia simplex, D. Don Mimosa pudica, L. Parthenium Paspalum conjugatum, Berg. Paspalum longifolium, Roxb Pavonia zelanica, Cav.

Pergularia pallida, W. & A. Phyllanthus neruri, L. Ruellia patula, Jacq. Ruellia prostrata, Poir Sida cordifolia, L. Sida rhombifolia, L.

Stachytarpheta indica, Vahl. Teliocora acuminata, Miers. Tephrosia purpurea, Pers. Tinospora cordifolia, Miers. Tridax procumbens, L. Tridax Sp. Triphyllus oxalis Tylophora asthmatica, W. & A. Vernonia cinerea, Less.

Medicinal herbs Indigofera tinctoria, L Justicia simplex, D. Don Justicia, Phyllanthus neruri, L.


Ruellia patula, Jacq. Ruellia prostrata, Poir Tridax procumbens, L. Tridax Sp. Triphyllus oxalis

Climbing Medicinally important herbs Abrus precatorius, L Gymnema sylvestre, R,Br Pergularia pallida, W. & A. Tinospora cordifolia, Miers. Tylophora asthmatica, W. & A Wattacaca volublis

Shrub Leea sp. Cassia sp. Cassia tora, L. Crotalaria juncea, L. Dichrostachys cinerea, W.&A. Glycine pentaphylla, Dalz. Lantana indica, Roxb. Pavetta indica, L. Pavetta parviflora Strobilanthes sp Tecoma stans Ipomaea sp. Zizyphus jujuba, Lam

Medicinally Important

Shrubs Anona squamosa, L. Atalantia monophylla, Corr. Azima tetragantha, L. Canthium parviflorum, Lam. Capparis zeylanica, L. Carissa diffusa, L. Cassia auriuilata, L. Fluggea leucopyrus, Willd. Glycosmis cochinchinensis, R,Br. Jatropha glandulifera, Roxb. Phyllanthus reticulates, Poir. Toddalia asiatica, Lam. Todonia viscosa Ipomaea sp.

Ornamental shrubs Dendrocalamus strictus, Nees.

Duranta repens, Nerium odorum, Soland.

Exotic shrubs Prosopis spicigera. L Lantana camara, L

Trees

Azadirachta indica, A. Juss. Bambusa arundinacea, Willd. Bassia latifolia, Roxb. Bauhinia purpurea, L. Borassus flabelliformis, L. Cassia alata, L. Crataeva religiosa, Forst. Dalbergia sissoo, Roxb. Emblica officinalis, Gaertn. Eucalyptus globules, Labill. Hardwicka binata,Roxb. Kigelia pinnata, Dc Maba buxifolia, Cl. Mangifera indica, L. Millingtonia hortensis, L. F. Morinda tinctoria, Roxb. Pongamia glabra, Vent. Santalum album, L. Swietenia mahagoni, L. Syzigium alternifolium, Walp. Syzigium jombolanum, DC. Terminalia catappa, L. Tinospora cordifolia, Miers. Wrghitia tinctoria, R. Br. Zizyphus jujuba var. fruticosa,Hains. Zizyphus jujuba, Lam Zizyphus oenoplia, Mill.

Dominant plants Amaranthus viridis, L. Cassia auriuilata, L. Techoma stans Hardwicka binata,Roxb. Kigelia pinnata, Dc Wrghitia tinctoria, R. Br

Rare occurrence Bambusa arundinacea, Willd. Dendrocalamus strictus, Nees. Leea sp


Endangered flora - Nil


Site - 2

Hanumanahalli Village Herbs

Boerhaavia diffusa, L. Boerhaavia rependa, Willd Clerodendron sp Gomphrena Sp. Ipomaea carnea, Jacq. Sch..&Wendle Sida rhombifolia, L.

Medicinal herbs Phyllanthus maderaspatensis, L. Solanum xanthocarpum, Sch. Todonia viscosa, Linn. Tridax sp

Climbing Medicinally important herbs

Coccinia indica, W.&A Solanum trilobatum, L

Shrub Agave americana, L. Cactus sp. Gajanus gajan, L Ipomaea sp. Zizyphus jujuba, Lam


Shrubs Cassia auriculata, L. Calotropis gigantea, R. Br. Fluggea leucopyrus, Willd. Jatropha glandulifera, L.. Randia dumetorum, Lam.

Exotic shrubs

Prosopis spicigera. L Lantana camara, L

Trees

Euphorbia antiquorum, Linn. Eucalyptus globulus, Labill Hardwickia binata,Roxb. Phoenix sylvestris, Roxb. Syzigium jambolanum, DC Moringa oleifera, Lam.

Dominant plants

Prosopis spicigera. L. Amaranthus viridis, L.

Rare occurrence Solanum xanthocarpum, Sch.

Endangered flora – Nil

Site - 3 Project site Herbs

Achyranthes aspera, L Amarantus sp.

Borreria hispida, K.Sch. Cassia fistula, L. Cassytha sp. Chloris barbata, Sw. Chloris bournei, Rang & Tad. Chloris polystachya, Roxb. Cyperus sp. L. .Duranta repens, Eclipta alba, Hassk Euphorbia heterophylla, Linn. Gomphrena decumbens, Jacq.

Amaranthus viridis, L. Ipomaea batatas, Poir

Ipomaea carnea, Jacq. Leucas aspera, Spr. Salvia sp. Lycopersicum esculentum, Mill. Melochia umbellate, Stapf. Mollugo sp. L. Ocimum canum, L Oldenlandia biflora, L. Paspalum longifolium, Roxb. Sesamum indicum, L. Sesamum prostratum, Retz Sida acuta, L. Sida cordifolia, L Sida rhombifolia, L.


Teliocora acumunata ,L Tephrosia purpurea, Pers. Threophonum sp

Trianthema decandra, L. Vernonia cinera, Lees. Waltheria indica, L Abutilon indicum, G. Don. Acanthus sp. Achyranthus aspera, L. Aristida depressa, Retz. Boerhaavia diffusa, L. Indigofera tinctoria, L Phyllanthus neruri, L. Triphyllus oxalis Tridax procumbens, L.

Medicinal herbs Catheranthus roseus Croton sparsiflorus, Mor

Cyanodon dactylon, Pers. Evolvulus alsinoides, L Phyllanthus maderaspatensis, L. Physalis minima, L Solanum nigrum, L. Solanum xanthocarpum, Sch.&Wendle

Climbing Medicinally important herbs Cardiospermum halicacabum, L. Dolichos lablab, L. Solanum trilobatum, L

Aquatic herbs.

Marselia sp Shrub

Ehretia buxifolia, Roxb Jatropha glandulifera, Roxb. Lawsonia alba, Lam Carissa diffusa, L. Cassia auriculata,L. Cassia sp. Cassia tora, L. Crotalaria juncea, L. Dichrostachys cinerea, W.&A. Glycine pentaphylla, Dalz. Hyptis suaveolens, Poit. Tecoma stans Ipomaea sp.


Shrubs Calotropis gigantea, R. Br Canthium parviflorum, Lam. Euphorbia tirucalli, L. Nerium odorum, Soland.

Ornamental shrubs

Rosa sp. Hibiscus rosasinensis, L. Thuja Duranta repens, Nerium odorum, Soland.

Ixora corymbosa ,Ham


Trees

Terminalia catappa, L Wrightia tinctoria, R. Br. Mangifera indica, L. Pongamia glabra, Vent. Syzigium jambolanum, DC. Tectona grandis, L. Acacia arabica, Willd Acacia leucophloea, Willd Acrus Sapota Albizzia lebeck, Benth. Areca catechu, L. Azadirachta indica, A. Juss. Borassus flabelliformis, L. Cocos nucifera, L Dichrostachys cinerea, W.&A Emblica officinalis, Gaertn Bassia latifolia, Roxb.

Dominant plants

Amaranthus viridis, L. Cassia auriuilata, L. Parthenium

Rare occurrence Acrus Sapota Bassia latifolia, Roxb. Mangifera indica, L.



Site – 4 Mariyammanahalli Tanda village

Herbs

Abutilon indicum, G. Don. Amaranths sp Commelina sp. L.

Cymbopogon citrates, Stapf. Cyperus sp. L. Eragosistis sp. Justicia simplex, D. Don. Lagenaria vulgaris, Ser. Martinia sp. Mimosa pudica, L. Mirabilis jalaba, L. Ocimum canum, L Sida acuta, L. Sida cordifolia, L Sida rhombifolia, L. Stachytarpheta indica, Vahl Teliocora acumunata ,L Vernonia cinerea, Less.

Climbing herbs Antigonon leptopus, Hk&A. Ipomaea staphylina R.&S.

Medicinal herbs Acalypha indica,L. Andropogon nadus,Linn Croton sparsiflorus, Mor Cyanodon dactylon, Pers. Datura stramonium, L Ocimum sanctum, L. Phyllanthus neruri, L.

Climbing Medicinal herbs Cardiospermum helicacabum, L. Pergularia pallida, W. & A. Solanum trilobatum, L Tylophora indica, L.

Aquatic herbs Hygrophilla angustifolia,R. Br. Typha angustata, B.& Ch Food crops Oryze sativa, L. Gajanus gajan, L. Dolichos lablab, L. Cucurbita melo, L. Arachis hypogaea, Willd Zea mays, L.

Shrubs Cactus sp. Dichrostachys cinerea, W&A. Zizyphus jujuba, Lam

Medicinal shrubs Calotropis gigantea, R. Br. Carissa diffusa, Roxb Cassia auriculata, L. Ehretia buxifolia,Roxb. Jatropha glandulifera, L Phyllanthus reticulates, Poir Randia dumetorum, Lam Todonia viscosa, Linn. Vitex negundo, L.

Ornamental shrubs Bougainvillaea glabara, Choisy


Exotic invasive weed

Parthenium hysterophorus L.

Trees Acacia leucophloea, Willt


Albizzia lebeck, Benth Borassus flabelliformis, L. Cassia fistula, L. Cocos nucifera, L Dalbergia sissoo, Roxb. Mangifera indica, L. Morinda tinctoria, Roxb. Moringa olefera, Lam Muraya konigii, Spr Pavetta hispidula,W&A. Pavetta indica, L. Phoenix sylvestris, Roxb. Pithocelobium saman, Nees. Pongamia glabra, Vent Strobilanthus sp Tamarindus indica, L.

Thespesia populnea, Cav.

Dominant plants Eragosistis sp. Abutilon indicum, G. Don. Sida acuta, L. Sida cordifolia, L Sida rhombifolia, L.

Rare occurrence Phoenix sylvestris, Roxb. Strobilanthus sp Hygrophilla angustifolia,R. Br.


Site – 5 MariamanahalliI

Herbs

Accanthus sp. Achyranthes aspera, L Clerodendron sp Cyperus sp. L. Gomphrena sp.Jacq. Scoporia dulsis,L. Sida acuta, L. Sida cordifolia, L Sida rhombifolia, L. Teliacora acuminata, Miers.

Medicinal herbs Aerva tomentosa, Forsk. Catheranthus roseus Croton sparsiflorus, Mor Euphorbia hirta, Linn. Ocimum sanctum, L. Tridax procumbens, Ham Solanum nigrum, L.

Climbing medicinal herbs Coccinia indica, W&A. Solanum nigrum, L.

Aquatic herbs.

Marselia sp Hygrophilla angustifolia,R. Br. Apanogeton monostachyon, L. Marselia sp Nymphaea sp. Typha angustata, B.& Ch

Food crops Cucumis melo, L. Zea mays. L. Sacharum officinarum, L.

Exotic invasive weed Parthenium hysterophorus L. Kyllinga sp.

Shrubs Anona squamosa, L. Cactus sp. Cassia alata, L. Cassia tora, L Hyptis suaveolens, Poit.

Medicinal shrubs Canthium parviflorum, Lam. Carissa diffusa, Roxb Fluggea leucopyrus, Willd Nerium odorum, Soland. Randia dumetorum, Lam Ricinus communis, L. Cassia auriculata, L. Jatropha glandulifera, L


Exotic shrubs

Prosopis spicigera. L Lantana camara, L

Trees Acacia arabica, Willd Azadiracta indica, A. Juss Bassia latifolia, Roxb. Cassia fistula, L. Delonix regia, Raf. Euphorbia antiquorum, Linn. Ficus Cretovara, Roxb. Ficus religiosa, L Phoenix sylvestris, Roxb. Pithecolobium dulce, Benth. Polyalthia longifolia, Hk.F&T.

Pongamia glabra, Vent Strobilanthus sp Tamarindus indica, L. Tectona grandis, L. Terminalia catappa, L.

Dominant plants Amaranthus viridis, L. Cassia auriuilata, L. Parthenium hysterophorus L.

Rare occurrence Marselia sp Nymphaea sp


Site – 6 Nandibanda

Herbs Abutilon indicum, G.Don. Achyranthes aspera, L Amaranths sp. Clerodendron sp Cyprus sp. Gomphrena procumbens, Jacq. Amaranthus viridis, L. Ipomaea sp. Sida cordifolia, L. Sida rhombifolia, L. Stachytarpheta indica, Vahl. Tephrosia pupurea, Pers Waltheria indica, L.

Medicinal herbs Aerva tomentosa, Forsk Croton sparsiflorus, Mor. Cyanodon dactylon, Pers. Eclipta alba, Hassk. Evolvulus alsinoides, L. Physalis minima, Linn Tridax procumbens, Ham

Climbing medicinal herbs Lagenaria vulgaris, Ser. Coccinia indica, W&A. Tinospora cardifolia, Miers.

Tylophora indica, Thw Pergularia pallida, W&A.

Food crops Arachis hypogaea, Willd Lycopersicum esculentum, Mill. Phaseolus mungo, L.

Exotic invasive weed Parthenium hysterophorus L.

Shrubs Cassia alata, L. Cassia auriculata, L. Cassia tora, L Clerodendron sp

Medicinal shrubs Calotropis gigantea, R. Br Euphorbia tirucalli, L. Phyllanthus rediculatus, Poir. Todonia viscosa, Linn. Vitex negundo, L.


Trees Acacia leucophloea, Willt. Albizzia lebeck, Benth. Azadiracta indica, A. Juss


Borassus flabelliformis, L Cocos nucifera, L Euphorbia antiquorum, Linn. Ficus religiosa, L Syzigium jambolanum, Dc Tamarindus indica, L. Wrightia tinctoria, R. Br.

Dominant plants

Amaranthus viridis, L. Cassia auriuilata, L. Parthenium hysterophorus L. Sida cordifolia, L. Sida rhombifolia, L.

Rare occurrence Lagenaria vulgaris, Ser.

Site – 7 Dhanapura village Herbs

Abutilon indicum, G.Don. Accanthus sp. Achyranthes aspera, L Amaranthus sp. Crotoloria ternatea, L. Dolichos lablab, L. Paspalum longifolium, Roxb. Salvia sp. Sida acuta, L. Sida cordifolia, L

Climbing medicinal herbs

Tinospora cordifolia, Miers Pergularia damea

Shrubs Crotoloria ternatea, L.

Medicinal Shrubs Fluggea leucopyrus, Willd Ricinus communis, L.


Exotic shrubs Prosopis spicigera. L

Lantana camara, L Trees

Aegle marmelos, Corr. Albizzia lebeck, Benth. Atlantia sp. Azadiracta indica, A. Juss Carica papaya, L. Cocos nucifera, L Dalbergia sissoo, Roxb. Eucalyptus globulus, Labill Fluggea leucopyrus, Willd Strobilanthus sp Psidium guajava, L. Syzigium jambolanum, Dc. Tamarindus indica, L. Tectona grandis, L.

Dominant plants Paspalum longifolium, Roxb. Salvia sp.

Rare occurrence Aegle marmelos, Corr. Atlantia sp.

Endangered flora - Nil Site – 8 Gaaga village

Accanthus sp. Amaranthus viridis, L. Commelina sp. Hygrophilla angustifolia,R. Br.

Ipomaea sp. Jasminum sp

Marselia sp Merremia vitifolia, Hall.f.. Mirabilis jalaba, L. Sida rhombifolia, L. Vernonia cinerea, Less.

Medicinal herbs


Acalypha indica,L. Boerhaavia diffusa, L Brassica campestris, L. Croton sparsiflorus, Mor Cyanodon dactylon, Pers Datura stramonium, L. Ocimum sanctum, L. Tribulus terrestris, L. Tridax procumbens, L

Climbing medicinal herbs Coccinia indica, W&A. Catheranthus roseus Cucurbita sp. Lagenaria vulgaris, Ser. Tinospora cardifolia, Miers. Tylophora indica, Thw Crotoloria ternatea, L.

Aquatic herbs. Marselia sp Hygrophilla angustifolia,R. Br. Typha angustata, B.& Ch


Shrubs

Cassia alata, L. Cassia tora, L Clerodendron sp Zizyphus jujuba, Lam. Zizyphus sp.

Medicinal shrubs Calotropis gigantea, R. Br Cassia auriculata, L. Randia dumetorum, Lam. Ricinus communis Todonia viscosa, Linn.

Ornamental shrubs Bougainvillaea glabara, Choisy Hibiscus rosasinensis, L. Ixora corymbosa ,Ham Jasminum sp Nerium odorum, Soland Rosa sp.

Tecoma stans Thuja


Trees Acacia arabica, Willd.

Acacia leucophloea, Willt. Aegle marmelos, Corr. Anona squamosa, L. Areca catechu, L. Azadiracta indica, A. Juss. Bauhinia diphylla, Ham. Bauhinia purpurea, Ham. Carica papaya, L Cassia fistula, L Casuarina equisetifolia, Forst. Cocos nucifera, L

Croton sparsiflorus, Mor Dalbergia sissoo, Roxb. Delonix regia, Raf. Emblica officinalis, Gaertn. Eucalyptus globulus, Labill Euphorbia antiquorum, Linn. Ficus bengalensis.L Ficus Cretovara, Roxb Ficus religiosa, L Mangifera indica, L. Millingtonia hartensis, L Morinda tinctoria, Roxb. Moringa olefera, Lam Nyctanthes arbor-tristis. L. Pithecolobium dulce, Benth. Pongamia glabra, Vent Strobilanthus sp Tamarindus indica, L. Tectona grandis, L. Terminalia catappa, L. Thespesia populnea, Cav.

Dominant plants Sida rhombifolia, L Eucalyptus globulus, Labill

Rare occurrence

Typha angustata, B.& Ch Hygrophilla angustifolia,R. Br.



Site – 9 TB DAM Herbs

Abutilon indicum, G.Don Accanthus sp. Canna indica, L. Cimbopogon citrates, Staf Crossandra sp. Crysanthimum sp. .Dendrobium sp. Ecbolium viridi Heliotropium brevifolium, Wall. Ipomea sp. Justicia simplex, D. Don. Salvia sp. Merremia vitifolia, Hall.f.. Paspalum longifolium, Roxb. Pongamia glabra, Vent Stachytarpheta indica, Vahl. Tephrosia pupurea, Pers Threophonum sp. Thuja Triphyllus oxalis, L. Vernonia cinerea, Less

Aquatic herbs. Typha angustata, B.& Ch

Medicinal herbs Acalypha indica,L Androphogon nadus, Linn. Brassica campestris, L. Euphorbia hirta, Linn. Evolvulus alsinoides, L. Leucas aspera, Spr. Ocimum sanctum, L. Cynodon dactylon, Pers Phyllanthus niruri, L. Ruellia paniculata, Nees Solanum nigrum, L. Tridax procumbens, Ham

Climbing herbs Dolichos lablab, L. Crotoloria ternatea, L

Climbing medicinal herbs

Tinospora cardifolia, Miers.


Shrubs Anona squamosa, L.

Brassica campestris, L. Cassia alata, L. Cassia auriculata, L. Cassia tora, L Clerodendron sp

Medicinal shrubs

Todonia viscosa, Linn Phyllanthus rediculatus,Roxb Ricinus communis Calotropis gigantea, R. Br Jatropha glandulifera, L

Ornamental shrubs

Bougainvillaea glabara, Choisy Ixora corymbosa ,Ham Ixora chinensis ,Ham Thuja Tecoma stans Duranda repens


Trees Acrus sapota Azadirachta indica, A. Juss. Callistemon rigidus, L Caesalpinia pulcherrima, L. Carica papaya, L. Cassia fistula, L. Casuarina equisetifolia, Forst. Cycas sp. Delonix regia, Raf. Ficus bengalensis.L Ficus glomerata, Roxb. Ficus religiosa, L Mangifera indica, L. Morinda tinctoria, Roxb. Odina sp. Pongamia glabra, Vent Tamarindus indica, L. Terminalia catappa, L.

Dominant plants Salvia sp. Cassia alata, L. Cassia auriculata, L.


Rare occurrence

Caesalpinia pulcherrima, L. Casuarina equisetifolia, Forst. Typha angustata, B.& Ch



Fauna Analysis

Based on actual field verification and interaction with local people and forest staff it is

observed that very few of the listed common wild animals and common birds are actually

found in the project area. Also because of high anthropogenic pressure due to the highway and

consequent development of human and industrial / mining activity it is not been conducive for

wildlife to inhabit the area. The list of wild mammals and reptiles found in the study area are

listed in Table 3.16.

Table 3.16 List of Wild Mammals Found in the Study Area

Common Name Scientific Name Schedule of Protection Act in which listed

A. Mammals

Common jungle cat Felis chans II

Common mongoose Herpestres edwardsii -

Jackal Canis aureus II,V

Wild dog Cuon alpinus II

Fox Vulpes bengalensis II

Porcupine Hystrix indica IV

Common hares Lepas sp. IV

Wild boar Sus scrofa III

Barking deer Muntiacus muntiacus III

Sambar Cervus unicolor III

Spotted deer Axis axis III

Striped Palm Squirrel Funambulus palmatum IV

Rhesus monkey Macaca mulata II

B. Reptiles

Indian Cobra Naja naja II

Yellow rat Snake Ptyas mucosus II

Common Krait Bungarus caeruleus IV

Russel’s Viper Vipera russelii II

Checkered Keelback Xenochropis piscator II


The common snakes found in the region are Kraits and Cobras.

The main T.B. Dam lies some 5 km away from site. Many of the duck like bird are seen in

main reservoir water near the project site. The birds found in the area are given in

Table 3.17.

Table 3.17 List of Birds Commonly Found in the Area

Common Name Scientific Name Schedule of Wildlife

Protection Act in which listed

Paddy Bird Ardeola grayii IV

Large Indian Parakeet P. eupatria IV

Rose Ringed Parakeet P. krameri IV

Brahminy Duck Tadorna ferrugninea IV

Red Wattled Lapwing Vannelus indicus IV

Crow Pheasant Centropus sinensis IV

Koel Eudynamis scolopacea IV

White Breasted kingfisher Halcyon smyrnansis IV

Small green Bee-eater Merops orientalis IV

Coot Fulica atra IV

Common Crow C. splendens V

Hill Mynah Gracula religiosa IV

Common Mynah Acridotheres tristis IV

House Sparrow Passer domesticus -

Golden Backed Woodpecker Dinopium benghalense IV

Red Vent Bulbul Pycnonotus cafer IV

Spotted Dove Streptopelia chinensis IV Spur Fowl Galloperdix spp IV

Auatic Ecology

The main water bodies in the area are T.B. Dam & Darojikere Reservoir.The data on

ecology of the aquatic ecosystem in the study area is based on literature and field survey.

There are a number of ponds in the villages in the study area. On visual observation these

ponds seems to be oligo-trophic to mesotrophic in nutrients status. The common rooted

plants and hydrophytes on the edges of these pons are Nelumbo sp., Potamogeton sp.,

Aponogeton sp.,Ipomea sp., Dichanthium sp., etc. The water in these ponds are colourless

to slight greenish in color.


The Phytoplanktons in the rivers are basically dominated by filamantous forms.

The dominant ones are, Chaetophora sp., Cladophora sp., Pithephora sp.,

Oscillatoria so., Spirogyra sp., Cymbella sp., etc.

The Zooplanktons are basically dominated by Crustaceans and Rotifers. The

dominant ones are Crustaceans : Crustacean eggs, Moinodaphina, Chydorus, Cyclops.

Rptifers : Brachionus, Rotiferan, etc. Others : Nematodes, Dipteran larvae, etc.

Fishes

The T.B. Dam is the main ecosystem supporting fishes in the area. The maximum abundance

of fishes was reported during April to July. The fishes observed in the T.B . Dam and the

nearby reservoirs is given in Table 3.18.

Table 3.18 Fish Fauna observed in the Study Area

Sl. No. Name of fish 1 Catla catla

2 Labeo fimbriatus

3 Labeo calbasu

4 Cirrhinus mrigala

5 C. reba

6 Barbus tor

7 Puntius sarana

8 Mystus seenghala

9 Mystus sor

10 Silonia silondia

11 Wallago attu

12 Pangasius pangasius

13 Rita chrysea

14 Eutropiichthys vacha

15 Bagarius bagarius

16 Notopterus notopterus

17 Notopterus chitala

18 Gudusia chapra

19 Rohtee cotio

20 Pama pama

21 Glossogobius guiris

22 Rhinomugil corsula

23 Xenentodon cancila


Sl. No. Name of fish 24 Chela sp.

