Bs Sponge Eia

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B.S. SPONGE PRIVATE LIMITED Village: Taraimal, Tehsil: Gharghoda, District: Raigarh, (C.G.) REIA Report for the Proposed Mini Integrated Steel Plant Chapter – 1 PIONEER ENVIRO 1-1 Environmental Impact Assessment Report Laboratories & Consultants Pvt. Ltd. CHAPTER – I INTRODUCTION 1.0 PREAMBLE M/s B.S. Sponge Private Limited is an existing plant operating 2 x 100 TPD Sponge Iron plant in Taraimal Village, Ghargoda Tehsil, Raigarh District, Chhattisgarh. The existing plant is having valid Consent to Operate issued by Chhattisgarh Environment Conservation Board vide order No’s 4496/TS/CECB/2008 & 4498/TS/CECB/2008 dated 04-08-2008 which is valid up to 30-06-2011. Now as a part of proposed expansion it has been proposed to enhance the production of Sponge Iron and also to go forward integration to produce Billets and Structural steels. The existing and proposed production capacities are furnished below Sr. No Units Existing production capacity (TPA) Proposed production capacity (TPA) Total (TPA) 1. Sponge Iron 60,000 1,20,000 1,80,000 2. Induction Furnace with Concast --- 1,62,000 1,62,000 3. Rolling Mill --- 1,05,000 1,05,000 4. Ferro alloys --- 25,000 25,000 WHRB --- 12 12 Power Plant FBC --- 36 36 5. Total 48 48 The proposed expansion will be taken up in the existing plant premises only. 1.1 PURPOSE OF THE REPORT As per the Ministry of Environment & Forests, New Delhi notification, dated 14 th September, 2006 Sponge Iron plant of 200 TPD and above capacity is classified under Category ‘A’ . Hence Form –I along with proposed draft TOR for REIA study & Pre - 1

Transcript of Bs Sponge Eia

Page 1: Bs Sponge Eia

B.S. SPONGE PRIVATE LIMITED Village: Taraimal, Tehsil: Gharghoda, District: Raigarh, (C.G.) REIA Report for the Proposed Mini Integrated Steel Plant Chapter – 1

P I O N E E R E N V I R O 1 - 1 Environmental Impact Assessment Report Laboratories & Consultants Pvt. Ltd.

CHAPTER – I

INTRODUCTION

1.0 PREAMBLE

M/s B.S. Sponge Private Limited is an existing plant operating 2 x 100 TPD Sponge

Iron plant in Taraimal Village, Ghargoda Tehsil, Raigarh District, Chhattisgarh. The

existing plant is having valid Consent to Operate issued by Chhattisgarh Environment

Conservation Board vide order No’s 4496/TS/CECB/2008 & 4498/TS/CECB/2008

dated 04-08-2008 which is valid up to 30-06-2011.

Now as a part of proposed expansion it has been proposed to enhance the production of

Sponge Iron and also to go forward integration to produce Billets and Structural steels.

The existing and proposed production capacities are furnished below

Sr. No Units Existing production

capacity (TPA) Proposed production

capacity (TPA) Total (TPA)

1. SSppoonnggee II rroonn 60,000 1,20,000 1,80,000

2. Induction Furnace with Concast

--- 1,62,000 1,62,000

3. Rolling Mill --- 1,05,000 1,05,000

4. Ferro alloys --- 25,000 25,000

WHRB --- 12 12 Power Plant

FBC --- 36 36

5.

Total 48 48

The proposed expansion will be taken up in the existing plant premises only.

1.1 PURPOSE OF THE REPORT

As per the Ministry of Environment & Forests, New Delhi notification, dated 14th

September, 2006 Sponge Iron plant of 200 TPD and above capacity is classified under

Category ‘A’. Hence Form –I along with proposed draft TOR for REIA study & Pre -

1

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B.S. SPONGE PRIVATE LIMITED Village: Taraimal, Tehsil: Gharghoda, District: Raigarh, (C.G.) REIA Report for the Proposed Mini Integrated Steel Plant Chapter – 1

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Feasibility report have been submitted to the Ministry Of Environment & Forests and

presentation was made before the Honourable Expert Appraisal Committee of the MoEF

on 13th May, 2008 for the approval of TOR for REIA study. This Draft REIA report has

been prepared incorporating all TORs issued by the Ministry vide letter No. J-

11011/313/2008-IA II (I) dated 6th June 2008.

This report furnishes the details of location of Site, Description of the project, prevailing

baseline status w.r.t Air Environment, Water Environment, Noise Environment; land

Environment, Flora & Fauna and Socio-economic environment. This report also helps in

identification of environmental impacts and suggesting mitigation measures to be

followed during Construction and Operation of the expansion project as a part of

Environmental Management Plan. This report also acts as guidance manual for the

proponent for following the Environmental Management Plan (EMP) and for adopting

post project Environmental Monitoring Program as per statutory norms.

1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

M/s B.S. Sponge Private Limited is a registered company established in the year of

2000 The following are the Board of directors of the company.

1. Shri. Parmanand Agarwal, Managing Director

2. Shri. Ashish Agarwal, Director

The turnover of the company is presently Rs. 58.00 Crores approximately. Now it has

been proposed to

• enhance the production capacity of existing Sponge Iron,

• forward integration i.e. to produce Billets and structural steel,

• produce Ferro alloys

• generate 48 MW Electricity using wastes generated from DRI Kiln (WHRB

based) & Char/ Dolochar/ Coal (FBC based).

Expansion project will be taken up in the existing plant premises only (admeasuring

about 90 acres).

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B.S. SPONGE PRIVATE LIMITED Village: Taraimal, Tehsil: Gharghoda, District: Raigarh, (C.G.) REIA Report for the Proposed Mini Integrated Steel Plant Chapter – 1

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1.3 BRIEF DESCRIPTION 1.3.1 NATURE OF THE PROJECT The proposed expansion project involves production of Sponge Iron, Billets, Structural

steels, Ferro alloys and generation of 48 MW electricity.

1.3.2 SIZE OF THE PROJECT

M/s B.S. Sponge Private Limited has proposed to go for expansion in the existing Plant

premises. The existing and proposed expansion details are furnished below

S.No Units Existing production capacity (TPA)

Proposed production capacity (TPA)

Total (TPA)

1. SSppoonnggee II rroonn 60,000 1,20,000 1,80,000

2. Induction Furnace with Concast

--- 1,62,000 1,62,000

3. Rolling Mill --- 1,05,000 1,05,000

4. Ferro alloys --- 25,000 25,000

WHRB --- 12 12 Power Plant

FBC --- 36 36

5.

Total 48 48

The capital investment of the expansion project is Rs. 329.95 Crores.

1.3.3 LOCATION OF THE PROJECT

M/s B.S. Sponge Private Limited is an existing plant operating 2 x 100 TPD Sponge

Iron Plant in Taraimal Village, Ghargoda Tehsil, Raigarh District. The following factors

have been considered for selection of site for the existing plant.

a. Availability of suitable and adequate facilities.

b. Availability of water.

c. Availability of raw materials.

d. Availability of man power.

e. Availability of infrastructural facilities

f. Suitability of land from geological and topographical aspects.

g. The following Environmental aspects

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Ø No National Parks, Wildlife Sanctuaries, Bird sanctuaries

within 10 Km. radius of the plant. (TOR # 1)

Ø No Historical places of tourist importance within 10 Km.

radius of the site.

Based on the above guidelines the existing plant premises have been chosen for proposed

expansion.

The existing plant is having a valid Consent to operate issued by CECB. The existing

plant is in accordance with MOEF norms. The proposed expansion will be taken –up in

the existing plant premises only. Total land available for existing and expansion project

is 90 acres. Hence the area earmarked for expansion will also be in accordance with

MOEF norms. The topographical map showing the location of the plant is shown in Fig.

1.1.

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B.S. SPONGE PRIVATE LIMITED Village: Taraimal, Tehsil: Gharghoda, District: Raigarh, (C.G.) REIA Report for the Proposed Mini Integrated Steel Plant Chapter – 1

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TOPOGRAPHICAL MAP SHOWING LOCATION OF PROJECT Fig No.1.1

PROJECT SITE

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1.3.4 IMPORTANCE OF PROJECT

Steel Production in India India is one of the few countries where the steel industry is poised for rapid growth.