25 Chela bacailla

26 Ailea coilfa

27 Ambassis nama

28 Ambassis sp

29 Puntius sophore

30 Puntius ticto

31 Puntius chola

32 Puntius dorsalis

33 Mastacembelus armatus

34 Mastacembelus pancalus

Conclusion

No endangered and endemic species ( flora & fauna ) recorded in the project site and its

surroundings, hence conservation plan is not required.

3.7 Socio Economic Study

Socio-economic development is closely linked with the growth of industrialization. The

industrial policy resolution in the year 1956 stressed the need of reducing regional disparities

in levels of development in order that industrialization may benefit the country as a whole.

This view was further endorsed in the new industrial policy statement (1980) which further

felt that revival of the economy was inhibited by infrastructure gaps such as shortage in

major industries. The policy also emphasized the need to promote suitable industries in rural

areas. The process of industrial transitions where new industrial units are setup in a

primarily agrarian economy is bound to create its impact on the socio-economic aspects of

the local people. Therefore studies on the socio-economic impact of industrialization on the

local population no doubt deserve considerable attention. The present study is being carried

out to ascertain the impacts of proposed plant on the socio-economic conditions of local

people. The data required to study the above aspects has been collected from secondary

sources.

3.7.1 Methodology The methodology adopted for the study is based on Review of secondary data (2001 District

Census) with respect to population, occupational structure and infrastructure facilities

available in the region.


3.7.2 Review of Socio-economic Profile

The information on socio-economic aspects of the study area has been compiled from

secondary sources, which include information from various public and semi-public offices.

The demographic data has mainly been compiled from Census of India 2001 data as this

document is comprehensive and authentic. The sociological aspects like human settlements,

demography and other socio-economic aspects in the study area have been covered in this

study. The socio-economic details are briefly described in the following sections.

Study area of 10 km falls in Hospet Taluk and part of study area falls in Sandur and

Hagaribommanahalli Taluk [H.B. Halli], Bellary District. Major portion of the study area

comprises only rural area. Study area contains 21 villages. Of these, 15 villages are in Hospet

Taluka, 5 villages are in Sandur Taluk and 1 village is in H.B. Halli Taluk. The villages that

come partly within study area of 10 km are also covered in the present study.

3.7.3 Demography As per 2001 census, the study area consisted of 51210 persons inhabited in 21 villages. The statistics

regarding the list of villages, number of households and human population is given in Table 3.19.

TABLE- 3.19 DEMOGRAPHY IN STUDY AREA

Sr. No. Name of Village No of Households Population 1 Ayyanahalli 160 927 2 Byalakundi 162 865 3 Danapuram 939 5083 4 Danayakanakere 392 2263 5 Devalapura 789 4563 6 Garga 348 1907 7 Gollarahalli 272 1533 8 Hanumanahalli 0 0 9 Haravanahalli 159 995 10 Kallahalli 391 2132 11 Mariyammanahalli 2277 12195 12 Mariyammanahalli Thanda 294 2089 13 Medarahalli (Jaisingapur) 335 1814 14 Nagalapura 735 4320 15 Nandibanda 198 1137 16 Rajapura 348 1922 17 Ramgad 111 553 18 Siddapur 181 1118 19 Varadapura 387 2252 20 Venkatapuram Colony 202 1314 21 Vyasanakere 445 2228 TOTAL 9125 51210


Source: Census 2001 Karnataka State PCA2912 The distribution of population in the study area is shown in Table-3.20.

TABLE- 3.20 DISTRIBUTION OF POPULATION

Particulars Rural Urban Total

Total Population 51210 0 51210 Male Population (% with total population)

25794 (50.37%) 0 25794

(50.37%) Female Population (% with total population)

25416 (49.63%) 0 25416

(49.63%) No. of Households 9125 0 9125 Average Household Size 5.6 0 5.6 Sex ratio (Female/1000 male) 985.34 0 985.34

Source: Census of India 2001 The configuration of male and females indicates that the males constitute to about 50.37%

and females to about 49.63% of the study area population. The sex ratio i.e. the number of

females per 1000 males indirectly reveals certain sociological aspects in relation with female

births, infant mortality among female children and single person family structure, a

resultant of migration of industrial workers. The study area at an average has 985.34 females

per 1000 males.

3.7.4 Social Structure Majority of the people in the study area belong to Hindu religion. The study area also

contains Scheduled Castes (SC) and Scheduled Tribes (ST). The distribution of population of

socially weaker sections in the study area is shown in Table-3.21

TABLE-3.21 DISTRIBUTION OF POPULATION BY SOCIAL STRUCTURE

Category Rural Urban Total

Total Population 51210 0 51210 Scheduled Castes 12599 0 12599 % to total population 24.60% 0 24.60% Scheduled Tribes 11751 0 11751 % to total population 22.94% 0 22.94% Total SC and ST 24350 0 24350 % to total population 47.54% 0 47.54%

In the study area 24.60% of the population belongs to Scheduled Castes (SC) while 22.94% to

Scheduled Tribes (ST), thus indicating that about 47.54% of the population is formed by SC and

ST population. Scheduled Caste and Scheduled Tribe sections are predominant in this area.

3.7.5 Literacy Levels


The distribution of literates and literacy rates in the study area are given in Table- 3.22


TABLE-3.22 LITERACY LEVEL

Particulars Rural Urban Total Total Population 51210 0 51210 Male population 25794 0 25794 Male literates 13383 0 13383 Female population 25416 0 25416 Female literates 7825 0 7825 Total literates 21208 0 21208 % of study area literates to total population 41.41% 0 41.41% Male literacy rate 51.88% 0 51.88% Female literacy rate 30.79% 0 30.79%

Source::Census of India 2001 The study area experiences a moderate literacy rate of 41.41%. The male literacy i.e. the

percentage of literate males to the total males of the study area is observed as 51.88% while

female literacy rate, which is an important indicator for social change, is observed as 30.79%

in the study area.

3.7.6 Occupational Structure The occupational structure of the study area is studied with reference to main workers,

marginal workers and non-workers. The main workers include 10 categories of workers

defined by the Census Department consisting of cultivators, agricultural laborers, those

engaged in live-stock, forestry, fishing etc. mining and quarrying; manufacturing, processing

and repairs in household industry; and other than household industry, construction, trade &

commerce, transport & communication and other services.

Due to boom in Iron Ore in recent years majority of farmers as well as agriculture laborers

are engaged in the mining activity. This information is not forthcoming from the Published

Census Data.

The marginal workers are those engaged in some work for a period of less than six months

during the reference year prior to the census survey. The non-workers include those engaged

in unpaid household duties, students, retired persons, dependents, beggars, vagrants etc.;

institutional inmates or all other non-workers who do not fall under the above categories.

The occupational structure of the study area is shown in Table-3.23.


TABLE-3.23 OCCUPATIONAL STRUCTURE OF STUDY AREA

Rural Urban Total Occupation No. % to

population No. % to

population No. % to

population Total Workers 25634 50.05 0 0 25634 50.05 Cultivators 6810 13.29 0 0 6810 13.29 Agricultural laborers 7527 14.69 0 0 7527 14.69

Household industries laborers 771 1.5 0 0 771 1.5

Others 5284 10.31 0 0 5284 10.31 Total main workers 20392 39.82 0 0 20392 39.82

Marginal workers 5242 10.23 0 0 5242 10.23 Non-workers 25576 49.94 0 0 25576 49.94 Total population 51210 100 0 0 51210 100

Source:Census of India 2001 Altogether the main workers work out to be 39.82% of the area population. The marginal

workers and non-workers constitute to 10.23% and 49.94% of the population respectively.

The distribution of workers by occupation indicates that the workers in the other category

are (10.31%) followed by cultivator’s laborers and household industries laborers respectively.

The cultivators and agricultural laborers together form 27.98% of the total population. The

occupational profile of total workers and their proportion to the total population of the

study area is shown graphically in the figure III.7.

FIG. III.7 Distribution of Total Workers in Study Area


3.7.7 Amenities Available Amenities available in the villages considered in the Study Area have been collected from

Census Book for the District. Educational facilities, Healthcare facilities, Water supply,

Communication facilities, Banking facilities, Road and Transportation facilities, availability

of news papers & magazines etc., are covered in these amenities. It is noticed that villages

have majority of all these facilities. A bigger town namely Mariyammanahalli is located

within distance of 8 to 10 Km from these villages were all these facilities are available.

Mariyammanahalli town is located at the intersection of National Highway-13 and State

Highway. The facilities available for all the villages in the Study Area and such

facilities available in respect of 5 villages in whose jurisdiction lands for the project is

being procured is furnished in Table:3.24 and 3.25 respectively.


TABLE 3.24 AMENITIES AVAILABLE IN THE STUDY AREA

AMENITIES AVAILABLE IN THE STUDY AREA

DISTRICT CENSUS HANDBOOK

SL. No VILLAGE NAME

Ayy

anah

alli

Dev

alap

ura

Gol

lara

halli

Han

uman

ahal

li

Har

avan

ahal

li

Kalla

halli

Mar

iyam

man

ahal

li

Mar

iyam

man

ahal

li

Than

da

M

edar

ahal

li (J

aisi

ngap

ur)

Nan

diba

nda

Raja

pura

Ram

gad

Sidd

apur

(H

unis

avut

i)

Vara

dapu

ra

Venk

atap

uram

Co

lony

Vyas

anak

ere

1 Number of Primary School 2 2 2 0 2 0 6 2 2 2 0 0 2 0 2 1

2 Number of Middle School 1 1 1 0 1 0 6 1 1 1 0 0 1 0 1 0

3 Number of Secondary School 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0

4 Number of Senior Secondary School 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 1

5 Number of Maternity Home 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

6 Number of Primary Health Sub Centre 0 1 0 0 0 0 2 0 0 0 0 0 0 1 0 0

7 Tap Water (T) √ x √ x √ x √ √ √ √ √ x x √ √ √

8 Well Water (W) x √ √ x √ x √ √ x √ √ x x √ √ x 9 Tank Water (TK) √ √ √ x x x √ √ x √ x √ x √ √ x 10 Tubewell Water (TW) √ √ √ √ x √ √ √ √ √ √ x √ √ √ √ 11 Handpumb (HP) √ √ √ x √ √ √ √ √ √ √ x √ √ √ √

12 Number of Telephone connections 0 15 1 0 1 1 50 5 0 1 0 0 0 8 1 3

13 Bus services x √ √ 0 √ √ √ √ 0 √ √ √ √ √ x √

14 Number of Co-operative Commercial Bank 0 √ 0 0 0 0 √ 0 x 0 0 0 0 0 0 0

15 Number of Agricultural Credit Societies 0 0 0 0 0 0 √ 0 x 0 0 0 0 0 0 0

16 Approach - Paved Road 0 √ √ 0 √ 0 √ √ √ √ √ √ √ √ √ √

17 Approach - Mud Road √ 0 √ 0 √ √ √ √ 0 √ √ 0 0 √ √ √ 18 Approach - Foot Path √ 0 √ 0 √ 0 √ √ 0 √ 0 0 0 √ √ √ 19 Electricity for all purposes √ √ √ 0 √ √ √ √ √ √ √ √ √ √ √ √

20 News Paper (Indicate N, if arrived) √ √ √ x x x √ √ √ √ √ x x √ √ √

21 Magazine (indicate M, if arrived) x √ x x x x √ √ x x x x x √ x X

Source: Census of India 2001 (Note: √ = Available, x = Not Available)


TABLE 3.25 AMENITIES AVAILABLE IN 5 VILLAGES FROM WHOM LAND IS TO BE PURCHASED

AMENITIES AVAILABLE IN 5 VILLAGES FROM WHOM LAND IS TO BE PURCHASED DISTRICT CENSUS HANDBOOK

Village Name SL.No Amenities available Byalakundi Danapuram Danayakanakere Garaga Nagalapura

1 Number of Primary School 2 3 2 2 2 2 Number of Middle School 1 3 2 1 2 3 Number of Secondary School 0 1 0 0 1 4 Number of Senior Secondary School 0 1 0 0 0 5 Number of Maternity Home 0 1 0 0 0 6 Number of Primary Health Sub Centre 0 1 1 0 1 7 Tap Water (T) √ √ √ √ √ 8 Well Water (W) √ √ x √ √ 9 Tank Water (TK) √ √ √ √ √ 10 Tubewell Water (TW) √ √ √ √ √ 11 Handpumb (HP) √ √ √ √ √ 12 Number of Telephone connections 1 26 3 1 4 13 Bus services √ √ √ √ √ 14 Number of Co-operative Commercial Bank x √ x x x 15 Number of Agricultural Credit Societies x √ x x x 16 Approach - Paved Road √ √ √ √ √ 17 Approach - Mud Road √ √ √ √ √ 18 Approach - Foot Path √ √ √ x √ 19 Electricity for all purposes √ √ √ √ √ 20 News Paper (Indicate N, if arrived) √ √ √ √ √ 21 Magazine (indicate M, if arrived) √ √ √ √ √

Source: Census of India 2001 (Note: √ = Available, x = Not Available)

Richardson & Cruddas (1972) Ltd. IV-1

3.7.8 Industries in the Neighborhood Although marked by forests and considered as one of the backward districts of the

state, the Hospet region has a number of industries. The principals among them

are Vijayanagar Steel Plant of M/s Jindal Steel Ltd located about 30 km from the

area. One Ferro-Manganese Plant of Sandur Manganese and Iron Ore Industry is

located SW of the area. Since the area produces high grade iron ore, there are a

few steel producing units, about 10 km from the Hospet Town. The principals

among them are M/s Kiroloskar Ferrous Industries Ltd and Kalyani Steels. There are

more than 50 mines working in the area, most of them produce iron ore. Thus

mining still forms main industry of the area. The list of industries in the study area

is given in Annexure 3 E

Hospet town has a number of small scale and medium scale units fulfilling the

‘service’ needs of the area. They total nearly 500. Besides this, there is also a

Sugar Mill and a Distillery outside Hospet Town.The Hospet Town is rail head to

visit Hampi the “World Heritage Site”. Thus there are number of Hospitality

related facilities like Hotels, Taxi Services etc.

3.7.9 Places of Archaeological and Religious Interest

The area is famous for the ruins of Hampi the erstwhile capital of Vijayanagar

Empire, which is, located about 15 km from the project site as the crow flies. It is

declared World Heritage Site. There are also several old ruins of that era in the

Tungabhadra River Valley. Almost all major villages and Hospet town have a

number of old temples, some of them as old as Vijayanagar time. However, none

of them is listed as Archaeological monument.


CHAPTER IV

ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

4.1 Identification of Impacts

General

An essential step in Environmental Impact Assessment (EIA) is to identify all the

potential environmental impacts by the proposed steel production on environment.

These are then examined critically and the major impacts (both beneficial and

adverse) are analyzed in detail. Of the various techniques available for impact

identification like checklists, matrices networks, cause effect diagram, computer

simulation models etc., the matrix method has been chosen for the present project

impacts identifications.

Identification of Impact

The impact identification matrix is given in Table 4.1. The environmental attributes

include ambient air quality, water resources & quality, Noise levels, flora & fauna

(ecology), soil and land-use, socio-economic environment and infrastructure

development, health etc., Various stages viz., siting, operation of Steel production and

secondary activities and also post operational phase.

The activities have been arranged in columns and environmental attributes in rows in

the matrix. A preliminary scrutiny has been made and the cells, which fall at the

junction of activity and attribute that have possible interaction with each other, have

been marked with proper notation.

The matrix thus, identifies the environmental attributes likely to be affected and the

activities responsible for this. The impacts may be beneficial or adverse. These will be

analyzed in detail during assessment of the impacts.


Table - 4.1 Impact Identification Matrix

Actions Raw material storage and handling, Steel production and other allied activities

Post Operationa

l Phase

Environmental Attributes

Cons

truc

tion

Ph

ase

Ope

rati

onal

Ph

ase

Mat

eria

l H

andl

ing

Ore

Sto

rage

/

hand

ing

Wat

er d

raw

l (S

urfa

ce w

ater

)

Wat

er d

isch

arge

Mai

nten

ance

W

orks

hop

Pow

er

gene

rati

on b

y D

G s

et

Gre

en B

elt

deve

lopm

ent

Empl

oym

ent

Urb

aniz

atio

n (B

uffe

r zo

ne)

Tran

spor

tati

on

Ambient air

Water resources

Water quality

Ambient Noise

Flora & Fauna

Soil & Land use

Infrastructure

Health & Safety

Socio-economics

Aesthetics

Adverse Impact Beneficial Impact Identification of Impact during Construction Phase The following are the impacts identified during construction phase.

Air : Grading of land, excavation, backfilling, storing and storage & handling of

construction materials, etc. The impact is temporary only during

construction period.

Noise : Blasting, Bore well drilling Concrete mixers, mobility of trucks and machinery

Water : Water consumption

Land use: Piling of debris, surface earth, waste packing material

Socio-economic: Employment, demand for goods and other off site infra structural facilities

Biological: Displacement of native fauna (snakes, frogs, Amphibians, etc.)


Identification of Impacts during Operational stage

The major activities at BMM Ispat Ltd site in the operational phase involves storage &

handling of ore, coal and other raw materials, processing of ore and coal for Steel

making, captive power generation and cement manufacturing. These activities may

affect the environment in varying degrees through natural resources depletion viz.

water consumption, release of particulates and gaseous emissions, contamination of

water body, run-off from waste storage area etc. During working life of plant, air,

water and noise may be affected due to material usage and processing for steel and

associated activities in general. The sources of pollution during operational is given in

Table 4.2.

Allied operations, e.g. transportation of materials, operations of workshop and garage,

canteen etc., may also affect air, water and noise environment.

Green belt development will have a positive impact not only on flora and fauna but

also on air quality, noise and soil characteristics.

Positive impacts on socio-economic environment are expected due to employment,

further infrastructure development and also due to socio-economic welfare

developmental activities to be taken up by BMMI.

Screening of identified Impacts

Some of the impacts identified in various phases are insignificant and do not warrant

much attention whereas some other are very important. The object is to identify those

impacts, which are significant and require a detailed analysis for decision making or

formulating adequate management measures.


Table- 4.2 Source & Types of Environmental Pollutants

released due to proposed project

Section /

Units Feed Materials & Fuels Operation Pollutants Recipient Form of

Pollution

Dust Air Air Pollution

Raw Material Handling

Low grade iron ore, imported coking coal, Non-coking coal, Limestone, Dolomite,

Storage Run off /Leachates Drain Water Pollution

Dust Air Air Pollution

Noise Workzone Workzone noise Pollution

Iron ore beneficiation Low grade Iron ore

wet grinding &

beneficiation Effluent Plant

drain/reuse Water Pollution

Sponge Iron Plants

Iron Ore, Coal, Dolomite

Reduction of Iron Ore Dust, SO2, NOx Air Air Pollution

Pelletization plant

Iron ore Concentrated

Heat hardening Dust Air Air Pollution

Heat, Dusts, SO2, NOx Air Air Pollution

Sinter Plant

Iron Ore concentrate, Limestone recycled fines, etc. as feed and coke and BF gas as fuel.

Sintering at an elevated temperature Noise Air Workzone noise

Pollution

Heat, Dusts, SO2, NOx Air Air Pollution Blast Furnace

plant

Coke, Iron Ore, Sinter, Fluxes and BF gas

Smelting of Iron oxide

Noise Workzone Workzone noise Pollution

Heat, Dusts Air Air Pollution

Steel Melting Shop

Hot Metal, Fluxes, Ferro Alloys

Steel Making, Refining and Continuous Casting of Slabs & billets

Particulate Dusts Laden

Water Plant Drain Water Pollution

Heat, SO2, NOx Air Air Pollution Noise Workzone Air Noise Pollution

Rolling mill Steel Slabs , billets and furnace oil

Hot Rolling of Slabs and

billets

Oil and Particulates Laden Mill Effluent

Concentrated/Treated in

thickener

Sludge to beneficiation

plant

Heat, SO2, NOx, Fly ash, Bottom ash

Air Air Pollution

Noise Work zone Air Noise Pollution

Captive Power Plant Flue gas & coal

Steam Raising and Power Generation

Wastewater of DM Plant

containing acids / alkalis

Guard pond Water Pollution


Section / Units

Feed Materials & Fuels Operation Pollutants Recipient Form of

Pollution Cooling Tower Guard pond Water Pollution

Dust Air Air Pollution Cement Plant BF Slag, Clinker,

Gypsum and Coal

Grinding, Screening and

packing Noise Work zone Air Noise Pollution

Coke Oven Plant Coal

Non-recovery type coke making

Flue gas Power plant Air Pollution


4.2 Prediction of Impacts

Impacts during Construction Phase

Impact on Ambient Air Quality

During the construction phase of the project, a considerable amount of civil work

activities like grading of land, excavation, back filling, storing, piling etc involving

movement and transportation of earth will take place. This will lead to generation of a

large emission of fugitive dust. The fugitive nature of dust will have local impacts in

the area where the activity will be carried out. Water spraying is proposed to be

carried out on the roads, which will be used for transportation of materials to suppress

fugitive dust. Further, the civil construction activities are temporary in nature and will

last for 18-24 months and will not have long term impact on the ambient air quality.

Impact on Noise Levels

Noise levels are also likely to increase due to increased movement of trucks and other

diesel powered material handling equipment. This will have an adverse impact in the

vicinity of the construction activities. However, movement of trucks and machinery

will be mainly during daytime to keep the impact of increased noise minimum.

Since the construction phase will be temporary, the impact on ambient noise levels

will be temporary and cease once the construction phase is over.

Impact on Water bodies

The water required for the construction purposes is around 800 cum per day and will

be met from down stream of TB dam/Almathi dam/ ground water. Debris, mud etc.

generated during construction in rainy seasons will contaminate the storm water run-

off with large amounts of suspended solids. This water will be channelized through

catch drain to a suitable size settling pond to trap the suspended solids.

Impact on Land use

During construction, a large amount of construction debris like surplus earth, scrap,

waste packing materials, cables etc will be generated. These will be stored in

identified areas, which can later be either used in the operational phase or sold to out

side parties for reuse.


Socio-Economic Impacts

The construction phase of the project involves large deployment of manpower, both

direct and indirect. This period has huge potential for employment, both direct and

indirect, which will affect the economy of the surrounding area. But these impacts will

be temporary in nature. The construction phases of the project will require different

skills of people at different times, involving large migration of labour force over short

periods. This will have adverse impact on the existing infrastructure unless adequate

precautions are taken in advance. However, over the years, a large number of

industries have been established in the surrounding area, as a result of which, the

availability of skilled manpower in the nearby area has improved considerably.

Further, the infrastructure in the surrounding area has developed in the intervening

period to accommodate the migrating population. As a result of which the impact

during construction will not be adverse at the project site.

Impacts during Operational Phase

During operation of the proposed steel plant, impacts are anticipated on ambient air

quality and noise levels, water, land-use, ecology and socio-economic environment.

Impact on Ambient Air Quality

The proposed Steel production of 2.0 Mt/YEAR, 1.4 Mt/YEAR cement production and

230 MW captive power plant will have impact on the air environment beyond the core

zone. While the impact of fugitive emissions will be within the core area. The effect of

emissions from the point sources is a major concern, as it will have an impact on the

ambient air quality in the surrounding area. It is also proposed to limit the design

emission norms well within the prescribed standards. The impact of pollution of the

steel production plant on the ambient air is assessed using mathematical modeling

(ISCST3). The data used in mathematical modeling are presented below.

Micro- meteorological data

The meteorological data recorded continuously during the winter season 2007-08 on

hourly basis on wind speed, wind direction and temperature have been processed to

obtain 24-hourly mean meteorological data as per guidelines of IMD for application of

ISCST 3 model. Stability classes computed for the mean hours are based on guidelines

issued by CPCB on modeling. Mixing heights representative of the region have been

taken from the available published literature. Table 4.3 provides information on

emission data.


Table 4.3 Source-wise Emission data

Emission (g/s) Sl. No Source No. of

Stacks Stack

height (m) Stack dia.

(m) Velocity

(m/s) Temp (oC) PM SO2 NOx

1. Pellet Plant Grate system 1 55 4.0 / 7.5 20 120 12.92 18.0 0.02 Proportioning bins 1 30 1.8/ 2.4 8.0 A 1.02 - - Cooler discharge area 1 30 1.8 / 2.4 9.8 A 1.247 - - Coal grinding system 1 30 1.5 / 2.0 7.6 A 0.67 - -

2 DRI Plants kiln 1 kiln2

1

90 4.1

16

130

5.22

7.93

8.99

kiln 3 kiln4

1

90 4.1

16

130

5.22

7.93

8.99

Day bins 1 30 1.8 11.2 A 0.792 - -

Coal preparation unit 1 30 1.5 /2.0 10.8 A 0.954 - -

Product Handling unit 1 30 1.8 /2.4 10.9 100 1.387 3 Coke Oven Plant Batteries 1 & 2 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 3 & 4 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 5 & 6 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 7 & 8 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 9 & 10 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 11 & 12 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 13& 14 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 15& 16 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Coal preparation unit 2 30 2 / 2.5 7.8 A 1.225 - - Coke quenching 2 30 1.8 / 2.4 13.1 100 1.66 - - 4 Sinter Plant Sinter machine 1 1 45 3.2 /4.5 22.0 110.0 9.166 13.750 1.83 Sinter machine 2 1 45 3.2 /4.5 22.0 110.0 9.166 13.750 1.83 Flux crushing units 1 30 2.25 / 3 12.8 A 2.545 - - Coke crushing unit 1 30 2.5 / 3.25 8.5 60 2.086 - - Proportioning bins 1 30 1.8 / 2.5 9.5 40.0 1.208


Emission (g/s) Sl. No Source No. of

Stacks Stack

height (m) Stack dia.

(m) Velocity

(m/s) Temp (oC) PM SO2 NOx

Cooler discharge & Sinter screening unit 1 30 2.5 / 3.2 8.2 80-100 2.012

5 Blast Furnace BF 1 1 55 2.0 11.0 250 1.736 - 0.004 BF2 1 55 2.0 11.0 250 1.736 - 0.004 BF3 1 55 2.0 11.0 250 1.736 - 0.004 BF 4 1 55 2.0 11.0 250 1.736 - 0.004 Stock house 2 30 1.8 / 2.5 12.6 A 1.603 - - Coal Pulverizing system 1 30 1.5 / 2.25 9.5 A 0.84 - - Cast house 2 30 2 / 2.5 12.8 40 2.01 - - 6 EAF & Steel making shop 1 40 1.4 11.0 110 0.833 0.001 - 7 Rolling mill Reheating Furnace 1 1 80 1.54 15 150 2.77 41.55 68.4 Reheating Furnace 1 2 80 1.54 15 150 2.77 41.55 68.4 8 Calcination plant 1 1 30 1.26 8.0 110 0.5 - - Calcination plant 2 1 30 1.26 8.0 110 0.5 - -

9. Cement grinding unit Granulated slag drying system 1 40 3 13.5 180 5.0 14.5 Traces

Materials Transfer points dedusting system 2 30 1.8 11.2 A 0.80 - -

Cement mix grinding system 1 60 4 / 6 15 80 9.02 - -

10 Captive Power Plant Coal crushing and handling system 1 40 1.5 9.5 A 0.84 - - Coal Firing system 1 220 3.0 / 4.5 18.0 140 12.72 15.2 7.52

Richardson & Cruddas (1972) Ltd. IX-1

Mixing Heights

Knowledge of site specific mixing height (Convective stable boundary layer and inversion

height or nocturnal boundary layer) is crucial in realistic adoption of appropriate plume rise

and vertical dispersion parameters. IMD generate data on mixing depth at Bangalore using

radiosonde technique with two readings a day, which are available with IMD, Pune. The

following tables list out the mixing heights which have been considered in air quality

modeling.

Date Mix (M) Mix (E) Date Mix (M), m Mix (E), m 01.11.2001 311 1675.3 01.12.2001 720.8 700.8 02.11.2001 277.5 315.6 02.12.2001 595 752.3 03.11.2001 668.6 1141.9 03.12.2001 311 672.2 04.11.2001 291.5 623.6 04.12.2001 77.7 1182.2 05.11.2001 238.8 450.4 05.12.2001 232.4 646.8 06.11.2001 1102.8 1190 06.12.2001 179.1 582.9 07.11.2001 611.4 240.2 07.12.2001 331.6 843.9 08.11.2001 682.5 799.8 08.12.2001 307.3 843.4 09.11.2001 708.5 1232.1 09.12.2001 203.0 655.8 10.11.2001 613.7 718.3 10.12.2001 342.0 911.5 11.11.2001 247.9 401.5 11.12.2001 426.7 961.5 12.11.2001 338.7 688 12.12.2001 606.1 997.2 13.11.2001 598.4 624 13.12.2001 321.4 1200 14.11.2001 272.4 400.1 14.12.2001 274.5 1308.5 15.11.2001 397.6 601.5 15.12.2001 1191.9 1370.1 16.11.2001 336.2 643.7 16.12.2001 679.2 1372.7 17.11.2001 364.3 651.9 17.12.2001 349.9 1263.8 18.11.2001 632.5 186.6 18.12.2001 663.8 742.8 19.11.2001 314.2 582.2 19.12.2001 670.4 617.6 20.11.2001 361.2 696.6 22.12.2001 1639.6 1287.7 21.11.2001 664.3 1223.3 23.12.2001 737.3 213.8 22.11.2001 363.6 353.1 24.12.2001 657.1 642.7 23.11.2001 313.4 338.2 25.12.2001 610.5 674.9 24.11.2001 381.5 644.1 26.12.2001 725.5 828.9 25.11.2001 727.3 1789.1 27.12.2001 889.4 1720.9 26.11.2001 728.2 1771.3 28.12.2001 1169.5 1807.7 27.11.2001 626.6 1730.5 29.12.2001 654 1170 28.11.2001 343.8 675.6 30.12.2001 396.1 1247.4 29.11.2001 586.5 2199 31.12.2001 617.9 716.3 30.11.2001 243.4 546.8

MIX (M) – Morning mixing height in meter

MIX (E) – Evening mixing Height in meter


Mixing Heights (Contd.,)

Date Mix (M) Mix (E) Date Mix (M), m Mix (E), m 01.01.2002 395 623.8 01.02.2002 672.9 1367.2

02. 01.2002 652.1 1169.8 02. 02.2002 221.9 105.8

03. 01.2002 409.9 684.6 03. 02.2002 873.6 1037.6

04. 01.2002 363.5 1249.1 04. 02.2002 602.6 1250.6

05. 01.2002 1682.7 1781.6 05. 02.2002 267.6 765.4

06. 01.2002 682.9 1666.1 06. 02.2002 272.3 1712.1

07. 01.2002 705.0 1175.0 07. 02.2002 328 1223.4

08. 01.2002 1104.2 1224.6 08. 02.2002 643 934.4

09. 01.2002 1278.1 1327.8 09. 02.2002 359 714.5

10. 01.2002 672.7 805.2 10. 02.2002 334.4 1197.3

11. 01.2002 674.4 1188.3 11. 02.2002 300.9 1132.6

12. 01.2002 913.6 1618.1 12. 02.2002 449.6 1021.5

13. 01.2002 475.4 1650.2 13. 02.2002 340.1 1175.7

14. 01.2002 583.2 1613.5 14. 02.2002 649.4 2222

15. 01.2002 651.2 1696.8 15. 02.2002 298.2 1343

16. 01.2002 381.1 1119.0 16. 02.2002 217.2 2268.5

17. 01.2002 573.8 1081.8 17. 02.2002 717.3 2083.6

18. 01.2002 301.5 701.3 18. 02.2002 278.1 1944.2

19. 01.2002 803.7 1434.7 19. 02.2002 228 2287.6

20. 01.2002 440.4 787.3 20. 02.2002 261.1 2317.2

21. 01.2002 690.4 1101.9 21. 02.2002 160.6 1764.8

22. 01.2002 268.9 1277.7 22. 02.2002 161.5 1348.3

23. 01.2002 744.9 1699.1 23. 02.2002 652.6 2350

24. 01.2002 364.9 1744.8 24. 02.2002 315.3 1680.2

25. 01.2002 1142.3 1786.6 25. 02.2002 199.9 1855

26. 01.2002 592.2 1773.7 26. 02.2002 166.3 1865.4

27. 01.2002 296.0 620.7 27. 02.2002 302.2 2868.6

28. 01.2002 697.6 1203.2 28. 02.2002 268.1 2228.5

29. 01.2002 1181.7 1559

30. 01.2002 461.9 1188.8

31.01.2002 1191.3 1598.9

MIX (M) – Morning mixing height in meter

MIX(E) – Evening mixing Height in meter

Terrain characteristics

The core and buffer zone areas are fairly plain in nature except in North Eastern area which

is hilly. No tall buildings, are present and the area is rural in nature.


Application of ISCST 3 for prediction of ground level concentration

Prediction of cumulative ground level concentrations due to emissions from the integrated

steel plant and cement plant have been computed using ISCST3 model.

ISCST 3 model with the following options has been employed to predict the ground level

concentrations due to emissions from the various units of steel production.

• Area being rural, rural dispersion parameters are considered.

• Predictions have been carried out to estimate connection values over a radial

distance of 10 km around the source.

• A total of 1200 receptors with combination of polar and Cartesian receptor network

have been considered.

• Emission rates from all the sources are considered as constant discharge and

magnitude during the entire period.

• Ground level concentration computed is based on without any consideration of

decay coefficient.

• Calm winds recorded during the study period have also been taken into

consideration.

• 24 hourly (for 24 hour mean meteorological data as per guide lines of IMD and MoEF)

mean ground level concentration was estimated for Winter`2007-08.

• An option of creation of data file giving average ground level concentration for the

mean meteorological data of winter season has been used for post processing in

Surfer-6 graphic package.

Basic Input data requirements

The basic data inputs include the run stream set up file and the meteorological data file.

The run stream set up file contains the selected modeling options, source location and

parameter data receptor locations, meteorological data specifications and output options.

The meteorological data file contains the hourly data on wind speed, wind direction,

ambient temperature, atmospheric stability class and mixing height.

Output data


The output may be obtained for short term (hourly, daily or monthly) averages or long term

(annual) averages.

Predicted ground level concentrations

Air Environment in Core zone - Post project Scenario (µg/m3)

24 hourly concentrations Suspended Particulate

matter(SPM) (max)

Sulphur dioxide (SO2) (max)

Oxides of nitrogen (NOX) (max)

Baseline Scenario(max) 176 9 18

Predicted Ground level Concentration(max) 41.3 41.2 25.6

Resultant concentrations 217.3 50.2 43.6

NAAQ standards 500 120 120

Isopleths for SPM, SO2 and NOx are give fig. IV.2 -IV.4.

Air Environment in the study area - Post project Scenario (µg/m3)

Baseline scenario (max) Predicted values Post Project

scenario NAAQ standards S. No. Location name

SPM SO2 NOx SPM SO2 NOx SPM SO2 NOx SPM SO2 NOx

1 Existing Plant (A2) 186 16 30 24.5 31.6 28.2 210.5 47.6 58.2 500 120 120

2 Dhanapura (A3) 146 7 10 23.1 28.4 26.1 169.1 35.4 36.1 200 80 80

3 Marimanhalli (A4) 145 8 18 21.0 12.6 12.5 166.0 20.6 30.5 200 80 80

4 Nagalapura (A5) 132 7 12 9.2 21.2 11.8 141.2 28.2 23.8 200 80 80

5 Mugimavinahalli (A6) 146 8 18 3.8 6.8 1.2 149.8 14.8 19.2 200 80 80

6 Haravanahalli (A7) 115 7 10 4.8 8.9 1.8 119.8 15.9 11.8 200 80 80

7 Ramgad (A8) 132 8 16 3.9 2.1 0.8 135.9 10.1 16.8 200 80 80

8 Medarahalli (A9) 134 8 14 4.9 1.3 0.4 138.9 9.3 14.4 200 80 80

9 Vysankari (A10) 112 7 12 3.6 2.4 1.4 115.6 9.4 13.4 200 80 80


Fig. IV.2


FIG. IV.3


FIG. IV.4


Impact on Water

The total make-up water requirement for proposed steel plant complex will be met by

augmenting the water from the down stream of TB Dam/Almathi dam by a pipeline. It is

proposed to build a separate reservoir to meet the requirements of the various uses. The

proposed plant will also draw ground water for steel plant operations. Thus operation of the

plant will not affect ground water availability in the study area.

The effluents likely to be generated from the following sources:

1. Wastewater generated from hot rolling mills.

2. Waste water from the run-off from Raw Material Storage Yards

3. Waste water from the soft / DM plant

4. Sanitary wastewater from canteens and toilets.

5. Blow-downs from ICW and DCW circuits

6. Backwash from side stream pressure filters of cooling towers

EAC water from GCP`s : The wastewater collected from the individual GCPs are

treated in respective clarifiers, where the solids are removed by addition of water

treatment chemicals. The clarified water is recycled back into the system. The

slurry collected at the bottom of the clarifier is pumped to the pellet plant.

However, due to continuous and repeated use of recycled water, the solid

concentration in the recycled water will increase needing periodic blow down. The

blow down water will be led to an effluent storage pond for further treatment and

will be recirculated.

Rolling mills: The water used in hot steel cooling operations gets contaminated with scales

and oil. The metallic scales are separated from the re- circulating water in scale pits. The

solids free water is passed through pressure filters for removal of residual solids. The

treated water after the filters are recirculated in the process. The wastewater collected

from the backwash of the pressure filter is further treated in a thickener for recovery of

water, which is led back to the system. The slurry is led to the pellet plant. However, due

to continuous and repeated use of recycled water, the solid concentration in the recycled

water will increase needing periodic blow down. The blow down water will be led to an

effluent storage pond for further treatment.

Run-off from Raw Materials Storage Yards: The wastewater from the run off of the raw

material storage area contains solids, which are led to a settling pond located at the

individual yard. The decanted water is led to the effluent collection pond for further


treatment. The pond gets is dried during non-monsoon seasons and the sludge is used in the

beneficiation plant.

Soft / DM plant: The wastewater from the soft / DM water plant contains acids, alkali

which are treated by neutralization in a tank and the neutralized effluent is led to the

effluent collection pond.

Sanitary waste from canteens and toilets: The wastewater contains organic solids, which

is treated in a centralized sewage treatment plant using a conventional activated sludge

process. The treated water is led to the effluent collection pond.

Blow-downs from ICW and DCW circuits: The blow down from the ICW and DCW circuits

contain dissolved solids and to some extent suspended solids. These are led directly to the

guard pond.

Backwash from side stream filters: The backwash from the side stream filters contains

large amount of solids. The slurry collected from the backwash is fed to the nearby gas

cleaning pant circuits for separation of water and solids.

Effluent collection pond: As can be seen, the effluent collection pond collects partially

treated wastewater from all the above units. Seven days storage guard pond will be

provided to avoid excess water discharge during rainy season. The influent water contains

suspended solids and dissolved solids. The water is used for gardening and dust suppression.

The sources of discharge from the proposed steel plant and the control measures to be

adopted are given in Table 4.4.

Table – 4.4 List of Water Pollution Control Systems

Sl. No.

Source Pollutants Control system / Treatment

1. Raw material handling yard SS Catch pits followed

2 Raw Water Treatment plant

SS, Colloidal matter, Dissolved gases, micro-organism

Chemical coagulation with sedimentation and filtration

3. Beneficiation Plant Hydrocyclones, Thickneres, slim pond

4. Pellet Plant Collection sump, guard pond

5. Sponge Iron Plant Collection tank & Ash handling dust suppression

6 DM Plant pH Neutralization pit 7 Steel Melting shop SS Guard pond

8 CCM Suspended Solids, Oil & Grease

Settling Tanks fitted with Oil & Grease Trap

9 Calcination & Oxygen plant SS, Alkalinity Settling with Guard pond 10 Rolling Mills SS, Oil & Grease , Settling Tanks fitted with


Sl. No.

Source Pollutants Control system / Treatment

mill scale Oil & Grease Trap

12 Captive Power Plant Direct use in ash handling & excess to guard pond

Cooling Tower & Boiler bow down

Temperature, Dissolved Solids

Reused in the plant for dust suppression and slag

granulation

13 Sewage Treatment system BOD, Suspended Solids Sewage treatment plant

Impact on Noise Levels

During normal operations of the plant, ambient noise levels will increase significantly only

close to the compressors and blowers and other plant operations. But this will be confined

only within plant boundary. The noise level within the plant boundary will be confined

within shops. The level will be further minimized when the noise reaches the plant

boundary and the nearest residential areas beyond the plant boundary, as elaborate green

belt development is envisaged for attenuation of noise and fugitive emissions. The noise

production in various units of the steel production plant are as presented below.

Noise Levels in various units of the steel making Plant

S.No. Source Noise Level dB(A) 1 Sponge Iron Plant

In front of Rotary Kiln & Cooler 70-82 Near Crusher and Screen 75-78 Near Bag filters 79-80 Near Main gate 65-68

2 Mini Blast Furnace Plant 75-80 3 Sintering plant (Phase II) 70-75 4 Pelletization plant 70-75 5 EAF & LF Plant 75 –80 6 Billet Casting machine section 75-80 7 Rolling mill section 85 8 Material Handling 70 –75 9 Material charging and conveying 75-78 10 Compressors 80 11 Pumps 75-80 12 ID Fans 85

All the equipment in the blast furnace complex will be designed/operated in such away that

the noise level shall not exceed 80 dB (A).


However, if during operation, the noise level exceeds the above norms then the protective

measures given in Environmental Management Plan will be followed. Hence, no impact due

to proposed plant on ambient noise is anticipated.

Noise Dispersion Model

For the purpose of Noise modeling, the plant is considered as one source. Hence, total

Noise will be equal to 80 - 87 dB(A). The dispersion of this noise is computed by using the

model

LP2 = LP1 – 20 log10 (r2/ r1)

Where LP2 and LP1 are Sound Pressure Levels at points located at distances r2 and r1 from

the source. The combined effect of all the sources then can be determined at various

locations by the following equation.

LP (total) = 10 log (10Lp1/10 + 10 LP2/10 + 10 LP3/10 ---------)

Where LP1, LP2, LP3 etc. are Noise levels at a point due to different sources.

Based on the above equation, a user-friendly model has been developed. The details of the

model are as follows.

Noise level can be predicted at any distance specified from the source

Model is designed to take topography or flat terrain

Co-ordinates of the sources in meters

Output of the model in the form of isopleths and

Environmental attention factors and machine corrections are made for the

measured Leq. Levels

Input to the Model

Major noise sources as Cumulative noise source has been identified and monitored in similar

type of proposed plants. The input to the model has been taken as the cumulative noise of

12 major noise generating sources in the plant. The resulting noise from the cumulative

source is taken as 87.8 dB(A).


Noise Impact analysis on surrounding community

There will not be any noise impact on surrounding village residents by the proposed Steel

production plant.

Impact on traffic density

To quantify the impact of the proposed steel plant at Danapura and its allied activities on

traffic, it is necessary at first to evaluate the existing load of heavy vehicular traffic at the

site. Proposed site is connected with a bitumen road of two lane from the highway (Hospet,

Bellary) at a distance of 2.6 km. As the site has quite significant traffic density, monitoring

was carried out in January 2008 for 4 days indicate that the traffic density in the Highway

range 300 to 350 vehicles per hour.

The mode of transportation of Raw Material required and Products and Byproduct generated

by rail and road due to the proposed project is given in the below table:

Quantity transported, t/yr Material By rail By road

Raw materials

Low grade iron ore fines 4,400,000 ---

Bentonite --- 8,400

Non coking coal 1,243,000 ---

Coking coal 924,000 ---

Limestone 526,000 ---

Dolomite 342,000 ---

Quartzite 125,000 ---

Clinker 726,000 ---

Gypsum --- 42,000

Rolled products 1,600,000 400,000

Portland slag cement 1,000,000 400,000

Cold pig iron --- 14,000

DRI --- 74,000

Coke breeze --- 22,000

TOTAL (Raw material & Products) 10886000

(~ 92%) 960400 (~ 8%)

From the above table, it is understood that the traffic density by road is insignificant as

major transportation of raw material and products is by rail. The construction and

operational Phases of the proposed plants is likely to increase the traffic density on

Highway and on the road leading to the plant from Highway.


The railway loading/unloading station is very nearer to the project site and the major

commodities of raw materials and finished products are planned to be transported by rail.

The transportation by rail is having more economical and environmental benefits and hence

no alternative method of transportation is planned.

Impact on Ecology

Ecological Impact of the proposed industry in the area is discussed under following sub

heads.

Aquatic

The important perennial water body is TB dam 5.0 Km away. As the plant is being designed

for maximum recirculation, with “zero discharge” concept no effluent will be discharged

outside.

The domestic and plant sanitary water is also proposed to be treated and used for

gardening purposes. Hence no adverse impact on aquatic bodies are anticipated.

Terrestrial

Air pollutants released by the steel making plant found to be well within the prescribed

standards and no significant impact on terrestrial flora is expected.

Solid Waste Generation

The major solid waste expected to be generated from the various facilities of integrated

steel plant are given in Table 4.5.

Table 4.5 Quantity of Solid Waste Generated and re-used in the Steel Plant

Sl. No. Solid Waste Nature of

Solid Waste Quantity

(tonnes/day) Probable Reuse

PELLET PLANT

1. Dust from ESP Dust 220.0 sintering plant

DRI PLANT

1. Dust Settling Chamber Sludge 20.0 Sintering plant

2. De-dusting System Dust 48.0 cement plant

4. Product Separator System (Char) Fines 684.0 captive power

plant

5. Heat Exchanger and ESP Dust with fly ash 215.0 cement plant


SINTERING PLANT

1. Sinter Dust Solid 113.0 Sintering plant

BLAST FURNACE

1. Sinter BF return Sinter 178.0 sinter plant 2. BF Slag Slag 1766.0 cement plant

STEEL MELTING SHOP

1. Slag Slag 732.0 control landfill

2. Flume dust from bagfilter dust 415.0 sintering plant

COTINUOUS CASTING MACHINE 1. Scale & Muck Scales 110.0 sintering plant

2. Scrap - 266.0 within the steel plant

ROLLING MILLS

1. Scrap Scrap 211.0 within the steel plant

2. Scale & Muck Scale 211.0 sintering plant

3. Oil and Grease Traps Oil and Grease 0.3

sold to authorised

vendors

4. Reheat Furnace Broken Refractories - Land filling

COKE OVEN PLANT 1. Coke breeze Dust 465 coke oven plant 3. Dust from bag filters Dust 31.0 cement plant

CAPTIVE POWER PLANT

1. Ash including fly ash Dust 316.0

2. Bottom ash Dust 80.0

cement mfg brick mfg/ road

construction

CEMENT PLANT

1. Dust from EAP Dust 38.0 Cement plant

Oil Soaked cotton waste, organic wastes Incinereated and control landfilling

Lead acid batteries sold to authorised vendors


Socio– Economic Impact

• The project is not going to cause significant damage to the existing agricultural

situation. Instead, it is likely to provide the farmers with supplementary income.

• The project has very strong positive employment and income effects.

• There is a great possibility of industrialization in the vicinity of the proposed steel

plant. This is likely to bring dramatic changes by transforming this backward area

into an industrially developed one.

• The project has very strong positive impact, which is likely to result in the

improvement of economic situation of Hospet

• Overall peoples’ perception on the expansion project is a mix of advantages and

disadvantages. On one hand, they expect job opportunities, market expansion etc.

as advantages and on the other hand they are worried about the damage to

agriculture.

• As an impact of identification of the project, small-scale industrial economy is likely

to flourish in the surrounding area. The small-scale industrial units are expected to

get financial supports from the financial institutions and banks. In this way, an

overall development may take place in this area.

• The process of development will have maximum impact on the lifestyle of the local

people. The project and the consequent peripheral industrial economy will generate

income to the local and migrated people which will increase the aggregate demand.

This demand will get realized in the market and finally, lead to the market

expansion in the locality of the project. Market expansion supported by expected

infrastructural developments like roads, electricity, water supply etc. will result in

improving the economic development in the entire region.


CHAPTER V

ENVIRONMENTAL MONITORING PROGRAMME

5.1 Preamble

Several measures have been suggested in the Environment Management Plan (EMP) for mitigation of identified adverse environmental impacts. These have to be implemented to ensure compliance with the environmental regulation and also to maintain a healthy environmental conditions in and around the steel plant.

A monitoring strategy is required to ensure that all environmental resources which may

be subject to contamination are kept under review and hence monitoring of the

individual elements of the environment is necessary. The Environment Management

Department (EMD) of BMM will be entrusted with this responsibility. The officers of EMD

will assess the progress and analyze the data periodically.

In addition to the above, the unit will take all necessary steps to implement the

measures suggested in the Charter on Corporate Responsibility for Environmental

Protection (CREP) for Integrated Iron and Steel Industry. Some of the measures have

already been included in the plant design. The others will include:

• Direct injection of reducing agents for examples, pulverized coal into the Blast

Furnaces.

• 100% utilisation of Blast Furnace and Steel Melting Slag.

• Hazardous wastes to be handled and disposed of strictly in accordance with the

Hazardous Wastes (Management and Handling) Rules, 2003.

• Specific water consumption to be brought down to less than 8 m3/ton of crude

steel.

• Promotion of Energy Optimization Technology including periodic energy audits.


5.2 Meteorological Station

It is necessary to monitor the meteorological parameters regularly for assessment and

interpretation of air quality data. The continuous monitoring will also help in

emergency planning and disaster management. BMM will install a designated weather

station for this purpose and the following data will be recorded and archived.

• Wind speed and direction

• Rainfall

• Temperature and humidity

5.3 Emissions and Air Quality

On-line continuous monitoring system will be installed in major stacks to monitor

particulate matter and gaseous emission. In case emissions are found to exceed the

norms, the on duty personnel will check the relevant process parameters and take

appropriate corrective action.

BMM ISPAT Ltd will monitor the ambient air quality regularly in 5 locations in and around the plant (downwind direction and where Max. GLC of SPM, SO2 & NOx) to ascertain the effect of process emissions on the ambient air quality. BMM will establish 2 continuous particulate matter monitoring stations. The locations will be identified in consultation with KSPCB. The equipment will have facilities to monitor both SPM, RPM, SO2 and NOx.