India's share in world production of crude steel increased from 1.5% in 1981 to around

3.5 % in 2004. While plant closures and privatization are rare in India, the private sector

is considered to be the engine of growth in the steel industry and technological changes

and modernization are taking place in both the public and the private sector integrated

steel plants in India. Steel production of India accounted for 14.33 million tons in 1990-

91, which gradually increased to 36.12 million tones in 2003-04, as shown in Table

below. The Indian steel industry got a giant importance in the recent past when the Tata

Steel purchased the Corus steel. Today India plays a significant role in the production of

steel in the world. The Indian steel industry is growing at 8.74 % of CAGR.

Production of steel in India (In Million Tonnes)

Year Main Producers Secondary Producers Grand Total

1991-92 7.96 6.37 14.33

1992-93 8.41 6.79 15.2

1993-94 8.77 6.43 15.2

1994-95 9.57 8.25 17.82

1995-96 10.59 10.81 21.4

1996-97 10.54 12.18 22.72

1997-98 10.44 12.93 23.37

1998-99 9.91 13.91 23.82

1999-00 9.37 16.29 25.66

2000-01 9.7 17.26 26.96

2001-02 11.46 18.98 30.44

2002-03 14.39 19.29 33.68

2003-04 15.12 21 36.12

Annual Compound Growth Rate = 8.74%

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In the light of the above scenario, M/s B.S. Sponge Private Limited has proposed to

enhance the existing production capacity of Sponge, produce Billets, Structural steels,

Ferro alloys and to generate Electricity.

The proposed expansion will be taken-up in the existing plant premises.

1.4. SCOPE OF THE STUDY

The scope of work includes a detailed characterization of the environment in an area of

10 km. radius of the plant for various environmental parameters like air, water, noise,

land, biological and social-economic aspects. This report is prepared in accordance with

the TOR issued by the Ministry vide letter No. J-11011/313/2008-IA II (I) dated 6th June

2008.

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CHAPTER – II

PROJECT DESCRIPTION

2.1 TYPE OF PROJECT

Steel consists mostly iron, with a carbon content between 0.02% and 1.7 or 2.04% by

weight (C: 1000–10, 8.67 Fe), depending on grade. Carbon is the most cost-effective

alloying material for iron, but various other alloying elements are used such as

manganese and tungsten. Carbon and other elements act as a hardening agent, preventing

dislocations in the iron atom crystal lattice from sliding past one another. Varying the

amount of alloying elements and form of their presence in the steel (solute elements,

precipitated phase) controls qualities such as the hardness, ductility, and tensile strength

of the resulting steel. Steel with increased carbon content can be made harder and

stronger than iron, but is also more brittle. The maximum solubility of carbon in iron (in

austenite region) is 2.14% by weight, occurring at 1149 °C; higher concentrations of

carbon or lower temperatures will produce cementite. Alloys with higher carbon content

than this are known as cast iron because of their lower melting point. Steel is also to be

distinguished from wrought iron containing only a very small amount of other elements,

but containing 1-3% by weight of slag in the form of particles elongated in one direction,

giving the iron a characteristic grain.

2

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B.S. SPONGE PRIVATE LIMITED Village: Taraimal, Tehsil: Gharghoda, District: Raigarh, (C.G.) REIA Report for the Proposed Mini Integrated Steel Plant Chapter – 2

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2.2 NEED FOR THE PROJECT

Driven by buoyant steel- intensive economic activity including construction and

infrastructure building in many developing economies, global apparent

consumption of steel has increased at an average pace of more than 7 percent per

annum since 2002 to reach a record level of 1.113 billion tonnes last year. To

meet this rise in demand, steel production growth has accelerated sharply,

reaching 1.24 billion tonnes in 2006, up by as much as 393 million tonnes (or

46%) compared to its level of 850 million tonnes in 2001. This growth in demand

for steel is creating a favourable situation for many steelmakers.