5.4 Water Quality

Surface and ground water will be sampled regularly once in a season from various locations in and around proposed plant to ascertain the trend of variation in the water quality, if any. Treated process wastewater quantity will also be monitored for pH, TSS, COD and Oil & Grease regularly. The metallic constituents in the untreated effluent will be ascertained once a month through recognized laboratory of KSPCB/CPCB .

5.5 Drainage System

The effectiveness of the drainage system depends on proper maintenance of all

drainage pipes/channels. Regular cleaning of drains will be done to remove

accumulated sludge/sediments. The catch-pits linked to the storm water drainage

system from the raw material handling areas will also be regularly cleaned to ensure

their effectiveness. This exercise will be carried out during the pre monsoon and at

regular intervals.

5.6 Noise Levels


Noise levels will be measured at the source of generation on quarterly basis- It is

desirable that the noise attenuation measures are taken at the design stage of the plant

itself. However, in case of high noise generating equipment which are not frequented

by the plant personnel, the area may be cleanly marked as `High Noise" area and the

employees be provided with personal protective equipment like ear plugs/ear muffs.

5.7 Occupational Health

Occupational health surveillance of the workers will be done on regular basis especially

for those to be engaged in handling hazardous substances and high noise generating

equipment and process area.

5.8 Biological Monitoring

A massive tree plantation will be taken up along the boundary of the plant leading to a

favorable impact on the surrounding environment. BMM will continue to improve the

green cover in the area by planting trees in the open area. Trees survival rate will be

monitored in the plantation areas and will be maintained at about 80% by replacement

of dead trees.

5.9 Socio-Economic Development

BMM ISPAT Ltd. will undertake various social welfare programmes for upliftment of

surrounding villages. The community which is benefited by BMM ISPAT Ltd. are thus one

of the key stake holders for steel plant. The BMM ISPAT Ltd. will have structured

interactions with the plant surrounding villages people to disseminate the measures

taken by the BMM ISPAT Ltd and also to elicit suggestions for overall improvement of

the surrounding villages.

5.10 Housekeeping

The EMD shall be keeping a very close monitoring of house keeping activities and

organizing regular meetings of joint forum at the shop level (monthly), zonal level

(once in two months) and apex level (quarterly). The CED (Civil Engineering

Department) shall take care for the house keeping of shops.

5.11 Interaction with State Pollution Control Board (SPCB)


EMD shall be in regular touch with KSPCB & MoEF and send them quarterly progress

report on EMP. Any new regulations considered by State/Central Pollution Control

Board for the Industry will be taken care of.

5.10 Laboratory facilities

It is imperative to BMM to have a well-equipped environmental control laboratory inside

the plant premises. The Environmental control laboratory shall apply for recognition as

per EP Act 1986 and notified in Government of India Gazette. The laboratory shall be

running continuously 24 hours in three-shift operation and will be carrying out all

monitoring as specified in their Consent and EC condition.

All the personnel deployed in the laboratory will be given training by external experts

so as to carry out necessary environmental monitoring as well as analysis. The

equipment to be made available for carrying out environmental monitoring is given in

Table 5.1.


Table 5.1 List of Monitoring / Analytical Equipments

Sl. No. Item Quantity

1 Respirable Dust Sampler 4

2 Stack Monitoring Kit 2

3 HVS Flow Calibrator 2

4 PM-10 HVS 2

5 Dry Gas Meter 2

6 Analytical Balance 1

7 Digital Balance 1

8 Personal Sampler 1

9 Nephelo Turbidity meter 2

10 DR-2000 Spectrophoto Meter 2

11 COD Reactor 2

12 Portable Dissolved Oxygen Meter 2

13 PDV-2000 Digital Voltameter 1

14 Selective Ion Meter 1

15 Composite Sampler 2

16 Visible Spectro Meter 1

17 BOD Analyser 1

18 BOD Incubator 1

19 Ultrasonic Flow Meter 4

20 Vaccum Pump 1

21 Drying Oven 2

22 Ultrasonic Cleaner 1

23 Adjustable Digital Pipettes 1

24 Spectrophotometer 1

25 Digital Multimeter 1

26 D.O Meter 1

27 Hot Plate 1

28 Muffle Furnace 1

29 Digital Conductivity meter 1

30 Sound Level Meter with calibrator & Octave Pilter Set 1

31 Electronic Balance 1

32 On-line ambient air monitoring station 2

33 On-line stack monitoring of major stack 10

34 weather monitoring station 1


5.11 Frequency of monitoring of pollution sources

Regular monitoring in a systematic and standardized manner helps in assessment of

current environment and provides information on operational performance of installed

pollution control facility.

Sl. No. Place of Monitoring Parameters of Pollution Frequency of Monitors

1. Stack emission Temperature, Velocity, Gas discharge, SPM, NOx and SO2

To be carried once in a month

2. Ambient air quality at plant boundary and nearby habitation

SPM, NOx, SO2 and RSPM Weekly twice at 6 locations and continuously at 2 locations

3.

Monitoring of Surface and ground water quality surrounding areas of dumping site

As per IS:10500 norms To be carried once in 3 months ( Seasonal )

4.

Noise monitoring near kilns, product house, raw material yard power plant and plant boundary

Leq dB(A)

Workzone noise levels once in a month Ambient noise levels once in 3 months

5. Effluent outlets pH, SS, Phenol, COD, BOD, DO, NH3-N, Temperature, Oil and grease

once in a week

Note : The monitoring will be carried out as per EC & Consent conditions and in consultation with KSPB

5.12 Cost Profiles of Pollution Control Measures

Cost of Project

Particulars Amount (Rs. in Lakhs)

Land & Site Development 200.0

Buildings 326.9

Plant & Machinery 3269.0

Engineernig Services 326.9

Preliminary and Preoperative expenses including interest during construction 375.8

Contingency 610.5

Margin money for working capital 206.9

Power Plant` 85.3

Total Project Cost 6151.3

Mode of Finance Rate of interest


Borrowing for working capital 14%

Term Loan 13%

5.13 Cost of Pollution Control/ Environmental protection Measures

Area of Expenditure Recurring cost per

annum (Rs. in Crores)

Capital Cost (Rs. in Crores)

Air Pollution Control 10.0 200.0

Water Treatment System 10.0 50.0

Waste Water Treatment System 3.0 30.0

Solid Waste Management System 5.0 50.0

Noise Pollution Control 0.50 2.0

Environmental Monitoring and Management

2.50 10.0

Social corporate responsibilities 2.0 10.0

Road diversion/development/Modification

2.0 15.0

Occupational Health 1.50 3.0

Greenbelt Development 5.0 25.0

Others 0.25 2.0

Total 41.75 397.00

Percent of recurring cost in terms of Capital Cost for pollution control measures

10.52 % -

Percent of capital cost of pollution control measures in terms of total project cost

- 6.45 %

CHAPTER VI


ADDITIONAL STUDIES

6.1 Risk Assessment, On-Site Emergency Preparedness & Disaster Management Plan

It is presumed that the proposed facilities in the 2.0 MT/Yr steel bars & rods, 230 MW captive

power generation and 1.4 MT/Yr cement manufacturing at BMM Ispat Ltd. Will be designed and

engineered with all possible safety measures and standard code of practices of engineering. In

spite of this, there may be some design deficiency or due to operation and maintenance faults,

which may lead to accidental events causing damage to life and or property. This Chapter

presents an overview of environmental risks associated with various production facilities,

suggested remedial measures and an outline of the emergency preparedness plan.

Risk Assessment

The objectives of environmental risk assessment are governed by the following, which

excludes natural calamities:

a) To identify the potential hazardous areas so that necessary design safety measures can

be adopted to minimize the probability of accidental events.

b) To identify the potential areas of environmental disaster which can be prevented by

proper design of the installations and its controlled operation.

c) To manage the emergency situation or a disastrous event, if any, from the plant

operation.

Managing a disastrous event will obviously require prompt action by the operators and the

crisis management personnel using all their available resources like alerting the people and

other plant personnel remaining inside, deployment of fire fighting equipment, operation of

emergency shut off valves, opening of the escape doors, rescue etc.

Minimizing the immediate consequences of a hazardous event include cordoning off,

evacuation, medical assistance and giving correct information to the families of the

affected persons and local public for avoiding rumors and panic.

Lastly, an expert committee is required to probe the cause of such events and the losses

encountered, and suggest remedial measures for implementation, so that in future such

events or similar events do not reoccur.


Identification of hazards

The hazards are attributable due to processing of raw materials and chemicals used in

steelmaking and the other plant operations. A list of major raw materials used in the Plant

and the process units with their hazard potential is presented below;

Hazard Identification of the proposed steel plant facilities

Group Item Hazard potential Remarks

Iron ore None -

Coal Moderate Fire

Other fluxing minerals None -

Product steel None -

Acids/Alkalis Major Bio corrosive

Raw materials & Products

Lube oil Moderate Flammable

Iron Ore beneficiation

Iron ore dust Moderate Environmental Pollution

Processing

Sintering/ Pelletization

Dusts Moderate Environmental Pollution

BF gas Major Flammable and CO pollution

Hot Metal Major Personnel injury & fire

Iron making in BFs

Molten Slag Major Personnel injury & fire

EAF / LD gas Major Flammable and CO pollution

Liquid steel Major Personnel injury & fire

Steelmaking in EAF`s

Molten Slag Major Personnel injury & fire

Rolling Mills Gas firing/LDO firing Moderate Fire

Utilities

Liquid Propane Leaks/ vapour cloud Major Fire/explosion

Fuel gas Distribution Gas leaks Major Fire and CO pollution

Electric power Supply

Short circuit Major Fire


Group Item Hazard potential Remarks

Transformer Small Explosion & Fire

Power Plant

Steam turbine

generator

building

Moderate

Fires in Lube oil system, Short circuit in control room / switch gear, cable galleries & oil drum storage

Boilers Moderate Fire / steam explosion

Coal Handling

plant

Moderate

Fire or dust explosion

Coal Storage Moderate Spontaneous combustion

FO/ LDO tank

farms

Major

Fire

Cement Plant Dust Moderate Environmental Pollution

From the above Table, it may be observed that major on-site emergency situation may

occur from the organic coal chemicals storage and handling, fuel gas handling, molten

metal and slag handling, acids and alkali storage / handling and electrical short-circuits.

The off-site environmental disaster may occur if large-scale fire and explosion occurs, the

effect of which extends beyond the plant boundary. The off-site environmental disaster

may occur due to significant environmental degradation prolonged for a sustained period.

HAZOP Study

It is suggested to have HAZOP Study for the fuel gas distribution network handling facilities

prior to commissioning, for last minute corrections in the design of the systems from fail

safe angle. The HAZOP analysis for the gasholder has been carried out for safe operations.

The degree of Hazard is identified based on FEI and TI range as per the criteria given below.

FEI Range Degree of Hazard

0-60 Light

61-96 Moderate

97-127 Moderately High

128-158 Heavy

159 & above Severe


TI Range Degree of Hazard

0 –5 Light

5 –10 Moderate

>10 Severe

Fire and explosion are the likely hazards which may occur due to the fuel storage. Hence F

& EI has been calculated for storage capacities of fuels in the plant and are shown in table

below.

Fire & Explosion and Toxicity Index for storage facilities

Fuel Total quantity of Storage F & EI Category TI Category

FO/ LDO 2x360 m3 8.5 Severe - -

Electrical safety: Adequately rated and quick response circuit breakers, aided by reliable

and selective digital or microprocessor based electro-magnetic protective relays will be

incorporated in the electrical system design for the proposed project. The metering and

instruments will be of proper accuracy class and scale dimensions.

Risk management measures

The risk management measures for the proposed project activities require adoption of best

safety practice at the respective construction zones within the works boundary. In

addition, the design and engineering of the proposed facilities will take into consideration

of the proposed protection measures for air and water environment as outlined in earlier

Chapter. The detailed risk management measures are listed below;

Coal Handling Plant

Coal dust when dispersed in air and ignited will explode. Crusher house and conveyor are

most susceptible to this hazard. The minimum of explosive concentration of coal dust (33%

volatiles) is 50 grams /m3. Failure of dust extraction & suppression systems may lead to

abnormal conditions and increasing the concentration of coal dust to the explosive limits.

The sources of ignition are incandescent bulbs, electric equipment & cables, friction &

spontaneous combustion in accumulated dust. Dust explosion may occur without warning

with maximum explosion pressure upto 6.4 bars. Another dangerous characteristics of dust

explosions is that it sets off secondary after of initial dust explosion. Stack pile area shall

be provided with automatic garden type sprinklers as well as to reduce spontaneous ignition

of coal stocks piles, necessary water distribution net work will be provided for distributing

water at all transfer pints, crusher houses, control room, etc.


A centralized control room with micro-processor based control system has been envisaged

for operation of the coal handling plant. Except locally controlled equipment like traveling

tripper, dust extraction / dust suppression / ventilation equipment, sump pumps, water

distribution / ventilation equipment, sump pumps water distribution system all other in line

equipment will be provided for safe and reliable operation of the coal handling plant.

Control measures for coal yard

The entire quantity of coal will be stored in separate stack piles, with proper drains around

to collect washouts during the monsoon. Water sprinkling system will be installed on stocks

of pile to prevent spontaneous heating combustion and consequent fire hazards. The stack

geometry will be adopted to maintain minimum exposure of stock pile areas towards

predominant wind direction temperature will be monitored in the stock piles regularly to

detect any abnormal rise in temperature inside the stock pile to be enable to control the

same.

Blast Furnace

Preventive Measures

If any job is to be undertaken in BF areas where the BF gas is toxic, the following procedure

has to be laid down to ensure safety of men and the equipment.

a) Gas Safety man will accompany the team and will test the atmosphere for the presence

of CO, before starting the work.

b) If `CO' concentration is found exceeding the safe limit, the job will be undertaken using

necessary safety appliances viz., Oxygen Breathing Apparatus/ Blower type Gas mask.

c) Any gas cutting/welding job will be undertaken with the clearance from Gas Safety

man.

Gas Explosion, Prevention & Preventive Measures

The following actions will be taken to prevent any gas explosions in case of gas leakage.

1. For jobs on gas lines/equipment, non-sparking copper tools will used. If such tools are

not available, grease coated steel tools will be used. Electrical drill & other electrical

equipment will not be used as these can give rise to sparks.

2. The gas line will be thoroughly purged with steam before undertaking the job on the

same.


3. Naked lights will not be used near any de-pressurized gas main or equipment unless the

same has been thoroughly purged.

4. In case of profuse leakage of gas, action will be taken for water sealing and isolating

that portion.

5. The approach road to the gas line complex will be kept free from any obstructions.

6. If gas catches fire due to some leakage, it will be extinguished with plastic clay, steam

or water. The portion of gas main affected will be cooled down with water. The valve

will not be closed when fire is still there and the pressure in the main will be

maintained at minimum 100 mm (WC).

7. Gas tapping points of flow or pressure measurement will be cleaned with wooden stick

or grease coated wire.

8. If lighting is necessary near gas line, portable spark proof electric lamps of low voltage

or explosion proof torchlight will be used for enclosed areas.

Hot Metal & Slag

Sudden break out of molten metal & slag may result in heavy explosions, due to their

coming in contact with water, thereby causing serious burn injuries to persons and damage

to equipment. These breakouts may take place from weak portions of the Hearth, Tuyeres

& monkeys.

Preventive Measures

1. Any accumulation of water will be prevented in such vulnerable areas.

2. In case of minor leakages, the flow of molten metal & slag will be controlled.

3. If there is major breakout, the area will be cut off and cordoned.

4. Vital connections e.g. water, gas, compressed air, oxygen etc. will be cut off or

regulated, as per requirement.

Steel Melting Shop

The main hazards arise out of the use of hot metal and oxygen at the Arc Furnace. The

spillage of hot metal/slag can cause serious burn injuries and fires. Severe explosions are

also caused due to hot metal/slag falling over a pool of water, resulting in injuries to


persons, fire and damage to equipment due to flying of hot splinters & splashing of liquid

metal/slag.

Preventive Measures

1. Any accumulation of water will be prevented in such vulnerable areas.

2. In case of minor leakages, the flow of molten metal & slag will be controlled.

3. If there is major breakout, the area will be cut - off and cordoned.

4. Vital connections e.g. water, gas, compressed air, oxygen etc., will be cut-off or

regulated, as per requirement.

Oxygen plant

The oxygen though not itself flammable, supports combustion and is, therefore hazardous

as any combustible material burns internally in its presence. Any oxygen leakage can also

cause severe burn injuries if it comes in contact with human body. Similarly, the liquid

oxygen, frequently referred to as LOX is liquid at about – 147°C. It is pale blue in color and

is slightly heavier than water. It is classified as a non-flammable gas. However, since it

supports combustion, any organic or inorganic combustible material burns with enhanced

intensity in its presence. Apart from this hazard, liquid oxygen due to low boiling point

when exposed to atmosphere takes away heat from the surrounding to get evaporated. This

results in instant freezing if any contact is made between the human body and this

material.

The protective material worn for fighting emergencies related to liquid oxygen will not be

used near any sources of ignition, as the large volume of gas produced from small amount of

liquid will create an oxygen rich atmosphere.

The part of human body coming in contact with liquid oxygen should be sprayed with

ordinary water and later treated in a similar way to frostbite treatment. For Fire fighting

involving LOX, water is the best extinguishing agent. Water will be sprayed to prevent rapid

boiling and splattering of liquid that may be caused by a straight stream.

Care will also be taken not to direct the water spray on to mechanical relief devices which

will result in freezing of water, rendering the devices in-operative.

Fuel oil Storage & Pipe lines

The fuel oils stored in bulk are L.D.O. & LPG. Main hazard in the storage areas and pipelines

is due to any leakages which may result in serious fire.


Preventive Measures

The storage tanks are constructed and maintained as per the guidelines laid down in the

Petroleum & Carbide Act.

Cable galleries

For container of fire and preventing it from spreading in the cable galleries, unit -wise fire

barriers with self –closing fire resistant doors with minimum fire rating of approximately 90

minutes are planned. The ventilation system provided in the cable galleries will be interlocked

with the fire alarm system so that, in the event of a fire alarm, the ventilation system is

automatically switched off. Also, to avid spreading of fire, all cable entries / opening in cable

galleries, channels, barriers etc., will be sealed with non-flammable / fire resistant sealing

material. Instrument cables will be fire resistant low smoke type.

Transformer Section

This section includes generator transformer, station reserve transformer, unit auxiliary

transformer and switch-gear bays. Temperature rise detectors will be used for detection of

fire for transformers and the lube oil storage area, while automatic type High velocity

Sprinkler Protection System is planned to put out the fires.

On-site Emergency Preparedness Plan

The On-site Emergency Plan relates to the laid-down and well-practiced procedure after

taking care of all design based precautionary measures for risk control. This plan is aimed

for tackling any emergency situation, if arises.

Objective of the Plan

The emergency plan has been prepared to ensure the smooth working of the steel plant

complex. The main objectives of the plan are to take immediate actions to meet any

emergency situation making maximum use of combined in-plant and allied resources for the

most effective, speedy and efficient rescue and relief operations. These are briefly

enumerated below:

1. Cordon and isolate the affected area for smooth rescue operation

2. Rescue and treat casualties and safeguard the rest

3. Minimize damage to persons, property and surroundings

4. Contain and ultimately bring the situation under control

5. Secure and safe rehabilitation of the affected area


6. Provide necessary information to statutory agencies

7. Provide authoritative information to the news media.

8. Ward off unsocial elements and prying onlookers.

9. Counter rumor mongering and panic by relevant accurate information.

Methodology

Keeping in mind the detailed information on the proposed steel plant, the plan is formed on

the following basis:

- Identification of possible hazards in various units and their impact on the surroundings

- Detailed information on the available resources and control measures.Industrial Safety

and Fire Fighting

As detailed above, many working premises of the plant have hazardous and fire-prone

environment. To protect the working personnel and equipment from any damage or loss and

to ensure uninterrupted production, adequate safety and fire fighting measures have been

proposed for the project.

Consequence analysis (Petroleum Class C)

Major Hazard scenario at the tank premises spillage of FO and LDO from pump discharge

nozzles side failure. The main hazard is of forming a pool of fire and toxic effect due to

release of above fuels.

Various scenarios of toxic and thermal radiations impact consequence have been estimated

and summarized based on the models presented in Gele Book or Yellow book published by

TNO, The Netherlands and other Tests.

Above Ground Tank Farm

Pool fire impact distances (m)

4 12.5 37.5

Sl.No Scenario

Stability class

and wind speed

Realease Rate (Kg/s)

Release duration (Sec)

Pool

dia. (m)

IDLH distance (m)

KWm2 KWm2 KWm2

Flash fire

impact distance

(m)

F,1 3.44 2353 37 - 44 23 5 23

1

FO storage tank bottom nozzle failure B,2 3.44 2353 37 - 44 22 5 23

2 LDO pump discharge F,1 3.1 500 - - 34 18 5 5


nozzle failure B,2 3.1 500 - - 42 20 5 5

Fire fighting arrangements

Types of fire extinguishers, its capacity and total numbers proposed in the Integrated Steel

plant of BMM Ispat Ltd are as follows.

S.No. Types of extinguishers Capacity Quantity

1 Dry Chemical Powder 10 Kg each 22.5 Kg each

264 Nos 72 Nos.

2 CO2 extinguisher 9 Kg each 2 Kg each

96 168

3 Water with CO2 catridge 9 litre 48

4 Foam type 50 litre 9 liters

48 72

5 ABC type extinguisher 2 Kgs 2.5 Kgs

24 24

Fire Hydrant system The list of hydrants proposed in the Integrated Steel plant are as follows.

S.No. Items Quantity

1 Hydrants 30 Nos

2 Hydrant Hoses 30 Nos.

3 Hose reel 4 Nos.

4 Fire suit 8 Nos.

5 Fire Pumps 4 Nos.

6 Water monitor 2 No.

7 Foam monitor 2 No.

8 Hose boxes 30 Nos.

9 Fix hose branches 30 Nos

10 Foam making compound 40 litres

11 Siren 2 No.

12 Emergency Stretcher 2 No.


13 Asbestos blanket 2 No.

14 Fire Engines 2 No.

Fire reservoir

Sources of firewater will be from the main water supply line connected to the fresh water

reservoirs.

Safety Plan during Construction & Erection phase

A highly qualified and experienced Safety Officer will be appointed. The responsibilities of the

safety officers include identification of the hazardous conditions and unsafe acts of workers

and advice on corrective actions, conduct safety audit, organize training programmes and

provide professional expert advice on various issues related to occupational safety and health.

In addition to employment of safety officer, every contractor, who employees more than

250 workers, should also employ one safety officer to ensure safety of the workers in

accordance with the conditions of the contract.

Safety of Personnel

All workmen employed in hazardous working conditions will be provided with adequate

personal safety appliance as applicable to the work like;

- Industrial safety boots

- Industrial helmets

- Hand gloves

- Ear muffs

- Welder’s screens and aprons

- Gas masks

- Respirators

- Resuscitators

Fire Protection facilities

Keeping in view the nature of fire and vulnerability of the equipment and the premises, the

following fire protection facilities have been proposed for the plant.


Portable Fire Extinguishers

All plant units, office buildings, stores, laboratories, MCCs etc. will be provided with

adequate number of portable fire extinguishers. The distribution and selection of

extinguishers will be done in accordance with the requirement of fire protection manual of

the Tariff Advisory Committee (TAC).

Hydrant System

Hydrants will be provided in the coal handling plants at suitable locations and in different

levels inside the plant buildings. Yard hydrants will be provided in the vicinity to meet the

additional requirement of water to extinguish fire.

Automatic Fire Detection System

Unattended vulnerable premises like electrical control rooms, cable tunnels, MCC, oil

cellars, etc. will be provided with automatic fire detection and alarm systems.

Manual Call Point Systems

All major units and welfare/administrative building will be provided with manual call points

for summoning the fire fighting crew from the fire station for necessary assistance.

Fire Station

BMM ISPAT LTD is going to provide elaborate arrangements for managing any incidents of

fire. The Fire station is centrally located with adequate communication facilities and

trained manpower. These are adequate for meeting the requirements of the proposed plant

facilities in the 10 MT/Yr stage also. There will be one central fire station with fire tenders

to extend the necessary assistance required for fighting fire in any of the plant units and

associate premises with requisite augmentation. The following equipment will be provided

in fire station/fire posts.

- Water tender

- Foam tender

- Portable pump

- Wireless set


- Hoses

- Hot line telephone, etc.

Plant Disaster Control

The On Site Emergency Plan is prepared considering all the different units of the proposed

steel plant complex.

Organization

A Central Disaster Control Cell will be set up under the direct charge of the Chief Executive

of the project. He will be the person nominated to declare any major emergency and will

be in-charge of all operations in such situations. In his absence, Sr. Vice President (Works)

will be the in-charge. He will be supported by the other nominated members of cell, e.g.,

Senior Manager for Plant operations and service agencies – BF, Coke Oven and by product

plant, SMS & Mill, Personnel, Security, Fire and safety, Administration and Medical Officer.

In case of any major emergency, the Disaster Control Cell would operate from Disaster

Control Room. At the shop level, Senior Managers, have been nominated as Controllers who

will be assisted by Manager, Shift-in-charges and trained key workers to deal with any minor

emergencies arising at the shop.