India's rapid economic growth is being built on a frame of steel. Soaring demand

by sectors like infrastructure, real estate and automobiles, at home and abroad,

has put India's steel industry on the world map.

Growth potential: The per capita steel consumption in India is abysmally low at

around 30 kgs as compared to 210 kgs of China and over 400 kgs in the

developed countries. This wide gap in relative steel consumption indicates that

the potential ahead for India to raise its steel consumption is high.

Continued demand: Meteoric rise in steel prices since 2003 until early 2005

helped the domestic steel companies immensely as many of them managed to

reduce their debt burden considerably, helping them either turn into profits or

increase the same significantly. Going forward, the demand for the metal is likely

to sustain on the back of continuing demand from the US and other South East

Asian nations.

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Domestic help: A robust housing and infrastructure sector, with growth potential

in the auto and the consumer durables sectors is likely to be a big positive for the

domestic steel sector.

2.3 LOCATION

M/s B.S. Sponge Private Limited is an existing plant operating 2 x 100 TPD

sponge iron plant at Taraimal Village, Gharghoda Tehsil, Raigarh District,

Chhattisgarh. The existing plant is having valid Consent For Operation from

CECB which is valid up to 30-06-2011. Now as a part of the proposed expansion

company has proposed to

• Enhance the production of Sponge Iron

• Produce Billets, Structural Steels, Ferro alloys and

• Generate Electricity of 48 MW in the existing Plant premises.

The site is well in accordance with the guidelines issued by MOEF. The following are the

salient features of the site proposed.

Ø Nearest habitation is at a distance of about 2.5 Km.

Ø The existing land is industrial.

Ø There are no National Parks, Wild life Sanctuaries and Bird Sanctuaries within

10 Km radius. (TOR # 1); however the following are the Reserved forests

exist in the vicinity:

Sr. No. Name of Reserved Forest Distance from Site Direction 1. Taraimal RF 0.6 KM N 2. Rabo RF 8.5 KM W 3. Urdana RF 5.25 KM SW

Ø Topography of the land is more or less flat without many undulations.

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Ø No clearance of vegetation is required thus there will not be any Soil erosion

Ø No habitations with in the site. Hence rehabilitation & resettlement are not

involved.

Ø No forest land is involved in the existing plant.

Ø The following industries are situated with in 25 Km. radius.(TOR # 4)

Sr. No. NAME OF THE INDUSTRY TYPE

1 M/s. Nalwa Sponge Iron Ltd Steel Plant 2 M/s. Ind Agro Limited Steel Plant 3 M/s. MSP Steels Pvt. Ltd Steel Plant 4. M/s. Singhal Enterprises pvt. Ltd. Steel Plant 5. M/s. Seleno Steels Ltd. Steel Plant 6. M/s. Ambica Sponge Iron ltd. Steel Plant 7. M/s. Shyam Steel Pvt Ltd. Steel Plant 8. M/s. Anjani Steels (P) Ltd. Steel Plant 9. M/s. Navadurga Fuels(P) Ltd. Steel Plant 10. M/s. Salasar Sponge Iron & Power Ltd. Steel Plant 11. M/s. Raigarh Ispat Ltd. Steel Plant 12. M/s. B.S. Sponge Pvt Ltd. (Applicant) Steel Plant 13. M/s. Raigarh Iron Industries Ltd. Steel Plant 14. M/s. Scania Steel Pvt Ltd. Steel Plant 15. M/s. Jindal Industrial Park. Steel Plant 16. M/s Jindal Steel Plant, Raigarh

Ø Total land available for existing and expansion is 90 acres. The following is the

land use statement

LAND USE STATEMENT

Area in acres Existing Expansion Total Built up area 1.5 5.0 6.5

Internal roads 1.0 3.0 4.0

Storage yard 1.2 15.0 16.2

Greenbelt 10.00 20.0 30.0

Open area 33.3 33.3

Total land 13.7 73.3 90.00

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2.4 SIZE / MAGNITUDE OF OPERATION

The details of the existing and proposed production capacities are furnished below

S.No Units Existing production capacity (TPA)

Proposed production capacity (TPA)

Total (TPA)

1. SSppoonnggee II rroonn 60,000 1,20,000 1,80,000 2. Induction Furnace with

Concast --- 1,62,000 1,62,000

3. Rolling Mill --- 1,05,000 1,05,000 4. Ferro alloys --- 25,000 25,000

WHRB --- 12 12 Power Plant FBC --- 36 36

5.