Information Flow

The following guidelines will be observed by any person after noticing a gas leak, fire, etc.

till help is made available from the Central Disaster Control Cell or Shop level Disaster

Control Cell.

- Raise alarm

- Communicate to the control room about the incident/emergency.

- Communicate to fire station for relief in case telephone is available otherwise try to

attract attention by any available means.

- Attempts to close doors, windows or ventilators of the room to prevent any

contaminated air getting in.

Central Disaster Control Room

Upon receiving information from any site regarding emergency, the person operating from

the Disaster Control room will :


- Depute a person to rush to site and assess the situation.

- Inform fire, transport, safety, medical and concerned control room.

- Organize operating personnel and arrange for control over the situation.

- Keep the management informed about the gravity of the situation from time to time.

- On receiving the call, the Disaster Control room will immediately direct the different

supporting service agencies as enumerated below :

- Security and Administration services : responsible for safety of the plant against

trespassers, saboteurs, any crowd, information to Government authorities and in the

neighborhood (if required), provision of transport facilities, telecommunication facilities

and fire service facilities.

- Safety service: responsible for implementation of safety measures at work place and

occupational safety.

- Medical service: responsible for providing medical care to the injured or the affected in

an event of emergency.

- Stores: responsible for providing adequate number of tools, tackles and accessories for

proper emergency control.

- Preservation of evidence and taking of photographs, if necessary, for future enquiries to

determine the cause and taking further preventive actions.-

- Welfare: Provide food, clothes, shelter etc., as per requirements.

- Power and water supply : To ensure supply of fire fighting water requirement and

provisions of power supply.

Shop Level Disaster Control Cell

The Controller at the shop level will take immediate charge of any emergent situation and

will assume full responsibility regarding mobilisation of resources, guide and help service

agencies in properly carrying out their assigned duties. Being from the operations side of

the plant, he has full knowledge of the process aspects and he will decide whether to stop

the plant/process. He will be responsible for overall co-ordination. In his absence, his

Deputy will be Controller of the operations. The duties of the Shop level Controller are

enumerated below:


- Assess the magnitude of emergency and decide, if any possibility of major emergency

exists and inform the Central Control Room, if necessary.

- Direct Safe close down of plant or any operation, if necessary.

- Direct evacuation of areas in the vicinity, which may be endangered.

- Ensure key personnel are called in immediately and they start carrying out their

assigned duties.

- Direct rescue and fire fighting operations from safe operation point of view.

- Direct the shop personnel to the designated places for safe assembly.

- Control rehabilitation of affected areas and any victim on emergency.

- Ensure complete safety before restarting the plant/ operation.

At Shop floor, teams of workers will be trained, who will be present at the incident site for

doing the needful. They will assist and extend help to the following :

- Fire brigade team in controlling fire.

- Operational staff in shutting down plant to make it safe.

- Search, evacuation, rescue team.

- Movement of vehicles for emergency control.

- Plant pollution monitoring staff for carrying out atmospheric tests.

- Medical team for providing necessary help.

- Any other special operation.

Contingency Plan

It is based on the following considerations:

- The plant general layout.

- The available resources.

- The analysis of hazards.

It is aimed at the


- Pre-emergency activities.

- Emergency time activities.

- Post-emergency activities.

In the event of an emergency, the people from affected pockets will be directed to move to

safe assembly places nearby the units.

The following facilities will be provided.

- Security service

- Fire fighting service

- Medical service

- Pollution control service

- Public relation service

- Telecommunication service

- Transport service

- Evacuation service

- Welfare service

An alarm system will be provided with a wailing type siren at a centralized place and

actuators at the strategic locations in the plant. Adequate number of telephones will be

provided in each unit at Shop floor so that a person can either directly raise the alarm or

ring up disaster control room from where the alarm can be raised directly. The wailing siren

will mark the beginning of the emergency while a continuous note will mark the end

meaning all clear signal.

All fire fighting equipment like valves, fire hydrants, pumps, monitors, etc., will be checked

periodically to detect defective parts and such parts would be immediately replaced. Mock

drills will be conducted for training the persons and to check the performance of men and

equipment and also to keep them fit for any emergency. The plant will be equipped with a

separate Medical Centre with necessary instrument/appliances, medicines and trained

manpower. The Medical Officer will maintain close liaison with different hospital in the

nearby city.

Rescue and Repair Services

The responsibility of effective working of Rescue and Repair Services will be with the

incident controller.


Rescue Services

- To extricate persons from the debris of collapsed building/structure and safe human

lives.

- To hand over the extricated persons to first aid parties.

- To take immediate steps as may be necessary for the temporary supports or demolition

of buildings and structures, the collapse of which is likely to endanger life or obstruct

traffic.

- To cut off supplies of water, gas, electricity to damaged buildings.

Trained Rescue parties will be formed at the Shop levels, who will be provided with the

following equipment:

1. Self contained oxygen breathing apparatus

2. Blower type gas mask

3. Resuscitators

4. Petromax lamp / Torches

5. Axe/hand saw

6. Bamboo ladder

7. Necessary Safety appliances

8. First aid box

9. Blankets

On-site emergency planning rehearsals need to be carried out from time to time. It requires

monitoring by experienced persons from other similar factories or by senior officials from

the State Inspectorate of Factories and/or the Directorate of Fire Services, who can help in

updating the emergency plan procedure.

Off-site emergency planning

Off-site emergency planning is normally under the jurisdiction of the district administration.

The designated official of the Steel Plant is required to have co-ordination with the District

administration for responsive action in off-site emergency planning.


Fire Fighting Organization and Procedure

There will be trained fire fighting personnel and a Fire Officer under the Fire & Safety

Department. The following important instructions will be given for fire prevention and

tackling of any fire in the plant.

- Overall control of the Fire fighting operations will rest with the senior most officer

present at the scene of fire, who will be assisted by the operational and fire staff. Close

co-ordination and planning for fire protection will be done between Plant Operations

and Fire Service.

- While turning out for fire calls, the fire staff will be guided to the correct location

immediately on their arrival.

- In-charge of the section at Shop floor will explain special risks involved and guide the

In-charge of the Fire fighting crew. He will, however, not interfere in the method of fire

fighting operations.

- No one will tamper with the sources of water supply/ fire hydrants or misuse them in

any manner. The passages/approach to/from fire hydrants to the fire appliances will

always be kept clear.

Fire drills will be held in each, zone periodically under the direction of the Fire Officer.


The organization and brief procedure for fighting small, major and simultaneous fire is

given below :

Degree of fire emergency Fire chief Siren code Persons attending

Small fire

Major fire

Simultaneous fire

Functional head in charge of affected area

Head of the production department

In-charge of affected area

No siren

Wailings two minutes

No siren except for major fire

First and second line fire-fighting teams

First, second and third fire-fighting teams

Persons already present at the scene of fire, operators

Definitions :

Small fire : A fire in its incipient stage which is controlled by the first line fire

fighting team.

Major fire : The fire is spreading to other equipment or areas and which

threatens to go beyond the control of first line and second line fire

fighting teams.

Simultaneous fire : More than one fire occurring at the same time.

Fire Control Office: The Fire Control Officer will be in-charge at the scene of fire. In case of

small fire, Section Head / Functional Head of affected area will be

fire Officer.

In major fire, the Head of Production Department will be the Fire Control Officer.

In simultaneous fires, in-charges of the respective affected areas will be the Fire Control

Officers.

Fire call: Fire call will be received at the fire station regarding occurrence of fire and its

location. The message will be conveyed either by telephone or fire alarm or in person.

While giving Fire call message on telephone, the person will

- Give his name, Section & Department.

- Exact location of Fire and if possible, nature of fire.


- Confirm that the Fire call message is repeated by the Control room attendant.

When the call message is given by the Fire alarm, the person will stand rear the Fire alarm

to guide the Fire fighting team to the location of the fire.

Fire Siren Code :

For small fire : No siren will be sounded.

For major fire : Wailing type continuously for two minutes.

For all clear : Straight sound for two signal minutes.

Testing of the Fire Sirens

Fire sirens may be tested by sounding straight for one minute on Wednesday at 9 AM for

cogeneration power plant.

Fire Fighting for Small Fire

The small fire will be tackled by the first line team which will comprise the persons already

present at the scene of fire. However, the second line fire fighting team whose composition

is given below will also report at the scene of fire immediately after receiving the Fire Call

of affected area at the time of fire. The team will consist of the following:

Fire Control Officer

First line Fire Fighting team:

Operational / maintenance staff and/or other plant personnel working in the area.

Second line Fire Fighting team :

- Fire station shift-in-charge and trained fire fighting personnel.

- Ambulance driver with ambulance.

- Functional head of affected area.

- Shift Officer production.

- Security personnel.

Third line Fire Fighting team :

- Fire Officer & Auxiliary Fire Fighting personnel.

- All Departmental & Functional Heads.

- Local Fire Brigade from Govt., if necessary.


Fire Fighting for Major Fire

The major fire will be tackled by the first line, second line and the third line fire fighting

teams. The fire chief in this case is the Head of the Production Department. The fire chief

for small fire will judge the nature of fire and in case of major fire, he will inform Fire

Officer (either himself or through responsible persons) to sound the fire sirens (wailing

type) continuously for two minutes. The team will consist of the following who will

immediately report at the scene of the fire.

1. Fire Officer

2. First, Second and third line Fire Fighting team.

3. Auxiliary Fire Fighting personal

All the members of the auxiliary fire fighting crew will have thorough training on the job.

Responsibilities of Fire Control Room Operator

During fire Call :

- To take correct message regarding location, type of fire etc., from the caller.

- To repeat the message.

- To inform fire fighting personnel on duty immediately for turn out by hearing the bell.

- To ask the pump house operator to maintain adequate head in the fire water line.

- To inform Telephone Exchange.

- To inform first aid centre.

Responsibilities of Fire Fighting Personnel :

- To report immediately at the scene of fire.

- To take instructions from Fire Officer.

Responsibilities of Fire Officer:

- To direct the deployment of Fire fighting personnel and fire fighting appliances.


- To organize additional fire fighting crew, if required, depending upon gravity of the

situation.

- To guide plant employees in fire fighting.

- To co-ordinate between different groups of fire fighting personnel & team of trained

workers from the department.

- To control the spread of fire and rescue operation, if necessary.

- To extinguish the fire.

- To replenish the required fire fighting material/equipment.

- To arrange relievers wherever necessary.

- To assess the situation and arrange additional help if necessary in co-ordination with

Disaster Control room.

- To advice for all clear siren to be blown after the major fire emergency is over.

Responsibilities of Ambulance Driver :

- To report to the scene of fire with ambulance immediately.

- To carry the casualties, if any, to the medical centre as directed by Medical Officer/Fire

Officer at the earliest.

- To park the ambulance without obstructing the fire fighting operations and traffic.

Responsibilities of Security personnel at the manned gate :

- To prevent entry of unauthorized persons.

- To keep the gate open for emergency vehicles and officers and staff concerned with fire

fighting and allied operations.

Responsibilities of Telephone Operator :

- To receive fire call messages.

- To inform Shift Officer for all fires.

Responsibilities of Medical Officer during major fire :

- To be available at the first aid centre for necessary medical advice.


- To depute one of the medical staff to the scene of fire to render any medical assistance, required at site.


Responsibilities of Head of the Personnel and Welfare Department during major fire :

- To arrange the transport of the fire fighting personnel with minimum loss of time in consultation with the Fire Control/Fire Officer.

- To make arrangements for the refreshment/meals for persons engaged in fire fighting.

- To inform the Fire Officer regarding the actions taken.

Responsibilities of Head of the Maintenance Department during major fire:

- To report to the Fire Chief and render all help that may be required from Maintenance

Department.

Responsibilities of Head of the Electrical Maintenance Department during major fire :

- To report to Fire Officer and render assistance to be required from Electrical

Department such as installation of equipment, provision of temporary lighting etc.

Responsibilities of Head of the Materials Procurement Department during major fire :

- To arrange to man the stores for emergency issue of materials. If the materials are not

available in the stores or are likely to be exhausted during fire fighting operations, he will

arrange for the same from other sources.

Cloud Burst / Lighting

Cloud burst/lighting may at times lead to minor to major emergency. In such an emergency,

actions indicated under fire and explosion will be undertaken.

Food Poisoning

In case of food poisoning in plant canteens, the following will be done :

- Disaster Controller will inform the Medical Officer for immediate first aid.

- Medical Officer will contact other hospitals and seek their help, if necessary.

- Security will help in evacuating the affected people to various hospitals, in

co-ordination with the Medical Officer.

Mutual-aid System

At times the possibility of a major emergency (a situation out of control of plant authority)

cannot be ruled out. In such a case, the plant authority will declare it to be a major

emergency and total control will be transferred to the district level office of contingency

plan committee.


Necessary help will also be sought from the concerned Government agencies having

necessary infrastructure for dealing with disaster.

6.2 Resettlement & Rehabilitation Plan Land use and Land required for the proposed Industry The State Government in its order No.CI/312/SPI/2008 dated 21.10.2008 has permitted the

industry to acquire 1429 hectares of land (3530.70 acres) coming in the jurisdiction of the

following five villages. Out of this land 785.54 hectares are patta land and the balance

643.35 hectares are Government lands. The details are as follows.

Gov. Land Patta Land (Private Land) Total Extent Sl.

No Name of the Village Hectares Hectares Hectares

1 Danapura 38.82 203.72 242.54 2 DN Kere 68.73 212.36 281.09 3 Nagalapura 243.58 25.73 269.31 4 Bylakundi 172.40 6.59 178.99 5 Garaga 119.83 337.13 456.96 Total 643.35 785.54 1428.89

As per the information gathered from Revenue Records the farmers from whom the land will

be purchased on “Consent Basis” have been classified based on their land holdings and

information is summarized in the table given below

Danapura

Nagalapura D.N.Kere Garaga Byalakundi

Area In Acres

Ranges Extent of land Acres

No of land loser

Extent of land Acres

No of land loser


No of land loser


No of land loser


No of land loser

0-1 100.57 218 0.66 1 11.63 20 10.77 31 0 0

1-2 91.51 63 3.40 2 48.86 35 50.99 43 1.8 1

2-3 106.98 44 9.15 4 74.46 32 123.21 51 0 0

3-4 52.74 16 23.74 7 66.96 20 135.98 48 10.04 17

4-5 63.82 14 14.84 3 110.47 25 329.91 83 4.45 2

5-10 84.94 14 11.80 7 37.31 7 69.53 14 0 0

Above 10 0 0 00 00 57.77 1 112.65 12 0 0

TOTAL 500.56 369 63.59 24 407.35 140 833.04 282 16.29 20

TOTAL LAND LOOSERS : 835


It is intended that only dry agriculture land will be purchased from the farmers. No “Village

Tana land” will be purchased. There will not be any displacement of people from their

house hold. There will not be any displacement of people from their respective villages.

Therefore, there will not be any Rehabilitation and Resettlement of any Agriculturist or

Landless laborers.

Recruitment in the Existing Industry.

BMM Ispat Pvt Ltd and its sister concern M/s HKT Mining Pvt Ltd., are the two existing units

in operation at Danapura. The company is always willing to honour the Government

Direction to comply with the Saroojini Mahishi report regarding providing jobs for the local

people. Right from the beginning the policy followed by the company is to give preference

to Kannadigas in general and local people in particular. These two companies have

presently recruited above 882 people in all caders and out of this, 660 people are from

Karnataka which works out to 75% of the total employment. It is further to be observed that

57% of staff about 506 people are from Bellary District and balance 18% are from Karnataka

State. Only 222 people which is 25% of the total strength are from out side the State.

It is further to be noted that the company has been providing jobs to persons who have sold

their land for the industry. We have recruited 147 persons who have sold their lands to the

company. This is one of the requirements of Dr. Saroojini Mahishi committee report and we

have been honouring the said requirement.

It will be our endeavor to follow the Dr. Sarojini Mahishi report to the maximum extent

regarding recruiting kannadigas and giving employment to one member of the family who

sell the land to the company for our proposed 2 MT/Yr Integrated Steel Plant.

Diversion of inter connecting village roads passing through the Project area

Following village connecting roads are passing through the proposed project area.

1. Danapur – Garaga Tanda

2. DN Kerre – Garaga Tanda

3. Mariammanahalli – Garaga Tanda

4. Nagalapura – Garaga village

The above village roads need to be diverted to provide connectivity to the road users. The

project proponent is willing to undertake diversion of these roads at his cost in consultation

with concerned village elected representatives. The project proponent is making adequate

budget provision for diversion of these roads.


Main features of R&R Policy

With the main object of establishing harmonious and continued relationships with Land

owners, the project proponents will be offering a lucrative package with a human face to

all such farmers who will be willing to offer their land for sale on “Consent Basis”.

The project proponents will ensure that special care is taken for protecting the Rights of

weaker section of society especially members of Schedule Caste and Schedule Tribes.

Though there is no displacement of any farmer or landless laborer from their Habitation

and yet the proponent is willing to adopt a benevolent farmer friendly

Rehabilitation and Resettlement Policy and is willing to discharge its social

responsibility to benefit the surrounding villages. The features of such a policy may

include the following.

1. The recommendations of Sarojini Mahishi committee report will be adopted in the

recruitment of staffs.

2. As far as possible the recommendations of the National Rehabilitation and Resettlement

policy 2007 pronounced by Government of India will be adopted.

3. The Proponent is willing to provide one job either to the Khatedar who has

sold the land to the company or to one member of his family to be identified by

the Khatedar, commensurate with his or her education qualification, age and

suitability for the job.

If needed, the proponent is willing to deploy to the extent of man power

required for the development of the green belt each year, the services of

landless labourers and farmers belonging to the above 5 villages in this program.

In addition to a benevolent rehabilitation policy, the proponent is likely to carry out the

following social responsibilities.

i. The company may adopt few villages located in the Study Area.

ii. The company will improve the drinking water supply, street light and maintain

them.

iii. The company will provide adequate drainage & sanitation facility to these villages

and plant trees in the village limits & develop green belt around the villages.


iv. The company will build additional rooms to the existing schools wherever it is

needed, provide drinking water and adequate sanitation facilities in these schools.

v. The company will extend financial help in providing Mid-day meal to school going

children.

vi. The company through their hospital will extend medical facilities to such villages.

vii. Widows and unmarried daughters of the land loosers from these villages will be

trained in tailoring and sewing machines will be supplied to each one of them.

viii. If the village authorities desire, the company will be willing to take up maintenance

of the water body (Tank) of these villages.

Financial Outlay

To meet the above social obligations, the proponent is willing to make the required

budget provision for capital as well as Operation & Maintenance expenses every year. The

total capital cost allotted for the socio economic development is 25.00 crores and

recurring cost assumed to be 4.0 crores per annum.

CHAPTER VII

PROJECT BENEFITS

7.1 Following aspects of State Industrial & Mining Policy favours the

establishment of the proposed project

• Government accords highest priority to the objectives of dispersal of

industrial investments in various backward regions / districts of the State so

that the fruits of economic development and employment opportunities are


shared by all segments of society and in all parts of the state in as equitable

manner as possible.

• To focus on strengthening of the manufacturing industry in the state and to

increase its percentage share in the GSDP from the present average of

16.70% to over 20% by the end of the policy period.

• Special incentives for entrepreneurs setting up units in backward areas.

Additional incentives for units promoted by entrepreneurs from the category

of SC/ST, Minority, Women, Physically challenged & Ex-servicemen.

• Industrial Corridor / Cluster development would be taken up in potential

locations viz. (i) Bangalore – Mysore (ii) Hospet – Bellary (iii) Mangalore –

Upipi (vi) Bhadravathi – Shimoga (vii) Nelamangala – Kunigal (viii) Davanagere

– Harihar (ix) Kolar – KGF etc.

• Bulk of Iron Ore Resources are in Bellary/Hospet area.

• State has declared Bellary – Koppal area as “Steel Belt”.

• To maximize value addition to the mineral extracted, the state is

encouraging maximum investments in down stream industries.

• Priority will be given to the entrepreneurs who propose establishment of

industries for value addition with in the vicinity of the mineral bearing areas.

• To promote indigenous utilisation of Iron Ore fines and Beneficiation of low

grade ore.

• Encourages existing / new industries to set up facilities to use available raw

material & enhance quality up to the required specifications by the

processes like. Beneficiation, Pelletization and Sintering.

• Stand alone industry is to be encouraged as it provides large scale

employments. Such industries enhance value to the raw material by

converting a resource into a product and spawn auxiliary industries.

7.2 Employment and income effects


Employment and income generation are the most important aspects that need

detailed investigation in case of any industrial project. The present project has

some positive employment and income effect. A sizable number of local persons

are likely to be involved in different activities of the plant. For execution of the

project, a large number of people will be required directly and indirectly. This

will create a huge employment and income effect on the socio-economy of the

study area. So far indirect employment is concerned, the effect is very strong

and widespread. The project is expected to generate indirect employment and

income which is 4-5 times higher than the direct employment.

In view of this, it can be justifiably concluded that the present project will have

tremendous positive employment and income effects. The manpower required

for the proposed integrated steel plant, cement plant and Captive power plant

are indicated below

S.No Category Nos.

1 Managerial 340

2 Supervisory 1070

3 Skilled 2680

4 Unskilled 510

Total 4600

In addition to the above, the operation of the steel plant, itself will generate

revenues to the State and Central governments. Some of the potential economic

benefits likely to be accrued from the project are as follows:

• Earnings by the Govt. by way of taxes levies and duties like ED, IT, VAT,

TDS etc

• Business opportunities for the local entrepreneurs to set up small and

medium scale industries

• Business opportunities for the local entrepreneurs serving as service

providers, suppliers, contractors

• Investment opportunity for local infrastructure development


Thus, the steel plant will facilitate in catalyzing the development of

infrastructure, health care, upliftment of civic amenities, education for

economic upliftment of the locals and improvement in their living standards.

7.3 Industrialization around the steel plant

Steel plants by nature serve as the nuclei for development of small-scale

industries in the areas around them. These small-scale units usually have

input-output linkages with the steel plants. The demand for spares, assemblies

and sub-assemblies by steel plants are generally met through the supply (of

these items) from small-scale units located nearly. The small-scale units, in

turn, get necessary steel products from the steel plants. In the vicinity of major

Indian steel plants e.g. Rourkela Steel Plant, TISCO, Bhilai Steel Plant etc.

similar type of small-scale industries are visible. This brings forth mutual

advantages with one acting as complementary to another. The advantages to

steel plants as well as small scale units are listed below :


Advantages to steel plant

i) Assurance of a reliable source of supply of spares and consumables;

ii) Supply on short-delivery schedules enabling maintenance of lower inventory;

iii) Saving foreign exchange through import substitution;

iv) Lower freight element in comparison to materials supplied by firm located far away;

v) Better service facilities

Advantages to small scale units

i) Availability of ready market;

ii) Availability of raw material source for steel / by-product consuming industries;

iii) Getting price preference over distant suppliers;

iv) Availability of facilities from government;

v) Availability of infrastructure support from the steel plant

Proper utilization of these mutual advantages is expected to play a catalytic

role in the development of the region where the present project is proposed to

be implemented.

The small scale industries that are likely to come up in the vicinity of the steel

plant can be grouped into two i.e - spares, metal based. These will be

complemented by the service units.

The proposed project is expected to serve as centre of significant small-scale

industrial economy around it complemented by the services sector. This is

expected to play a major role in the future economic and social development of

this area.


7.2 Improvement In The Physical Infrastructure

Road

Improvement and extension of the existing network is, essential to

develop remote areas, better connection between the economic centers of

state, and also cross-border transport and for personal mobility of the masses.

Rail Network

Railways provided an important mode of transportation in the public

sector spreading over the entire country. It contributes to the country’s

economic development by catering to the needs of large-scale movement of

freight as well as passenger traffic and is a major source of promoting

integration among the masses. Railway provides transport facility to people and

handles freight above 600 million tons annually. The Indian railway is intended

to modernize the vast railway network, keeping both the economic and social

dimensions in mind.

Other Tangible Benefits

The other tangible benefits will be in the form of plant township hospital and

schooling facilities which will also help local population to enjoy the fruit of

better facilities in nearby. BMM Ispat Ltd also will undertake various community

welfare measures for up liftment of plant surrounding villages. These measures

include:

• Encouraging female education

• Encouraging entrepreneurship among locals Vocational training

• Upgrading one/ two primary school buildings and play grounds.

• Adoption of few villages for infrastructure development (Sanitation,

water supply, education, primary health)

• Construction of bus shelters.

• Health camps and eye camps.


• Improvement of road network in the nearby villages

• Traffic islands, wherever required in Bellary / project surroundings


CHAPTER VIII ENVIRONMENTAL IMPACT STATEMENT After collection of base line data, subsequent identification, prediction and

evaluation of impacts, EIS has been delineated for five basic environmental

components that are likely to be affected or benefited due to the proposed 2

MT/Yr steel plant, 1.4 MT/Yr and 230 MW captive power plant and its allied

activities near Danapura village, Bellary District, Karnataka state. For proper

assessment of environmental changes in the coming years, impacts predicted

due to proposed industry are presented for each environmental parameter in

table 8.1. Impact check list for plant construction and operation phases are

presented in table 8.2 and 8.3. The environmental impact matrix is presented in

table 8.4. which classifies the environmental parameters listed under impact

statement and check lists into different heads. Likely beneficial impact is

indicated by positive sign, likely harmful impact is indicated by negative sign.