Total 48 48

The plant will be operated for a maximum of 300 days in a year. The total capital

investment of the proposed expansion project is 329.95 Crores. The proposed expansion

project will be implemented in 18 months from the date of issue of Environmental

Clearance.

2.5 TECHNOLOGY AND PROCESS DESCRIPTION

2.5.1 RAW MATERIALS (TOR # 5)

The following will be the raw material requirement for existing and proposed expansion

project are furnished below

CONSUMPTION ( TPA) S.NO. RAW

MATERIAL Existing Expansion Total SOURCE OF

SUPPLY METHOD OF TRANSPORT

STEEL & POWER PLANT

1 Iron Ore 96,000 1,92,000 2,88,000 NMDC,

Chhattisgarh, Barbil, Orissa

--

2 Coal (DRI) 78,000 1,56,000 2,34,000 SECL -- 3 Dolomite 2,400 4,800 7,200 Local Covered trucks 4. Scrap --- 1,41,750 1,41,750 Local -- 5 Ferro Alloys --- 810 810 Local -- 6 Coal (Power) --- 1,67,400 1,67,400 SECL Covered trucks

FERRO ALLOYS PLANT 9 Manganese Ore --- 82,500 82,500 Orissa Covered trucks 10 Coke/Coal --- 44,500 44,500 SECL Covered trucks 11 Dolomite --- 13,200 13,200 Local 12 Quartz --- 13,200 13,200 Local

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2.5.2 RAW MATERIAL STORAGE & TRANSPORT

Major raw materials will be stored in covered sheds.

SIZES OF SHEDS (Existing)

IRON ORE - 60M X 20M X 8M

COAL - 60M X 20M X 8M

SIZES OF SHEDS (Proposed Expansion)

IRON ORE - (60M X 20M X 8M) x 2

COAL - (60M X 20M X 8M) x 2

Transportation of raw materials

All the trucks required for transportation of raw materials will be covered. Pucca road

exist up to the site. The existing road is capable of absorbing this additional truck

movement. Hence there will not be any adverse impact on air environment due to the

transportation of raw materials.

2.5.4 MATERIAL BALANCE

2.5.4.1 EXISTING PLANT

The following is the material balance for the existing plant

SPONGE IRON (60,000TPA)

INPUTS OUTPUTS S. No. Item Quantity

(TPD) Item Quantity

(TPD) 1 Iron Ore 96000 Sponge Iron 60000 2 Coal 78000 Char/Dolochar 18000 3 Lime stone 2400 Gases 77100 4 Ash / Dust 18000 5 Wet Scraper sludge 2760 6 Accretion slag 540 Total 1,76,400 Total 1,76,400 Gases * 77100 Gases 77100 Electricity (WHRB)

2 X 2 = 4 MW

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* In the proposed expansion these gases w ill be utilized for power generation

through WHRB Boiler

2.5.4.2 EXPANSION PROJECT

The following is the material balance for the proposed expansion project.

SPONGE IRON (1,20,000 TPA)

INPUTS OUTPUTS S. No. Item Quantity

(TPA) Item Quantity

(TPA) 1 Iron Ore 192000 Sponge Iron 120000 2 Coal 156000 Char/Dolochar 36000 3 Lime stone 4800 Gases 154200 4 Ash / Dust 36000 5 Wet Scraper sludge 5520 6 Accretion slag 1080 Total 352800 Total 352800 Gases 154200 Gases 154200 Electricity (WHRB)

4 X 2 = 8 MW

SMS (Billets: 1,62,000 TPA)

INPUTS OUTPUTS S. No. Item Quantity (TPA) Item Quantity

(TPA) 1 DRI 141750 Billets 162000 2 Scrap, Mill end cuttings 44550 Slag 16200 3 Ferro Alloys