EIS has been furnished for the following;

I. Air Environment

II. Water Environment

III. Noise Environment

IV. Land and Biological Environment

V. Socio Economic Environment


TABLE 8.1 COMPARATIVE CHART OF VARIOUS IMPACTS

Component Impact Due to Plant

I. Air Environment

1. Air Quality Impact scenario of air component due to the proposed plant emissions is significant. However the predicted concentrations are well within the standards as prescribed by CPCB.

2. Meteorology The meteorological data collected confirmed that the climatic status of the study area is consistent with regional meteorology. The industrial activity that is coming up has very negligible influence on the meteorology of the region. As such, the same pattern may continue.

II. Water Environment

3. Water Surface water quality will not get affected as entire quantity of effluent generated from sanitary uses will be treated within the plant site. Similarly, the process effluent from the Steel manufacturing units, boiler blow downs and cooling water discharges will be taken in to a large guard pond. The outlet of the guard pond is treated and treated by physico-chemical treatment process and treated water is utilized for green belt development. The storm water during season is harvested from roof tops, vacant plots, landscaping and paved roads. The harvested water is infiltrated and percolated into the ground water table.

4. Water Supply The water used for the industrial purpose is very significant. Water will be drawn from down stream of TB dam/Almathi dam/ ground water to an extent 3880 m3/hr. The impact on the water resources in and around the industry is significant. Water conservation practices, especially Rainwater harvesting and subsequent recharge into ground water table would likely improves the groundwater potential on a local basis.

III. Noise Environment


5. Noise There may be slight increase in noise levels due to the steel plant operations such as compressors, ID fans, pumps, material handling systems etc., There is no direct or indirect impact on nearby residence due to the noise produced in the plant. The noise level beyond one kilometer from the industry is insignificant.

IV. Land and Biological Environment

6. Forests No impact on forests and endangered plant species.

7. Flora and Fauna Greenbelt has a positive impact on flora. Slight dislocation of fauna due to increased human activity.

8. Land use Plant site, which is about 1429 Ha (3530 acre) is utilized for various establishments. As human activities increases around the plant site, land prices may likely to increase

9. Landscape Plant erection and rich plantation improve the visual effect.

10. Livestock Positive impact due to demand for milk, eggs and meat.

11. Solid waste Solid waste generated, which are not usable for any purpose will be disposed in control land filling in plant premises. Other solid waste will be reused in the plant itself. Fly ash will be utilized in cement manufacturing.


V. Socio Economic Environment

13. Educational Facilities No significant impact is anticipated immediately.

14. Medical Industry will provide medical facilities at factory premises at initial stage itself.

15. Occupational Facilities Some of the employees will find direct employment and many others indirect employment.

16. Transportation Slight impact due to increase in vehicular traffic.

17. Power supply Power will be drawn from the captive power plant established by BMM Ispat as auxiliary units.

18. Housing Some increase in house construction activity.

19. Economic aspects Local economy may improve through employment and rise in commercial activity.

TABLE - 8.2 IMPACT CHECKLIST FOR PLANT CONSTRUCTION

Environmental

Parameters Activities

Land use

Water Quality

Air Quality Noise Solid

Waste Housing Infra structure Services

Site clearing T T T T P

Road laying P T T T P

Foundation Works P T T T T P

Concrete Works P T T T P

Mechanical Erection T P

Material Storage T

Material Handling T T

Transportation T T

Water Requirement T

Temporary Constructions T T T

Temporary Services T T T

Hazardous Materials T T

Social Services T

T – Temporary Impact

P – Permanent Impact


TABLE - 8.3 IMPACT CHECKLIST FOR PLANT OPERATION PHASE

Environmental Parameters

Activities

Land use Water Water

Quality Air

Quality Noise Solid Waste Housing Infra

structure Services

Plant Commissioning Y Y Y Y Y

Water Requirement Y

Gaseous Emissions Y

Raw Material Handling Y Y Y

Product Handling Y Y Y

Spill/Leakages Y Y Y

Startup/Shutdown Y Y Y Y Y

Equipment Failure Y Y Y Y Y

Transportation Y Y

Housing Y Y Y Y

Education Y Y

Health and Recreation Y Y

Note: Y – Indicates Possible Impact


TABLE 8.4 IMPACT STATEMENT MATRIX

Environmental Parameters

Activities

Land use Water Water

Quality Air

Quality Noise Solid Waste

Infra structure Services Socio

Economy Ecology

Construction N N N N N P P P N

Plant Operation N N N N N P P N

Water Requirement N N N

Gaseous Emissions N N

Spills/Leaks/

Equipment Failure

N N N N

Material Handling N N P P N

Transportation N N P P N

Social Activities P P

Note: N – Indicates Negative Impact P – Positive Impact

CHAPTER - IX


ENVIRONMENTAL MANAGEMENT PLAN

9.1 General

This chapter discusses the environmental management plan (EMP) to minimize the adverse impact of the proposed project of 2.0 Mt/Yr steel production, 1.4 Mt/Yr cement manufacturing and 230 MW captive power production. Environment Management Plans are a useful vehicle for integrating and implementing the environmental management commitments, conditions, and statutory requirements. Environmental Management Plans and statutory requirements that are developed by proponents / his consultant during a proposal’s planning and design stages are presented in this chapter.

9.2 Objectives of EMP

The objectives of the proposed EMP are aimed for meeting five basic requirements,

namely

i) To integrate comprehensive monitoring and control of impacts.

ii) To comply with the environment protection regulations.

iii) To ensure that adverse environmental impacts on the core and buffer zone are

minimized, and

iv) To fulfill the Corporate Responsibility on Environment Protection (CREP)

v) To plan for ecologically sustainable development (ESD) within the frame work of

existing legislation and environmental management policies.


9.3 Applicable regulations

Following regulations on environment protection have been considered in formulating

this EMP:

• Section 21 of the Air (prevention and Control of Pollution) Act, 1981

• Section 25 and 26 of the Water (Prevention and Control of Pollution) Act, 1974

• The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989

• The Hazardous Wastes Management Handling Rules, 2000

• The noise pollution (Regulations and Control) Rules, 2000

• The Environment (protection) Rules, 1986.

9.4 Scope of EMP

In order to meet the above stated objectives, the proposed EMP would be an integral part

of the project from the design stage itself. This EMP is not conclusive and may require

further improvement as and when the situation demands.

The EMP is prepared in three stages, viz.,

• EMP at design stage

• EMP at construction stage and

• EMP at operational stage

9.4.1 Environmental Management Plan at Design Stage

Technological improvement

At the design stage of the proposed production facilities, the basic process route of

steel & Cement productions, and captive power generation, latest technologies

available to minimize pollution generation and reduction of water and power

consumption, wastewater recycling, solid waste recycling, waste heat recovery and

energy savings which are required to be looked into while selecting the process route of

each of the major production units. Following are the key areas where technological

improvements are suggested for arresting environmental pollution.


Conservation of Air ,Water and Energy recovery

• Fugitive dust emission control by dry fogging and dust extraction system.

• Fugitive emission control at raw materials storage and handling by land based

fume suppression system by sprinkling water.

• Fugitive emissions control at Sinter Plant and pelletization plants through feed

material controls and enclosures

• Extraction of electric power from BF top gas.

• Heat recovery in BF stoves.

• Arresting fugitive dust emissions in MBF shop.

• Reuse/recycling of treated wastewater.

Instrumentation & Controls

1. Blast Furnace Instrumentation

Cooling water flow / temperature metering

Humidity control / water injection

Hot blast / dome temperature control Fuel / Air ratio control

Oxygen enrichment control

2. Electric Arc Furnace (EAF)

Cooling water flow, temperature and pH metering

Gas flow metering

3. Converter

Cooling water flow, temperature metering

Gas mixing stations

VD/VAD/VOD instrumentation

4. Ladle Furnace

Cooling water flow, temperature metering

Argon rinsing station


5. Con-cast continuous casting of steel

Mould cooling water Flow control

Pressure control

Temperature monitoring

Secondary cooling system

Flow control

Temperature monitoring

6. Rolling mill Instrumentation

Furnace Pressure control

Furnace temperature control

Fuel / Air ratio control

Temp core system

7. Sintering Plant

Damper settings controls

Pressure drop controls

Strand speed controls

Feed material controls

Sectional re-circulation of gases controls

8. Pelletisation Plant

Feed material controls

Pressure drop controls

Damper controls

9. Power Plant

Automatic blow down control

Foot traps with trap monitoring, strainers, disk check valves

Direct acting temperature regulations


Land environment management

It is necessary that at the plant layout design stage, optimum land area should be

considered, with requirements for material movement logistics so as to have more free

space for future retrofitting measures and beautification of the landscape. There is a

scope for beautification of the land area within the steel plant and township by

planting trees, flower gardens, grass lawns and fountains to improve the aesthetic

quality of the steel plant, as has been done in the existing steel plant.

Green Belt Development

Green belt is an important sink for air pollutants. Trees also absorb noise and by

enhancing the green cover, improve the ecology and aesthetics and affect the local

micrometeorology. Trees also have major long-term impacts on soil quality and the

ground water table. By using suitable plant species, green belts can be developed in

strategic zones to provide protection from emitted pollutants and noise.

In the proposed plant, green belt will be developed in vacant areas, around office

buildings, around stores, along the side of roads, along the plant’s boundaries and

around the waste dump area. Plant species suitable for green belts should not only be

able to flourish in the area but must also have rapid growth rate, evergreen habit, large

crown volume and small / pendulous leaves with smooth surfaces. All these traits are

difficult to get in a single species. Therefore a combination of these is sought while

selecting trees for green belt. The green belt should be planted close to the source or

to the area to be protected to optimize the attenuation within physical limitations. A

total of approximately 33% of total area will be developed as green belt or green cover.

The following species are suitable for planting in the area as recommended by Central

Pollution Control Board in their publication “Guidelines for Developing Greenbelts”

(PROBES/75/1999-2000): A very elaborate green belt development plan has been drawn

for the proposed plant. The areas, which need special attention regarding green belt

development in the industrial area, are:

- Along Plant Boundary

- Along Road Side

- Around Various Shops

- Around Office and Other Buildings

- Stretch of Open Land

- In and Around Township


Selection of Species The species for plantation have been selected on the basis of soil quality, place of

plantation, chances of survival, commercial value (timber value, ornamental value,

etc.), etc. It is to be noted that only indigenous species will be planted. Exotic species

such as Eucalyptus and Australian Acacia will not be planted. The Species will be

selected in consultation with State Soil Conservation Department.

Mixed plantations will be done keeping optimum spacing between the saplings.

Along Plant Boundary The row of plants facing plant should be smaller species and those facing outside should

be taller species. The species suggested for plantation is:

Small Species

• Kaneer (Nerium sp.) • Prosopis (Prosopis juliflora) • Bougainvellea (Bougainvillea spp.) • Ber (Zizyphus spp.) • Gulmohar (Delonix regia) • Duranta (Duranta sp.) • Kamayani (Murriya exocitica) • Bilayati Babool (Prosopis juliffera) • Babool (Acacia arabica) • Tall Species • Amaltas (Cassia fistula) • Siris (Albizzia lebbeck) • Neem (Azadirachta indica) • Druping Ashok (Polyalthia longifoila) • Mango (Mangifera indica) • Peepal (Ficus religiosa) • Arjun (Terminalia arjuna) • Jackfruit (Artocarpus heterophylla) • Palash (Butea spp) • Cassia (Cassia siamea) • Bottle brush (Callistemon lanceolatus) • Road Side Plantation • Avenue plantation should include the following species: • Siris (Albizzia lebbeck) • Gulmohar (Delonix regia • imli (Tamarindus indica) • Siris (Albizzia lebbeck) • Neem (Azadirachta indica) • Druping Ashok (Polyalthia longifoila) • Mango (Mangifera indica) • Peepal (Ficus religiosa)


• Bargad (Ficus bengalisis) • Arjun (Terminalia arjuna) • Cassia (Cassia siamea) • Around Various Shops

As there will be limited space (in height) due to various over head pipelines, thus small

and medium sized species are suggested and they should be planted depending on the

vertical height and lateral space available for the plant growth.

The species selected will be from among the following:

Small Species • Ber (Zyziphus sp.) • Sharifa (Annona squamosa) • Prosopis (Prosopis sp.) • Cassia (Cassia auriculata) • Duranta (Duranta sp.) • Kamayani (Murrya exotica) • Medium Size Species • Kaner (Nerium sp.) • Amaltas (Cassia fistula) • Subabool (Leucaena leucocephala) • Cassia (Cassia alata) • Babool (Acacia arabica)

Around Office and Other Buildings Plantation will be done around various shops, stores and other buildings, along the side of connecting roads. Species suggested for plantation are as follows which are mostly ornamental plants:

• Cassia (Cassia javanica) • Amaltas (Cassia fistula) • Cassia (Cassia siamea) • Amaltas (Cassia fistula) • Arjun (Terminalia arjuna) • Lagerestromea (Lagerestromea flosregennae) • Peltophorum (Peltophorum feruginium) • Gulmohar (Delonix regia) • Druping Ashok (Polyalthia longifoila)

Stretch Of Open land In the proposed plant, green belt will be developed in vacant areas. Species suggested for such areas are:

• Siris (Albizzia lebbeck) • Pakur (Ficus racemosa) • Gulmohar (Delonix regia • Imli (Tamarindus indica) • Peltophorum (Peltophorum feruginium) • Gulmohar (Delonix regia • Siris (Albizzia lebbeck) • Neem (Azadirachta indica) • Mango (Mangifera indica) • Peepal (Ficus religiosa)


• Bargad (Ficus bengalisis) • Arjun (Terminalia arjuna) • Cassia (Cassia siamea)

Mixed plantation will be done to take care of different heights and rates of growth. In and Around Township

In the proposed township plantation will be done in following areas:

- Along the township boundary

- Along the roads

- Stretch of open land

For the above areas the plants to be planted will be from among the list given

above for respective areas in the plant premises. Phase Wise Green Belt Development Plan

Green belt will be developed in a phase wise manner right from the construction phase

of the proposed plant. In the first phase (in the first and second year of construction)

along with the start of the construction activity the plant boundary, the township

boundary, around the proposed waste dumps, and the major roads will be planted. In

the second phase (in the third year of construction) the office building area will be

planted. In the third phase (in the fourth and fifth year of construction) when all the

construction activity is complete plantation will be taken up in the plant area, in

stretch of open land, along other roads and in the township will be taken up. The trees

may be watered using the effluent from the sewage treatment plant. They will be

manured using sludge from the sewage treatment plant. In addition kitchen waste from

the town-ship and plant canteen can be used as manure either after composting or by

directly burring the manure at the base of the plants. The green belt development plan

is shown in Fig. IX.1


The year-wise planning of the trees & shrubs is presented below.

Year Number of plant species to be planted Shrubs Landscaping

2009-2010 1,00,000 - - 20010-2011 1,50,000 10000 Grasses & Avenue plants 20011-2012 2,00,000 20000 Grasses & Avenue plants 2012-2013 1,00,000 10000 Grasses & Avenue plants 2013-2014 1,00,000 10000 Grasses & Avenue plants

Total 650000 50000 -


Total area : 1429 ha Green Belt Area : 472 ha Management of Water environment: During design stage, water environment

management measures will consider two aspects, that is,

i) Conservation of water by Rain water harvesting, and

ii) Waste water treatment, recycling and disposal system

Rainwater harvesting

BMM is planning to have a system of rainwater harvesting at plant. Rainwater harvesting

is primarily dependent on various site characteristics such as soil properly, catchments

characteristics; rainfall characteristic, and ground water table etc. There are artificial

as well as natural rainwater harvesting system. The recharging system can be

implemented for

i) Individual units

ii) Centralized collection system

Scheme I: Collection of rainwater harvesting from individual building units and

construction of filter beds at individual building unit. Rainwater falling on other open

area is to be collected, through constructed drainage system and discharge system and

discharge to surface out-fall (by passed for rainwater harvesting) Scheme II:

Construction of rainwater filter bed at centralized place where water from individual

unit as well as storm water from open area shall be diverted. The rainwater carries

suspended solids as washed out from open area. A filter bed filters the particles thus

prevent them from reaching / contaminating ground water. The first layer of filter bed

shall be coarse sand the second layer shall be pebbles and third layer shall be gravel.

The filtrate thus collected from the bottom of filter bed shall be piped to recharge bed.


Liquid waste handling system

(i) Clear water sump ensures continuous cleaning of the contaminated water for its

reuse for the operation.

(ii) Unloading sprout helps in avoiding the dust nuisance during the unloading of

coal char from the bunker.

(iii) A large waste dumping yard will be developed in an area at a safe distance

between the plant where the waste products generated during the process of

sponge iron production is disposed. To avoid its flying, a thick layer of sweet soil

is spread over the heaps and grass is planted to make the area clean and green.

(iv) Concrete flooring will be done at such areas inside the plant where the dust

normally settles in some amount. Continuous water spraying will be done to

clean these floors and allow the dust to flow to the nearby drains from where

the dusts are collected and disposed in waste yards.

Wastewater treatment, recycling and disposal

Wastewater will be generated in individual steel production facilities. It is

recommended that each of the production units be designed to utilize less amount of

water and recycle of water to the maximum by cascading use of water. There will be

blow downs from each of the systems. It is suggested that the blow down water be

collected centrally and treated to make the water usable in less critical applications

like slag quenching, green belt development etc.

All efforts will be made to re-use and re-circulation the water and to maintain zero

effluent discharge. The following schemes are proposed for wastewater management

comprising treatment, recycling and disposal systems:

Gas Cleaning Plant wastewater

The Blast Furnace gas cleaning scheme will be of the conventional venturi type which

have become the bench mark for similar application. The effluent coming out of the

wet scrubber will be contaminated with high concentration of suspended solids. The

slurry effluent will be clarified in the clarifier to recover clarified water for recycling to

the wet gas scrubber after cooling in the cooling tower. The sludge settled in the

clarifier will be pumped to the existing pellet plant as a feed material for making


pellets. It is suggested that the blow down water from the cooling water circuits be

used as make up in the gas cleaning re-circulation systems.

Treatment of billet Caster effluent and mill effluents

This effluent will be contaminated mainly with suspended solids and traces of oil. The

effluent from the mill will be collected first in scale pit which is a large settling basin

to separate out the floating oil and settable iron scales The clean water is passed

through sand filters to remove finer particles, after which the water is recycled in the

process. The backwash from the filters is sent to the settling tank for removal of

particulates. The settled sludge is sent to either pellet plant and/or sinter plant for

agglomeration. It is suggested that the blow down water from the cooling water circuits

be used as make up in direct contact re-circulation systems.

Treatment of Power Plant effluent

The power plant effluent will be the backwash of DM water plant. This effluent will be

relatively free from solids and oil and thus the effluent will be treated in a neutralizing

pit for pH correction only. The neutralized effluent will be stored in the treated

effluent lagoon for reuse along with cooling tower blow down in the direct cooling

system.

Use of Cooling Tower blow downs

It is noted that the re circulating water in cooling towers gets contaminated with the

dust in the atmosphere, necessitating blow down. It is recommended that all cooling

towers be provided with side stream pressure filters to reduce the volume of blow

down. The cooling towers shall be designed to operate at high cycles of concentrations

(>8) to conserve water. Further, Cooling Tower blow downs of indirect cooling water

system shall be used for slag quenching, as make up to direct contaminated cooling

water circuits and surplus if any will be stored in the treated wastewater lagoon for in-

plant use.


Design details of proposed wastewater treatment plants

The following scheme shows the proposed Wastewater Treatment plants in BMM ISPAT

LTD.

The design of the effluent treatment plant for waste water generated from process

operational system need to be aimed towards zero discharge which means practically

no discharge or minimum discharge. It will be difficult to attain zero discharge, as

repeated recycling will disturb the quality of recycled water, making the plant

operation unsafe. Hence, a part of treated water needs to be discharged through the

plant drain into the guard ponds for maintaining the water quality of recycled water.

It is proposed that in spite of having total recycling based design of the plant, for all

practical purposes, the plant should have drainage provision 15-20 m3/hr of treated

water, in compliance with the regulating standards. That is around 0.4 m3 per MT of

steel. Thus the water usage in the steel plant will be around 99.5%. The drainage of

treated wastewater will be made through the treated waste water lagoon, serving as a

guard pond for quality control of effluent to be drained.

Flow Assessment from Different Sources (m3/hr)

1. Beneficiation plant = 6.0 2. Pellet Plant = 8.0 3. DRI Plant = 5.0 4. Coke oven plant = 13.0 5. BF Plant = 58.0 6. Steel melting shop = 44.0 7. CCM shop = 16.0 8. Calcination & Oxygen plant = 15.0 9. Rolling mill = 114.0 10. Power plant = 320.0 11. Cement Plant = 1.0 ---------- Total 600.0

----------


Recycle

Likely Characteristics of Wastewater

Wastewater Characteristics (mg/l) Sl. No.

Source pH SS Oil and

Grease Metals / others

1. Beneficiation Plant 6.0 – 6.8 6000 - 8000 <3 Fe,

2. Pellet Plant 6.0 – 7.0 1000 – 1500 < 5 Fe, Mn, Zn

3. Sponge Iron Plant 6.0 – 7.0 200 – 300 < 3 -

4. Coke oven plant 8 - 9.5 1500-2000 - -

5 Blast furnace 7-8 1000-1200 < Fe, Mn, Zn

6 Steel Melting shop (EAF +LF 7 -7.5 200 -250 Fe, Mn, Zn

7 CCM 6.5 – 7.0 300 – 400 10 – 30 Mill Scale

8 Calcination & Oxygen plant 10 -10.5 500 -1000 - -

9 Rolling Mills 7 – 8 500 – 600 50 – 70 Mill Scale

10 Captive Power Plant 6 – 7 200 – 300 < 2 –

11 Cement Plant 7 -8 100-200 <1 -

Treatment Processes

Beneficiation plant effluent

The tailings will be first dewatered in hydro-cyclones and then treated in thickeners for

water recovery. The thickener sludge will be filtered to recover water and the solid waste

will be transported in trucks to the dump area.

Tailings Thickeners Water recycling

Hydro-cyclones

Slime Pond To Loading

Point


Pellet Plant

The waste water requires treatment for the removal of suspended solids.

Sponge Iron Plant

No treatment is required. The entire flow is utilized in ash handling and dust

suppression.

Blast Furnace

EAF + LF Plant To guard pond Flow

Collection Tank Ash handling

Dust suppression

Sponge Iron

Plant Flow Pump

Collection Sump Tube Settlers BF Plant

Flow Pump

To guard ponds

Sand Drying Beds

Collection Sump Pellet Plant

Flow To guard ponds


Removal of SS

CCM Plant A. Mould and equipment

Cooling Water blow downs To guard pond Oil & Grease recovery B.

Rolling Mills Captive Power Plant Cooling Water blow down = 172 m3/hr Boiler blowdown = 28.0 m3/hr (UF + RO + MB + Softner + Filter) Rejects = 87.0 m3/hr Side stream Filter rejects = 33.0 m3/hr ---------------

Total 320 m3/hr -----------------

Scale

Pits

Oil and GreaseTrap

Spray water

blowdowns

Sintering

Plant

Mill Scale

To Re-circulation

Scale Pit

Settling Tank

Rolling Mills

Flow

Scale to Sinter Plant

To re-circulation /guard pond


A. B. (SSF Backwash water)+ (UF + RO + MB + Softener + Filter Reject )

Cement Plant Effluent Effluent Guard Pond

Process of Guard Pond Effluent Treatment Seperate guard ponds for major production units will be designed with HDPE lining. The effluents from the ponds will be treated by physical and chemical processes. The treated effluent will be reutilized for various secondary uses. The overall treatment process is presented below.

Direct Re-Use Cooling water blowdowns Boiler blowdowns Collection

Pit Pump

Flash Mixer Plate/Tube Settlers Guard

Ponds Pumps

Treated Effluent

Mixer

Polymer Sludge

Lime + Alum

Floccu lator

Pump

Centrifuge

controlled land fill

Centrate

To guard pond


Uses 1) Slag quenching

2) Ash handling

3) Green belt

4) Dust suppression purposes.

Treatment of Plant Sanitary wastewater

Sanitary waste generated from all sections of the steel plant are collected from a

closed drain and treated by fluidized aerobic biological treatment. The treated

wastewater is utilized for green belt development.

Process description The raw sewage shall be collected in the equalization tank after passing through a bar screen where from it is pumped to the Sewage Treatment Plant comprising the following units.

1. Flash mixer (RCC tank) - Installed with slow speed agitator for chemical

mixing.

2. PAC and Polymer Dosing Systems: (Comprising HDPE Tanks, Dosing pumps

and agitators) - for coagulation and flocculation of Colloidal and suspended

solids.

3. Reactivate or clarifier (RCC tank) - for primary chemical treatment

4. FAB Reactor (RCC tank) - Fluidized Aerobic reactor with diffused aeration

system for bio degration of dissolved organics.

5. Secondary Clarifier (RCC tank) - to provide sedimentation and sludge re-

circulation of activated sludge from FAB.

6. Chlorine Contact Tank (RCC tank) - to disinfect the treated sewage

Estimation of design flow i) Rate of water supply = 60 litres / capital / day ii) Total man power = 4600 iii) Rate of sewage generation = 85% of water supply iv) Quantity of sewage = 0.85 x 60 x 4600 = 234 m3/day Canteen wastewater generation = 250.0 m3/day ∴Total flow = 295 + 200 = 484 m3

= 500 m3/day ∴ Design sewage flow = 500 m3/day


CHIEF DESIGN AND PERFORMANCE PROJECTIONS Chief Design parameters The characteristics of the sewage will be as follows

Parameters Characteristics

1. Total Sewage flow - 500 m3/day 2. pH - 7.5 3. BOD - 200 - 450 mg/L 4. COD - 400 - 900 mg/L 5. TSS - 600 mg/l 6. TS - 1200 mg/l

Performance projections The sewage after the proposed treatment system will give the following output character tics when operated under optimum design conditions.

Parameters Characteristics

1. Total flow - 500 m3/day 2. pH - 6.5 - 7.5 3. BOD - < 10 mg/l 4. COD - < 250 mg/l 5. SS - < 10 mg/l

Management of Air environment

The design and engineering of the proposed production facilities require adequate air

pollution control measures to minimize the adverse impact on air environment . While

adequate pollution control systems have been established for process emissions, the

major area of concern will be to mitigate the fugitive emissions, from non-point sources

both in open and within the shop. The fugitive emission control measures are given in

Table 9.2 . The secondary fugitive emission control measures are given in Table 9.3 and

shown Fig IX.1. The details of stacks provided in the integrated steel plant, cement

grinding unit and captive power is presented in Table 9.4. The dedusting facilities is

given in Table 9.5.

Fugitive dust emissions control of Raw Materials Handling Section (RMHS)

To control the fugitive dust emissions at the stock piles on the ground, stacker

reclaimer, conveyor transfer points, vibrating screens, etc, both water sprinkling and

dry fogging (DF) will be adopted for dust suppression. The DF system generates a layer

of fine water droplets (fog) with which dust particle collide. DF requires only

compressed air and water pressure for atomization through specially designed nozzles.


DF is applicable for coal dusts, coke dust, ore dust etc which are non-reactive with

water. No dust suppression reagent will be used. For lime dust abatement, conventional

dust extraction (DE) will be adopted. No dust suppression agent will be used.

The DE system based on electrostatic precipitator (ESP) and fabric filter will be

provided for room air cleaning such as Sinter Plant Stock House, BF Stock FA House and

BF Cast House fume extraction. The EAF Shop will be one of the prime sources of

fugitive dust emissions during charging/tapping/blowing, argon rinsing, steel pouring,

de-slagging etc. The EAF shop will thus be provided with secondary emission control

system by means of dust and fume extraction system followed by bag filter/ESP. The

converters will be totally enclosed during the oxygen blowing operations. The

summarized list of APC measures for the production facilities is given in Table 9.1.

Table - 9.1 : SUMMARISED LIST OF APC MEASURES FOR THE PRODUCTION FACILIIES

Sl. No Area of operations Air pollution control measures proposed

to be adopted

Raw material handling · Dust suppression systems (chemical and dry fog type)

Fugitive emissions in material handling · Water sprinklers 1

· DE systems with bag filters in case of

conveyors, lime handling

2 Sponge Iron Plants Electrostatic precipitators, bag filters 3 Sinter Plant

Raw material preparation and handling (procurement of proposed sized materials to minimize crushing and screening) · DE systems with bag filters

Sintering process · ESP for collected waste gases

Sinter screening and transport · Bag filters 4 Pelletization Plant

Raw Material Preparation and Handling · DE System with bagfilters.

Pelletization Process · ESP

5 Blast Furnaces De-dusting with bag filters

6 Cacination · Bag filters

7 Steel melting shop Bag filetrs

8 Coke oven plant De-dusting with bag filters

9 Rolling mills Use of Low sulphur fule

10 Power Plant WHRB & AFBC · Electrostatic Precipitator

11 Coal Handling Plant · Bag filters

12 Cement plant · Bag filters


Table 9.2 Characteristics of Secondary Fugitive Emissions

Sl. No.

Item

Secondary fugitive Emissions

Control Strategy

1) Leaking of Pipe Connection

Iron Oxide, coal dust, H2S, CO, NOx, SO2 etc Weld together

2) Valves Iron Oxide, coal dust, H2S, CO, NOx, SO2 etc Seal-less Design

3) Fans, Compressors

Iron Oxide, coal fines, H2S, SO2, NOx and other

Closed vent system Dual mechanical seal

4) Raw material preparations Iron Oxide, Coals, recycled ducts

Binding agent in the water spray dedusting with bag filters. plantation around source

5) Sinter and pellet plants

Dust from sinter plant cooler and transfer points

Recovery by suctionhood installation with bag filters. Recycling of cleaned heated air

6) Coke ovens Coal or coke dusts sulfur oxide or, carcinogenic emissions, smoke, steam

Dust capturing devices coke side enclosure hoods and fans to reduce emissions at all transfer points.

7) Blast furnace Iron Oxides, H2S, cast house fumes, CO, coke dust

Closed conveyers, hoods to bag filters converted hoods at all transfer points runner side root extraction

8) Hot metal treatment Na2O, K2O, Lime Oxide fume, Dust, iron Extraction of fumes and scrubbing/ bag

filters. Acid – alkali neutralization.

9) Steel making Fine Iron Oxide, Alloy flumes Hoods with fume extraction followed

by bag filters partial enclosures.

10) Casting Fume, lead, SOX, Fluorides Fume extraction, water spray

11) Rolling Fumes Dust extraction and venting, side stream water spray

12) Cooling Chlorined hydrocarbons Solvents, acid mist

Extraction of fume followed by wet chemical scrubbing / bag filter.


Table 9.3 Fugitive Emission Control Measures

Fugitive EmissionSource Control Technique Control Equipments

Categorization OfControl System

Capabilities

Active Storage Piles

a) Watering b) Windscreens c) Plantations

- Water Sprinkler on yard RACT

Conveyor & Transfer Points

b) Water Sprays b) Hooding &

Ducting

- Dust suppression system - Bag Filters RACT

Product Handling a) Windscreen b) Hooding &

Ducting - Bag Filters RACT

Loading & Unloading

a) Windscreens b) Water Sprays - Water Sprinkler on yard RACT

Internal Road Transportation

a) Water Spray b) Concrete/Tar

Road c) Plantation

- Water Sprinkler - Construction of Internal roads

- Plantation at road sides

RACT

Crushing & Screening

a) Watering b) Windscreens c) Hooding &

Ducting

- Dust Separation system - Bag Filters

RACT

Waste Gas a) Heat Recovery b) Dust Collection

- WHRB - Electrostatic Precipitator BACT

Waste Sites

a) Chemical Stabilizers

b) Vegetative Cover

c) Windscreens d) Plantations

LAER

RACT – Reasonable available Control technology

BACT – Best Available Control Technology LAER – Lowest Available Emission Rate


Fig. IX.1 Schematic diagram of Secondary emission control in Electric Arc Furnace


Table 9.4 Details of Chimney

Plant unit Flow rate, Nm3/h No. of

Chimneys Height,

m Diameter, m top/ bottom

Scrubber/ ESP and its efficiency

Pelletising plant 930,000 1 55 4.0/ 7.5 ESP > 98% DR plant 376,000 2 90 4.1 ESP > 98% Coke plant 266,000 8 70 3.5/5.0 -- Sinter plant 660000 2 45 3.25/4.5 ESP > 98% BF plant 125000 4 55 2.0 -- Calcination plant 36000 2 30 1.26 Bag filter > 98 % Rolling mills 100000 2 80 1.54 -- Cement grinding unit

650000 1 60 4/6 Bag filter > 98 %

Power plant 458,000 1 220 3.0/4.5 ESP > 98% Steel making shop 60000 1 40 1.4 Bag filter > 98 %

Table 9.5 Details of Dedusting Units

Plant unit Location of dedusting systems

No. of dedusting systems

Air cleaning system Stack height, m

Proportioning bins 1 Bag filter 30 Cooler discharge area 1 ESP > 98% 30 Pelletising plant Coal grinding system 1 Bag filter 30 Day bins 2 Bag filter 30 Coal preparation unit 2 Bag filter 30 DR plant Product handling unit 2 Bag filter 30 Coal preparation unit 2 Bag filter 30

Coke plant Coke quenching station 2 Bag filter 30 Flux crushing unit 1 Bag filter 30 Coke crushing unit 1 Bag filter 30 Proportioning bins 2 Bag filter 30 Sinter plant Cooler discharge and sinter screening unit

2 Bag filter 30

Stock house 2 Bag filter 30 Coal pulverizing system 1 Bag filter 30 Cast house 2 Bag filter 30

BF plant

PCM shop 1 -- 5 m above roof Limestone/ dolomite screening unit

1 Bag filter 30 Calcination plant

Product screening unit 1 Bag filter 30 Granulated slag drying system

1 Bag filter 40

Cement grinding Materials Transfer points de-dusting system

2 Bag filter 30

Power plant Coal crushing unit 1 Bag filter 40


Point source dust emission control: BF stoves and reheating furnace mills use cleaned

fuel gases as fuel as such no dust emission control devices are proposed.

Process dust emission control: In case of sinter plant and lime kilns. the waste gases

contain large amount of dust and will require ESP/bag filter to arrest the particulates.

The ESP/Bag filters will be designed to limit the emissions to less than 50 mg/NM3.

S02 emission control: The main source of sulphur dioxide from the steel plant

operations is the metallurgical coal. In consideration to this, it is proposed to use low

sulphur blended coal. (S < 0.5 wlw). A major portion of sulphur present in coal or coke

will be fixed in BF and EAF slag. The other major source of SO2 emission is due to coal

firing in power plants. Since it is envisaged to use relatively sulphur free fuel gases for

power generation. the sulphur dioxide emissions will be drastically reduced. The other

sources of sulphur dioxide emissions are from the sponge iron and sinter plants. The

emissions can be reduced by using metallurgical coal with low sulphur (<0.5%) and also

by incorporating waste heat recovery systems.

NOx emission control: NOx will be formed during combustion of fuels. It is therefore

proposed to have combustion control devices by adopting waste gas re-circulation in

the combustion process and using low NOx burners so as to minimize the formation of

NOx.

Carbon monoxide emission control: The sources of carbon monoxide generation are

from the waste gases from the combustion operations. The control of air/fuel will be

adjusted in such a way that formation of carbon monoxide is minimized in the presence

of excess oxygen in the flues.

Energy conservation measures: Energy conservation measures at the design stage are

equally important as pollution prevention and control measures, since the energy

consumption has a direct linkage to the emission of carbon dioxide, a green house gas.

It is suggested that the energy conservation measures be adopted wherever possible to

reduce the specific energy consumption. The incentives offered for energy conservation

by the National and international bodies like CDM mechanism should be used to

conserve energy.

The project at the design stage, envisages energy consumption of 6.0 Gcal/tcs, but

after plant stabilization, further reduction of energy consumption needs to be

attempted.


Other considerations of EMP at the Design Stage The following aspects also need to be looked into:

Noise emission control: The design criteria for selection of noise prone moving

machineries should be of low noise design. These equipment require dynamic balancing

and vibrations dampened by suitable mounting mechanisms and proper grouting. The

work zone standard noise level shall be maintained at 85 dB(A) Leq for 8 hrs continuous

exposure. Where there is a high noise prone equipment generating continuous noise

above 90 dB(A) Leq, the same needs to be housed separately to ensure that continuous

attendance is not necessary. The operational control rooms and pulpits will be provided

with noise shield walls. In addition, administrative control will be required to adopt the

practice of using ear plugs in very high noise prone areas.

Air conditioning and ventilation: The design shall look into best practicable congenial

work environment from occupational health care point of view. The control rooms, pulpits

and control cabins will be provided with chilled water air conditioning facility. The room

inside temperature will be maintained at 25±2°C and relative humidity at 55 ± 5%.

It is suggested that CFC free refrigerants be used in air conditioning.

The production shops will be designed with adequate natural ventilation. The additional

heat within the shop floor may be ventilated by forced air clean supply system.

Dust handling: It is a common source of instantaneous fugitive emissions while

collecting the dust from the DE equipment and transportation of collected dust to the

other plant units. While designing the dust handling system, pneumatic transport or

covered conveyor system will be preferred if layout permits. Otherwise, the collected

dust will be moistened or pug milled and transportation of the same by in-plant

vehicular transport system covered with Tarpaulin so that no further dust is emitted to

the plant environment.

Provision for continuous monitoring of stack emissions : It is proposed to install on-

line continuous monitor for particulate matter in the major stacks like Sinter Plant

waste gas stacks, Power Plant combustion stacks and BOF& BF secondary emission

stack. On-line monitored values will be logged in the process computer of each plant or

a central data logging computer.

Landscaping: While developing the Plant General Layout, it needs to be ensured that

no unpaved areas will remain vacant. The unpaved areas will either have black

top/cemented or will have grass lawn cover to prevent wind borne fugitive dust.


Each production shop layout shall leave open land area by the sides of the access road

for landscaping purpose with plantation of flowering trees, water fountains for

beautification purpose.

9.4.2 Environmental management measures during Construction period

Construction activities at site will also require environmental management measures,

which are as follows:

• The earmarked zones where the construction activities will be taken up will be

fenced so as to prevent entry of unauthorized persons.

• The storage site for stockpiling of construction materials will be contained within

the temporary bund wall of low height. The storage site should be such that no spill

of construction materials like sand, gravels & stone chips, choke the plant drain.

• The excavated earth left over after land filling will be used for grade level

preparation, terracing and filling up of low lying areas.

• Attempt will be made to bring the plant equipment by rail.

Batching plant washings will be drained only after passing through Settling chamber.

This sentence is deleted.

• Alf construction personnel will be given safety training and will use compulsorily

safety helmets, gum boots, goggles as required by the construction safety manual.

• Safety surveillance on each working day.

• No child labour

• Cleaning of site after completion of construction and erection activities at the

respective construction zones.

• The construction wastes will be disposed of in an earmarked site within the steel

plant till its safe disposal place is found out or sold out.


9.4.3 Environmental management measures during Operation

Once the plant is ready for commercial production, the following pre- commissioning checks will be done:

• Witnessing the environmental performance test for the APC equipment and

wastewater treatment plant as stipulated in the design specification.

• Implementation of necessary corrective measures for the installed facilities for

environment protection

• Training of operating personnel who will run and supervise these environment

protection equipment

The plant operation will be brought under comprehensive Environmental Management

System (EMS) in accordance with ISO 14001:2004.

Solid waste management

It is proposed to dispose / reuse solid wastes as per plan given below.

Beneficiation of Tailings

Tailings are only the solid waste in beneficiation plant. The quantity of tailing are

about 220 T/day on dry basis.

Management System

Tailing will be dewatered before dumping in the earmarked area.

Pellet Plant

Sl. No. Waste Generation Location Nature of Waste Quantity (T/day)

1. Flue Dust from ESP Dust 220

Management System

Flue dust from ESP will be collected and recycled into the sintering plant.


Solid Waste Generation in sponge iron plants

Sl. No. Waste Generation Location Nature of Waste Total Quantity

(T/day)

1. Dust Settling Chamber / Wet Scrubber Sludge 20.0 2. De-dusting System Dust 48.0 3. Product Separator System (Char) Fines 648.0 4. Heat Exchanger and ESP Dust with fly ash 215.0 Management System

The solid waste generated from the plant is collected in bunkers through bag filters

and magnetic separation system

Sludge will be reused in sintering plant.

The dust with fly ash collected from heat exchanger and ESP will be temporarily

stored in waste disposal yard and to cement manufacturing

Dolochar and dust from bag filters will be collected and used as a fuel in WHRB of

Captive power plant.

Sintering Plant

Sl. No. Waste Generation Location Nature of Waste Quantity (T/day)

1. Flue dust from ESP Dust 220.0

Management System

Flue gases dust collected from ESP will be collected and recycled into the pellet

plant


Blast Furnace

Sl. No.

Waste Generation Location Nature of Waste Total Quantity

(T/day)

1. Sinter B.F. Return Sinter 178

2. B.F. Slag Slag 1766

Management System

Sinter B.F. returns are recycled back into a sinter plant.

B.F. Slag for production of cement.

Steel Melting Shops (EAF + LF)

Sl. No.

Waste Generation Location Nature of Waste Total Quantity (T/day)

1. Slag Slag 732 2. Flume dust from bag filter Dust 415

Management System

Slag is discharged into suitably designed landfill.

Fume dust is utilized in sintering plant.

Continuous Casting Machine


(T/day)

1. Scale & Muck Scales 110

2. Scrap - 266

Management System Mill Scale is returned to sintering plant.

Scrap will be reused.

Rolling Mills

Sl. No.

Waste Generation Location Nature of Waste Total Quantity

(T/day)

1. Scrap Scrap 211.0


3. Scale & Muck Scale 211.0

4. Oil and Grease Traps Oil and Grease 0.3

5. Reheat Furnace Broken Refractories 200*

* Annual Discharge

Management System Scrap will be collected and reused.

Reheating and rolling mills scales will be recycled in sintering plant.

Oil and Grease collected in drums and sold to authorized vendors.

Broken brick refractories will be dump in suitably designed landfill.

Coke oven Plant


(T/day)

1. Coke breeze dust 466

3. Dust from bag filters dust 31.0

Management System

Coke breeze will be recycled to Coke oven

Bag filter dust will be utilized in cement manufacturing

Cement Plant

Sl. No. Waste Generation Location Nature of Waste Total Quantity (T/day)

1 Dust from EAP dust 38.0


Management System

Re-use in cement plant

Captive Power Plant

Sl. No. Waste Generation source Nature of Waste Total Quantity

(T/day)

1 Ash including Fly ash Dust 316.2

2 Bottom ash dust 79.2

Management System The solid waste in the form of bottom ash and fly ash will be utilized for

manufacture of cement, brick manufacture, road and embankment constructions.

Ash pond

The Fly ash generated in the captive power plant and other ESPs of the plant unit will

be totally utilized in the captive cement plant proposed. How ever an ash pond for

emergency usage at the plant site will be established. The ash pond will be lined with

geo textile membrane to make the pond impermeable. The coordinates of ash pond is

given in Fig IX.2.

Incineration Ash Oil socked cotton waste, organic wastes collected in steel plant, paper, plastics, waste bag filters etc. will be about 2200 MT / annum. These will be incinerated in the incineration plant. Approximately about 22 T/annum of ash will be generated. This is disposed into the suitably designed landfill.

Lead Acid Batteries

About 2500 – 3000 number of lead acid batteries will be generated per annum. These

will be stored properly and sold to the authorized vendors.


Fig 1x.2

DESIGN OF CONTROLLED LANDFILL

Design Data 1. Quantity of Solid Waste (T/year)

SMS sludge : 219600

Broken Brick Refractories : 200

Incineration Ash : 22 --------------- Total 219822


2.0 Design Life of the Landfill : 15 Years

3.0 Average till depth : 10 m

4.0 Solid waste to cover ratio : 4 : 1

5.0 Average bulk density of solid waste : 1.45 MT/m3

Calculations Total quantity of solid waste per annum : 2,19,822 MT/year

2,19,822 Volume of solid waste = -------------- = 151601 m3/year 1.45

Additional Volume required for soil cover = 37900 m3/year

Total required volume = 189501 m3/year

189501 Area required = ------------ = 18950.1 m2/year 10

Life of the Land fill = 15 years

Area required for the entire life

period of the land fill = 18950.1 x 15

= 284251 m2

= 28.42 Hectares

Additional land area required for access roads, greenbelt and buildings = 20%

Gross area required (for 15 years) = 34.10 Hectares.

A typical landfill section is presented in Fig. IX.2


Fig. IX.2 Schematic diagram of Composite Double liner system for Land fill

Richardson & Cruddas (1972) Ltd. I-1

Leachate Collection And Management

Leachate is generated during rainy season. This leachate is a liquid that contains a number of dissolved and suspended materials. The leachate volume so generated is calculated based on: Leachate Volume = (Volume of Precipitation) +

(Volume of Pre Squeeze Liquid)

– (Volume Loss through evaporation)

– (Volume of water absorbed by the waste)

Leachate Management 1. Recirculation

One of the methods for the treatment of leachate is to recirculate it through the

landfill. This has two beneficial effects: a) the process of landfill stabilization is

accelerated and b) the constituents of the leachate are attenuated by chemical

and physical changes occurring in the landfill. Recirculation of leachate requires

the design of a distribution system to ensure that the leachate passes uniformly

throughout the entire waste.

2. Evaporation of Leachate

Another technique used to manage leachate is to spray it in lined leachate ponds and allow the leachate to evaporate. Such ponds have to be covered with geo membranes during the high rainfall periods. The leachate is exposed during the summer months to allow evaporation. The above two methods are quite satisfactory for management of hazardous solid

wastes of integrated steel plants. If required lime is added to the leachate for

immobilization and precipitation of soluble metallic constituents.

It is suggested to install an incinerator to handle organic wastes that do not have

any use or cannot be sold to out side parties. The incinerator shall be designed to

handle all solid & liquid wastes. The ash collected from the incinerator shall be

stored in a specifically designed pit with impervious lining and covered to prevent

rainwater ingress.


Hazardous Management

All solid wastes found to be hazardous will be handled and disposed of in

accordance with the procedures laid down in the Hazardous Wastes (Management

and Handling) Rules, 2003 and as directed by the Karnataka State Pollution Control

Board. The following table gives the type of waste, their quantity and mode of

disposal. No hazardous waste will be used in the process.

Name of the waste Approximate quantity per year Mode of disposal

Waste Oil 400-500 KL To be used in the non-recovery coke/coal for process improvements

Lead acid batteries 2500 – 3000 Nos. Sold to authorized vendors

Oil soaked cotton waste, organic wastes collected in steel plant

450 – 500 To be incinerated

Safety surveillance: From a safety perspective, the steel making process is a high

temperature and bulk solids processing operation. This requires significant amount

of thermal and electrical energy, water, handling of molten metals, bulk material

and product handling. The steel plant therefore requires best practice of safety

surveillance for which no compromise is made. Some of the key areas requiring

routine safety surveillance are listed below;

• Fuel gas distribution pipe work — its pressure, temperature, line isolation

device and purging device with portable gas leakage monitoring instrument,

control valves etc.

• Corrosive chemicals, acid/alkali storage and handling

• Electrical installations, tripping devices

• Smoke detection alarms and operation of automatic fire extinguishers

• Fire hydrant systems

• Emergency systems like DG sets, lighting, evacuation areas etc.

• Quality of house keeping

• Compulsory use of safety appliances like gum boots, helmets, ear muffs,

goggles and heat insulated hand gloves


A full-fledged safety department headed by GM (Safety) along with a team of

trained staff, which looks after the safety aspects will be set up for the plant. This

arrangement is adequate, with up gradation of facilities and staff to handle the

additional requirements. The productivity of the plant is linked with the plant

safety, the lapses of which will lead to loss of man-hours and productivity loss.

9.5 Organization

In order to implement the suggested measures, it is necessary to have the

adequate team in place. A Environment Management Department, headed by GM

(EMD) is to be created. This department will have staff and monitoring facilities as

detailed earlier.

Training: To have the good results of comprehensive environmental management

system of the steel plant, it becomes essential to train the operational and

maintenance personnel, including senior executives by formulating appropriate

training modules. The objective of the training will be to make aware of

environmental performance of the plant, amendments in the environmental

regulations, corporate policy on environment, health and safety, and community

perception.

Social Upliftment

As a responsible corporate organization, BMM ISPAT LTD cannot survive only on the

growth of business potential unless it has got much wider vision to the overall

development of the society. The BMM ISPAT LTD should take several initiatives in

encouraging entrepreneurship among locals, female education, primary education

etc with established Liaison department. The following are the areas where Social

uplifment will be initiated by the BMM ISPAT LTD.

Encouraging Entrepreneurship among locals – Vocational Training.

Encouraging Female Education

Upgrading One/Two Primary Schools

Improvement of Road Network in the nearby villages.

Tree Plantation in Wastelands.


Adoption of few village for infrastructure developments (Sanitation,

Education, Health & Water Supply)

9.6 Occupational safety and health

Maintenance of occupational safety and health is very closely related to

productivity and good employer-employee relationship. In addition to these, safety

of employees during construction, operation and maintenance of plant and

equipment shall be achieved by following proper safety measures.

For occupational safety, the following will be provided.

• Inspection and maintenance of pollution control systems only after getting

official shutdown or with permission of authorized officer.

• Regular cleaning of floors, road, rooftops, conveyer galleries and any other

dusty place.

• Checking for availability of spray water system for moistening the coal

yard/dump. Heat insulation of hot surfaces

• All pollution control systems will be interlocked with operation of process

equipment.

• The workers exposed to noisy equipment will be provided with ear plugs. If

necessary, the duty hours will be rotated, so that noise exposure time is kept

within specified limits.

• Regular medical check up for the employees will be done.

9.7 Environment management department (EMD) An Environment Management Department (EMD) headed by a General Manager with

adequate number of analysts, scientists and engineers, who will be responsible for

environmental monitoring and also initiate environment improvement in line with

ISO-14001 systems will be established.