810 Gases including dust 8910

Total 187110 Total 187110 ROLLING MILL (1,05,000 TPA)

INPUTS OUTPUTS S. No. Item Quantity (TPA) Item Quantity (TPA) 1 Ingots/ Billets 108150 TMT Bars 105000 Mill scales 2625 Gases 525 Total 108150 Total 108150

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B.S. SPONGE PRIVATE LIMITED Village: Taraimal, Tehsil: Gharghoda, District: Raigarh, (C.G.) REIA Report for the Proposed Mini Integrated Steel Plant Chapter – 2

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POWER PLANT (36 MW AFBC Based Power Plant)

INPUTS OUTPUTS S. No. Item Quantity (TPA) Item Quantity

(TPA) 1 Dolochar 54000 Ash 93960 2 Coal 167400 Gases 127440 Total 221400 Total 221400 2.5.5 MANUFACTURING PROCESS (TOR # 6)

2.5.5.1 DRI KLIN:

Major plant facilities

The major plant facilities for the sponge iron plant envisaged are as follows:

Ø Day bins

Ø Rotary kiln and cooler

Ø Off gas system

Ø Product processing and product storage.

Day bins

There shall be a day bin building to cater to raw material requirement of the kiln. The

day bin building will comprise of six bins, one for iron ore, two for feed coal, one for

limestone/dolomite and two bins for injection coal. These bins will generally have

storage of about one day's requirement of screened iron ore feed (5-20 mm), feed coal (6-

12 mm, 12 – 25 mm), limestone/dolomite (1-4 mm) and injection coal (3-6 mm. 6-

12mm). Weigh feeders will be provided to draw the required quantity of various

materials in proportion from the bins and the same will be conveyed to the kiln feed end

and discharge end.

Rotary kiln and cooler

The rotary kiln of 3.0 m dia. and 42 m length will be provided for reduction of iron ore

into sponge iron using non-coking coal as reductant. The kiln will be lined with abrasion

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resistant refractory castables throughout its length with damps at feed end and discharge

end.

The rotary kiln will be supported on four piers. A slope of about 2.5% shall be

maintained. Then main drive of the kiln will be by two DC motors with thyristor control.

The speed of the kiln can be varied depending upon the operating conditions. The speed

of the kiln will be in the range of 0.25-0.75 rpm. The auxiliary drive of the kiln will be

by two AC motors.

The other main components of the kiln will be as given below:

• Feed end and discharge end transition housing of welded steel construction with

refractory lining including feed chute.

• Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating

system at feed end and discharge end.

• On board equipment like fans, manifolds, ports, slip ring, instrumentation etc.

• Cooling fans at feed end and discharge end.

• Feed end double pendulum valve & dust valves.

The kiln feed from the charging end will consist of sized iron ore (5-20mm), non-coking

coal (6-25 mm) and limestone/dolomite (1-4mm). Air will be supplied to the kiln

through shell mounted air fans. A part of the required coal (3-6mm, 6-12mm) shall be

thrown from kiln discharge end. The slinger coal will be withdrawn from the respective

bins in suitable proportion and pneumatically injected into the kiln. Necessary rotary

feeder, compressor, piping and valves will be provided.

In the kiln, the iron ore will be dried and heated to the reduction temperature of 1000 –

1050ºC. The iron oxide of the ore will be reduced to metallic iron by carbon monoxide

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generated in the kiln from coal. The heat required for the reduction process will also be

supplied by the combustion of coal.

Thermocouples will be installed along the length of the kiln shell for measurement of

thermal profile of the kiln. The temperature will be controlled by regulating the amount

of combustion air admitted into the kiln through no. of ports with the help of fans

mounted on the kiln shell and by controlled coal slinging. The DC main drives provided

to rotate the kiln will have variable speed. Auxiliary drive is provided for slow rotation.