The EMD will interact with the various units of plant, Environmental Laboratory &

Horticulture Department, for functional requirements primarily responsible for

work environment monitoring and industrial hygiene. The EMD will also conduct


monitoring of air, water, noise and soil in and around the plant. The major portion

of work under EMP Implementation and monitoring will be carried out by EMD.

To achieve the objectives of pollution control, it is essential not only to provide

best pollution control and monitoring systems but also provide trained manpower

to operate and maintain such systems. So, the Environmental Management

Department (EMD) personnel will be provided with additional specialized training

to operate, maintain the equipment to be deployed on the installation. All persons

will be trained to deal with pollution emergencies also.


CHAPTER X SUMMARY AND CONCLUSION

1.0 Introduction

M/s BMM Ispat Ltd. (BMMl) is a registered company under Companies Act 1956,

promoted by Mr. Dinesh Kumar Singhi, proprietor of Singhi Group of companies in

Bellary District, Karnataka. The Singhi group is a well known business group in the

field of mining iron ore and has its mining operations in Bellary-Hospet-Sandur belt.

The group is also operating a mini steel plant producing Sponge Iron, TMT Bars and

Electric Power at Danapur, Hospet Taluk in Bellary District of Karnataka. The Group

sales turnover is exceeding Rs. 442 crores. The companies belonging to Singhi

Group are

• BMM Ispat Ltd., Danapur

• HKT Mining Pvt Ltd., Danapur

• Bharat Mines and Minerals, Bellary

BMM intend to put up a 2.0 Mt/yr Integrated Steel Plant to produce rolled steel

products and 1.4 MT of BF slag based cement plant. The power requirement for the

steel plant will be met by captive power plant of 230 MW.

1.1 Scope of the EIA study

A detailed presentation was made before the Expert Appraisal Committee of the Ministry of Environment & Forests (MoEF) on 7th July, 2008. MoEF have provided the TOR vide their letter no. F. No. J-11011/236/2008-IA-II dtd. 07.07.2008 for the preparation of EIA / EMP report. The EIA/EMP report has been prepared as per the approved Terms of Reference issued by MoEF.

2.0 Project Description

It is proposed to provide iron ore Beneficiation which can convert low grade iron

ore into a high grade concentrate to feed the Pellet Plant and sinter plant.

Depending on the characterization of the ore, gravity and magnetic separation

methods will be employed to beneficiate the ore. Non recovery type Coke Ovens

Plant will be installed to supply coke to Blast Furnaces and coke breeze to Sintering

Plant. The sensible heat in the coke ovens gas will be used for power generation. A

230 MW Captive Power generation using coke oven gases, DRI kiln gases and coal is


proposed. A Pellet Plant is proposed to manufacture pellets, which would be used

to feed DR plant and replace lump iron ore in the Blast Furnace. Sinter Plant will

supply fluxed sinter to the Blast Furnace and will aid in achieving high productivity.

Sinter Plant will be supplied with high grade iron ore concentrate from the

Beneficiation Plant. Liquid iron or hot metal, as it is known in steel industry, will

be produced in high energy efficient Blast Furnaces, where coal dust injection will

be practiced to reduce the requirement of metallurgical coke. Electric steel

making and oxygen blown steel making are considered to produce liquid steel and

feed the continuous casting machines. The feed to the hot strip mill will be slabs

and to non flat rolling mills, it will be billets. The Rolling Mill will be designed to

produce both flat and non flat products utilizing the state of art technology.

Granulated slag from Blast Furnace, clinker, gypsum and coal are used for

manufacturing of Portland cement.

The various unit operations envisaged under the proposed 2 Mt/year Integrated Steel Plant are indicated in the below table.

Manufacturing Units Unit Capacity

Iron Ore Beneficiation Plant Mt/year 3.4 Pelletization Plant Mt/year 1.20 DRI Plant Mt/year 0.7 Coke Ovens Mt/year 0.8 Sinter Plant Mt/year 2.5 Blast Furnace Mt/year 1.7 EAF & BOF steel making Mt/year 2.3


Mt/year 1.10 1.10

Rolling Mills • Hot strip mill • Structural / wire rods

Mt/year

1.00 1.00

Oxygen Plant t/year 2x500 Calcining kilns t/year 1080 Cement Plant Mt/year 1.4 Power Plant MW 230

Estimated cost of the project : Rs. 6151.3 Crores

Project Completion Target : September 2012

2.1 Raw Material Requirement


Raw material Quantity Mt/year Source

Low grade iron ore fines 4.4 Captive mines and from indigenous sources

Iron ore pellets 0.43 Indigenous source Bentonite 0.008 Indigenous source Non coking coal 1.243 Imported Coking coal 0.92 Imported Limestone 0.53 Indigenous source Dolomite 0.34 Indigenous source Quartzite 0.13 Indigenous source Clinker 0.73 Indigenous source Gypsum 0.04 Indigenous source 2.2 Man power

The manpower required for the proposed integrated steel plant, cement plant and

Captive power plant is indicated below.

Sl.No Category Nos.

1 Managerial 340

2 Supervisory 1070

3 Skilled 2680

4 Unskilled 510

Total 4600

3.0 Description of Environment 3.1 Location

The proposed plant is located near Danapura village in Mariammanahalli Hobli,

Hospet Tq, Bellary (Dist.), Karnataka. The latitude and longitude of the project site

is 15°5’ - 15°10’N and 76°22’ – 76°27’E respectively in the Topo sheet no 57A/8.

The proposed plant area is surrounded by iron ore mines.

3.2 Land


The government of Karnataka has already allotted 1429 Hectors of land in

Danapura, Nagalapura, Danayanakere and Garaga villages in Hospet Taluk in Bellary

district and acquisition of land is in progress.

3.3 Water requirement

The Government of Karnataka has already allotted 100 MLD (22 MGD) of water from

downstream of TB dam/Almathi dam/ ground water.

3.4 Power

The annual electrical energy consumption in the plant is estimated to be about

1740 million units. The average demand of the plant is estimated to be 230 MW. It

is proposed to meet the entire requirement of electric power from captive sources

taking the support of State Electricity grid for stability.

3.5 Baseline Environment

Monitoring of Ambient Air, Noise level, Surface & Ground Water quality, Soil &

Socio Economic Study was carried out during December`07- February`08 (winter)

3.6 Micro Meteorology

Meteorological data collected during the study reveals the following status.

Predominant wind was from Northeast quadrant. Wind velocity readings were

ranging from 1.2 to 18.8 Kmph. Temperature values were ranging from 15.0 °C to

30.5°C. The mean relative humidity value was found to be 66.7%. Sky was clear

during the study period. The mean atmospheric pressure was found to be 752 mm

of Hg. A total rainfall of 17.3 mm was recorded during the study period.

• Ambient air quality: Ambient air quality in both core zone and buffer zone (10

km radius from core zone) showed the SPM, RSPM, SO2 and NOx are well within

the NAAQ standards specified for rural and residential area.

• Noise levels monitored in core zone and buffer zones were found to be well

within limits.

• Water samples collected within study area showed compliance of all

parameters with the prescribed standards.

• Soil samples analysis showed moderate fertility.

• Socio-economic status of the study area is found to be moderate.


• Ecological Environment. No endangered and Endemic species have been

identified. As such, conservation plan is not needed.

4.0 Anticipated Environmental Impacts and Mitigation Measures

4.1 Environmental Attributes likely to be affected and the activities responsible

are indicated below.

Table 4.1 Impact Identification Matrix

Actions Raw material storage and handling, Steel production and other allied activities

Post Operational

Phase

Environmental Attributes

Cons

truc

tion

Pha

se

Ope

rati

onal

Pha

se

Mat

eria

l Han

dlin

g

Ore

Sto

rage

/

hand

ing

Wat

er d

raw

l (S

urfa

ce w

ater

)

Wat

er d

isch

arge

Mai

nten

ance

W

orks

hop

Pow

er g

ener

atio

n by

DG

set

Gre

en B

elt

deve

lopm

ent

Empl

oym

ent

Urb

aniz

atio

n (B

uffe

r zo

ne)

Tran

spor

tati

on

Ambient air

Water resources

Water quality

Ambient Noise

Flora & Fauna

Soil & Land use

Infrastructure

Health & Safety

Socio-economics

Aesthetics

Adverse Impact Beneficial Impact 4.2 Air Pollution Control Measures proposed for various sources to

mitigate Air Emission and to meet the standard stipulated by the State Pollution Control Board are furnished below.

Sl. No Area of operations Air pollution control measures proposed

to be adopted 1 Raw material handling

· Dust suppression systems (chemical and dry fog


type) Fugitive emissions in material

handling · Water sprinklers

· DE systems with bag filters in case of conveyors,

lime handling

2 Sponge Iron Plants Electrostatic precipitators, bag filters 3 Sinter Plant

Raw material preparation and handling (procurement of proposed sized materials to minimize crushing and screening) · DE systems with bag filters

Sintering process · ESP for collected waste gases Sinter screening and transport · Bag filters 4 Pelletization Plant

Raw Material Preparation and

Handling · DE System with bag filters. Pelletization Process · ESP 5 Blast Furnaces De-dusting with bag filters

6 Cacination · Bag filters

7 Steel melting shop Bag filetrs 8 Coke oven plant De-dusting with bag filters 9 Rolling mills Use of Low sulphur fule

10 Power Plant WHRB & AFBC · Electrostatic Precipitator

11 Coal Handling Plant · Bag filters 12 Cement plant · Bag filters

4.3 Air Environment: Post - Project Scenario

Ambient Air Quality at the station monitored are furnished below together with the predicted values due to the proposed activity. The post project scenario is compared with the stipulated standards. The details are furnish in the below table.

(Units in µg/m3)

Baseline scenario (max) Predicted values Post Project

scenario NAAQ standards Sl. No.

Location name SPM SO2 NOx SPM SO2 NOx SPM SO2 NOx SPM SO2 NOx

1 Proposed Plant (A1) 176 9 18 41.3 41.2 25.6 217.3 50.2 43.6 500 120 120 2 Existing Plant (A2) 186 16 30 24.5 31.6 28.2 210.5 47.6 58.2 500 120 120 3 Dhanapura (A3) 146 7 10 23.1 28.4 26.1 169.1 35.4 36.1 200 80 80 4 Marimanhalli (A4) 145 8 18 21.0 12.6 12.5 166.0 20.6 30.5 200 80 80 5 Nagalapura (A5) 132 7 12 9.2 21.2 11.8 141.2 28.2 23.8 200 80 80

6 Mugimavinahalli (A6) 146 8 18 3.8 6.8 1.2 149.8 14.8 19.2 200 80 80

7 Haravanahalli (A7) 115 7 10 4.8 8.9 1.8 119.8 15.9 11.8 200 80 80 8 Ramgad (A8) 132 8 16 3.9 2.1 0.8 135.9 10.1 16.8 200 80 80 9 Medarahalli (A9) 134 8 14 4.9 1.3 0.4 138.9 9.3 14.4 200 80 80 10 Vysankari (A10) 112 7 12 3.6 2.4 1.4 115.6 9.4 13.4 200 80 80

4.4 Water Environment The estimated water requirement for the industry is 100 MLD mostly used as

makeup water. The industry is adopting state of Art Technology in its water use

and “Zero discharge” of effluents Concept is adopted.


Water Pollution Control Measures adopted in the industry are furnished below.

Sl. No

Source Pollutants

Control system / Treatment

1. Raw material handling yard SS Catch pits followed

2 Raw Water Treatment plant SS, Colloidal matter,

Dissolved gases, micro-organism

Chemical coagulation with sedimentation and filtration

3. Beneficiation Plant Hydrocyclones, Thickneres, slim pond

4. Pellet Plant Collection sump, guard pond

5. Sponge Iron Plant Collection tank & Ash handling dust suppression

6 Blast furnace SS Clarifier, Thickener, Sludge

Pond 7 DM Plant pH Neutralization pit 8 Steel Melting shop SS Guard pond

9 CCM Suspended Solids, Oil & Grease


10 Calcination & Oxygen plant SS, Alkalinity Settling with Guard pond

11 Rolling Mills SS, Oil & Grease , mill scale


12 Captive Power Plant Direct use in ash handling & excess to guard pond

Cooling Tower & Boiler bow down

Temperature, Dissolved Solids

Reused in the plant for dust suppression and slag granulation

13 Sewage Treatment system BOD, Suspended Solids Sewage treatment plant

4.5 Based on the above studies following conclusions are drawn • Air Environment : No significant impact is expected on Air Environment • Water Environment: No significant impact is expected on water quality

• Noise Environment: No significant impact on Noise Environment. The

predicted noise levels will be within the limits as prescribed by CPCB

both during construction and operational phases of the industry.

• Land Environment : No significant impact on land environment

• Biological Environment : No significant impact

• Socio-Economic Environment: The project will have positive impact in terms

of employment, infrastructure facilities and enhancement of per capita

income in the near by region.

5.0 Environmental Monitoring Program


A monitoring strategy is required to ensure that all environmental resources which may be subject to contamination are kept under review and hence monitoring of the individual elements of the environment is necessary. BMM will install a Automatic weather monitoring stations to measure Wind speed and direction, Rainfall and temperature and humidity on hourly basis. On-line continuous monitoring system will be installed in stacks to monitor particulate matter. BMM will monitor the ambient air quality regularly at five locations in and around the plant (downwind direction and where Max. GLC of SPM, SO2 & NOx) to ascertain the effect of process emissions on the ambient air quality. Surface and ground water will be sampled regularly once in a season from various locations in and around proposed plant to ascertain the trend of variation in the water quality, if any. Treated process wastewater quantity will also be monitored for pH, TSS, COD and Oil& Grease regularly. Ambient and work zone noise levels will be measured on quarterly basis- Occupational health surveillance of the workers will be done on regular basis especially for those to be engaged in handling hazardous substances and high noise generating equipment. Trees survival rate will be monitored in the plantation areas and will be maintained at about 80% by replacement of dead trees. The BMM will have structured interactions with the plant surrounding village’s people to disseminate the measures taken by the BMM and also to elicit suggestions for overall improvement of the surrounding villages. A separate Environment Management cell equipped with full-fledged laboratory facilitate will be set up to carry out environmental management and monitoring functions.


6.0 Additional Studies

6. 1 Disaster Management Plan

• Identification of hazards

• Risk assessment of hazards

• Risk management applications

I . Preventive measures

II. On site emergency preparedness plan

• Off site emergency preparedness plan

• Industrial safety and fire fighting

• Rescue and repair services

• Shop level disaster control cell

• Central disaster control room

• Information flow

6.2 Resettlement & Rehabilitation Plan

The State Government in its order No.CI/312/SPI/2008 dated 21.10.2008

has permitted the proponent to acquire 1429 hectares of land (3530.70

acres) coming in the jurisdiction of Danapura, Nagalapura, D.N. Kere,

Byalkundi, Garaga villages. Out of 1429 hectors, 785.54 hectares is

patta land and the remaining 643.35 hectares is Government Lands.

The proponent is willing to adopt a benevolent farmer, friendly

Rehabilitation and Resettlement Policy and is willing to discharge

its social responsibility to benefit the surrounding villages.

6.3 Objectives of R&R Plan

Though there is no displacement of any farmer or landless laborer from their

Habitation and yet the proponent is willing to adopt a benevolent farmer

friendly Rehabilitation and Resettlement Policy and is willing to discharge

its social responsibility to benefit the surrounding villages. The features of

such a policy may include the following.


1. The recommendations of Sarojini Mahishi committee report will be

adopted in the recruitment of staffs.

2. As far as possible the recommendations of the National Rehabilitation and

Resettlement policy 2007 pronounced by Government of India will be

adopted.

3. The Proponent is willing to provide one job either to the Khatedar who

has sold the land to the company or to one member of his family to be

identified by the Khatedar, commensurate with his or her education

qualification, age and suitability for the job.

If needed, the proponent is willing to deploy to the extent of man power

required for the development of the green belt each year, the services of

landless labourers and farmers belonging to the above 5 villages in this

program.

6.4 In addition to a benevolent rehabilitation policy, the proponent is

likely to carry out the following social responsibilities.

• The company may adopt few villages located in the Study Area.

• The company will improve the drinking water supply, street light and

maintain them.

• The company will provide adequate drainage & sanitation facility to these

villages and plant trees in the village limits & develop green belt around the

villages.

• The company will build additional rooms to the existing schools wherever it is

needed, provide drinking water and adequate sanitation facilities in these

schools.

• The company will extend financial help in providing Mid-day meal to school

going children.

• The company through their hospital will extend medical facilities to such

villages.


• Widows and unmarried daughters of the land loosers from these villages will

be trained in tailoring and sewing machines will be supplied to each one of

them.

• If the village authorities desire, the company will be willing to take up

maintenance of the water body (Tank) of these villages.

6.5 Diversion of inter connecting village roads passing through the Project

area Following village connecting roads are passing through the proposed project area.

1. Danapur – Garaga Tanda

2. DN Kerre – Garaga Tanda

3. Mariammanahalli – Garaga Tanda

4. Nagalapura – Garaga village

The above village roads need to be diverted to provide connectivity to the road

users. The project proponent is willing to undertake diversion of these roads at his

cost in consultation with concerned village elected representatives. The project

proponent is making adequate budget provision for diversion of these roads.

7.0 Project benefits

• State Industrial & Mining Policy is favoring the proposed project

• Direct employment for about 4600 people.

• Earnings by the Govt. by way of taxes levies and duties like ED, IT, VAT, TDS

etc

• Business opportunities for the local entrepreneurs to set up small and

medium scale industries

• Business opportunities for the local entrepreneurs serving as service

providers, suppliers, contractors

• Investment opportunity for local infrastructure development

• Improvement In The Physical Infrastructure like road and rail net work

• BMM Ispat Ltd will undertake various community welfare measures for

upliftment of plant surrounding villages.

• Plant township hospital and schooling facilities which will also help local

population to enjoy the fruit of better facilities in nearby.


8.0 Environnemental Management Plan

8.1 Air Pollution Control

Fugitive dust emission will be extracted by extractors with dry fogging and will

be treated in bag house and discharged through tall stacks for atmospheric

dispersion. Suspended particulate matters are arrested by ESP and discharged

through tall stacks by induced draft fans. Material and product yard fugitive

emissions are controlled by dust suppression with sprinkling water. A general

enforcement in air pollution control process is observed which include

Stable and consistent operation of all steel production units

Correct proportion of feed materials

Hood and dust extraction, wherever required

8.2 Water pollution control

These measures include conservation of water by Rainwater harvesting and

waste water treatment, recycling and reuse. The zero discharge concept will be

adopted.

8.3 Conservation of water

• Rain water harvesting

• Design of units for less amount of water and recycle of water to the

maximum by cascading use of water

• Use of boiler blow downs and cooling water blow downs for slag quenching,

green belt development

8.4 Waste water treatment, recycling and reuse


Gas cleaning plant waste water, billet cast and mill effluents, thermal power

plant, cooling tower blow downs are separately treated with standard process

and the treated effluent are utilized for slag quenching, ash handling. Excess

treated effluents are stored into a guard pond for further secondary use in the

plant and for Green Belt Development activities. Treated sanitary waste water

will also be used for gardening.

8.5 Noise pollution control

• Design of equipment for less noise generation

• Dynamic balancing and vibration damping by suitable mounting mechanism

and proper grouting

• Separate housing of high noise product machinery

• Use of ear plugs in very high noise prone areas

• Green belt development around each unit

• Road side tree plantation

8.6 Solid Waste Management

Major solid waste will be reused in the plant itself. Fly ash will be utilized in

cement manufacturing. Other solid waste generated, which are not usable for

any purpose will be disposed in control land filling in an identified area with in

the plant premises.

8.7 Energy conservation measures

• Adoption of CDM mechanisms

• Adoption of “power saving is power produced” principle

8.8 Green belt development

Out of the total area of 1429 Hectors Green Belt will be develop on 472

Hectres. The local plant species will be selected based on soil quality. The

plantation will be taken up at the following areas.

• At plant boundary

• At road sides


• Around various steel producing units

• Around office and other buildings

• Stretch of open land

The year -wise planning of the trees & shrubs is presented below.

Year Number of plant species to be planted Shrubs Landscaping

2009-2010 1,00,000 - - 20010-2011 1,50,000 10000 Grasses & Avenue plants 20011-2012 2,00,000 20000 Grasses & Avenue plants 2012-2013 1,00,000 10000 Grasses & Avenue plants 2013-2014 1,00,000 10000 Grasses & Avenue plants

Total 650000 50000 -

8.9 Cost of Pollution Control/ Environmental protection Measures

Area of Expenditure Recurring cost per

annum (Rs. in Crores)

Capital Cost (Rs. in Crores)

Air Pollution Control 10.0 200.0

Water Treatment System 10.0 50.0

Waste Water Treatment System 3.0 30.0

Solid Waste Management System 5.0 50.0

Noise Pollution Control 0.50 2.0

Environmental Monitoring and Management

2.50 10.0

Social corporate responsibilities 2.0 10.0

Road diversion/development/Modification 2.0 15.0

Occupational Health 1.50 3.0

Greenbelt Development 5.0 25.0

Others 0.25 2.0

Total 41.75 397.00

Percent of recurring cost in terms of Capital Cost for pollution control measures

10.52 -

Percent of capital cost of pollution control measures in terms of total project cost

- 6.45


9.0 Conclusion

The potential environmental, social and economic impacts of the project have been assessed and comprehensive mitigation and community developmental plans have also been developed integrating the safety and health system in the work place.

M/s. BMM Ispat Limited will successfully implement the environmental protection and safeguard measures as per EMP at a capital cost of Rs.397.00 Crores and a recurring expenditure of Rs.41.75 crore per annum. Environmental Management Plan will be exercised at

Design stage

Construction stage

Operational stage to meet all the consent norms of KSPCB and

Environmental condition as per MoEF / CPCB direction.

With commitment and dedication, BMM Ispat Ltd. will commission the Integrated

Steel Plant, cement plant and captive power plant with modern equipments.

Recommendations made in the CREP for the integrated steal plant and draft

guidelines by CPCB for Sponge Iron Plant will be totally implemented. BMM Ispat

Ltd. has committed to responsible environmental protection. BMM Ispat Ltd has

been discharging its social responsibility and is willing into carry this forward and

strictly implements its declared R&R policy and helps this area to achieve

economical Prosperity.


CHAPTER XI

CONSULTANT DETAILS

11.1 Environment Impact Assessment Study

Richardson & Cruddas (1972) Ltd., Chennai

A Govt. of India undertaking under Ministry of Heavy Industry, one of the pioneers in

the field of Environmental Engineering for the past three decades. R&C Laboratory is

recognised as Environmental Laboratory by the Central Pollution Control Board

(CPCB), Ministry of Environment & Forests (MoEF) under the Environmental

Protection Act, 1986 and is, also, recognised by Tamil Nadu Pollution Control Board

for carrying out air and waste water emissions monitoring as per Air (Prevention and

Control of pollution) Act, 1981 and Water (Prevention and Control of Pollution) Act,

1974. We are also recognised by various other State Pollution Control Boards as

Environmental Consultants for such studies.

R&C is regularly undertaking EIA, EMP, DMP, Risk Analysis, Pollution Atlas,

Prediction Modelling studies besides ambient air, stack emission, water/

wastewater/sewage, sediment/ soil quality monitoring, analysis & operation and

maintenance of Treatment plants.

11.2 Feasibility/ Environmental Study

FerroGreen Technologies Pvt. Ltd, Bangalore.

FerroGreen Technologies Pvt. Ltd., (FGT) is promoted by Dr. S. K. Gupta and Dr. T. M. Srinivasan with the aim of providing engineering and technology implementation and associated consultancy/advisory services in the Iron & Steel domain comprising iron and steel, mining, mineral engineering, power & industrial gases. The services include Engineering, Construction & Project Management, Environmental Management, etc, to cater to the needs of various Clients. Following divisions constitute FerroGreen Technologies:

• Technology Development

• Technology Implementation

• Assistance for Take-Over/Acquisition of Steel Companies by carrying

out Asset Valuation & Technical Due Diligence of Steel Plants


FGT will provide expert services whenever requested/required and offers a single

window services to the promoter(s) / investor(s).

Environment & Power Technologies Private Limited, Bangalore

Environment & Power Technologies Private Limited, [EPTPL] is a private company

manned by eminent and qualified Technocrats having practical experience for

more than three decades, in the field of Environmental Protection & Power

Technologies. The main objective of the company, while offering technical

consultancy is to protect/conserve environment and contribute to sustainable

power development through renewable energy sources. Till date the company has

handled, Environmental Issues concerning Bulk Drugs and Pharmaceutical

Industries, Sugar, Distillery, Thermal Power Plants, Mining Industry, Integrated

Steel Plants, Cement Plants, Residential Layouts, Hospital, Wind Mills, Mini Hydel

Plants, etc., and helped these industries in getting necessary Statutory Clearance

such as Single Window Clearance from State government, Environmental Clearance,

Consent for Establishment, Consent for Operations, Water permissions, Renewal of

consents, etc. Besides 10 Directors (one PhD Holder, six Post Graduates in

Environmental Engineering, one in Power Engineering and one Mechanical Engineer,

and one Software Engineer) it has three Environmental Engineers, one Civil

Engineer and two administrative Staff assisting EPTPL as supporting staff.