The reduced material from the kiln will be cooled indirectly in a rotary cooler by an

external water spray. The kiln will be provided with one rotary cooler. The rotary cooler

will be of 2.3 m dia. And 22 m length and will be supported on two piers with a slope of

about 2.5 %. The main drive and the auxiliary drive of the cooler will be by one no.

separate AC motor. The speed of the drive will be about 1 rpm. The cooler will be

provided with one plain riding ring and one thrust riding ring and will be provided with

two sets of support rollers at two piers and one set of hydraulic thrust rollers with

antifriction bearings. About 1 m end portion of the cooler acts as a screening section,

which separates all the accretions larger than 50 mm from the reduced material. These

lumps will be discharged separately via Lump gate. Rest of the material will be

discharged on to the conveyor via double pendulum valve.

The other main components of the cooler will be the following.

• Feed end housing (part of reactor to cooler transition) of welded steel

construction with refractory lining.

• Cooler discharge end housing of welded steel construction.

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• Pneumatic cylinder acuted labyrinth air seal complete with auto lubricating

system at feed end and discharge end.

The cooler will be lined with refractory castable for about 4.0m length from the feed end.

Bypass arrangement will be provided at the discharge end of the cooler for emergency

discharge of materials. The cooled product will be conveyed to the product processing

building by a system of belt conveyors.

The cooling water will be collected in the trough below the cooler and sent to the cooling

tower for cooling. The cooled water will be re-circulated. Closed circuit cooling system

will be followed in the plant. The rotating parts of the kiln and cooler will be sealed

suitably against the stationary parts at the connecting points to avoid leakage of dust

laden gases.

Off gas system

The kiln shall have its separate off gas circuit. Hot waste gases leave the rotary kiln at

about 950 – 1000ºC through kiln feed end housing, dust settling chamber and come to an

After Burning Chamber (ABC), where combustibles are burnt completely by supplying

excess air. The gases at about 900 – 950ºC will then be led to a Waste heat recovery

Boiler. After heat recovery the gases will pass through an Electro-static precipitators

(ESPs) before letting them out into the atmosphere through ID fan and a combined stack

of 60 m height( with twin fuels).

Product processing and storage

There shall be one product processing unit for handling the cooler discharge. The

product containing sponge iron, char and spent lime, from the cooler discharge end will

be discharged to a set of conveyors and sent to the product processing building. The kiln-

cooler system shall have a separate surge bin of approx. 800 Tons. Product from surge

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bin can be withdrawn through vibrating feeder and fed to the product processing building

by conveyor. In the product processing building, the product will first be screened in a

double deck screen having 3mm and 20mm screens. +20mm material shall be dumped

as rejects. The screened product i.e., +3-20 mm and -3 mm fraction shall separately be

sent to the product storage separation. Sponge iron lump (3-20 mm) shall be sent to the

product storage building for storing in two no. of bunkers where three days storage has

been proposed. The sponge iron fines (-3 mm) will be stored in the fines bunker in the

product processing building itself where one day storage capacity will be provided. The

sponge iron lump & sponge iron fines will be further conveyed from the respective

bunkers by truck. The char/non-magnetic shall be stored in separate bins. Char will be

utilized for power generation in the FBC Boiler.

2.5.5.2 STEEL MELTING SHOP

Steel Melt Shop (SMS) is crated to melt the Sponge Iron along with melting scrap and

fluxes to make pure liquid steel and than to mould it in required size billets. The shop

consists of following equipment and subassemblies:

Induction Furnaces: Induction Furnace is a device to melt the charge material using

electrical power. It consists of Crucible lined with water cooled induction coils, Electrical

system to give controlled power to induction coil, Hydraulic tilting system, Heat

exchanger to cool the circulating water, water softener for generating soft water, furnace

transformer, Power Factor improvement system and surge suppressor.

Ladles: Ladles are pots with refractory lining inside to withstand 1600º C temperature. It

has side arms so that can be lifted with the help of crane. Ladles are used to stores the

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liquid steel from Induction Furnace and take it for further processing. Ladles are with

bottom nozzle and pneumatically operated gate for discharge of liquid.

Ladle Refining Furnace (LRF): Ladle furnace is a mini electric arc furnace. It has three

carbon electrodes, roof to cover the ladle, and furnace transformer of suitable capacity.

The operation of electrodes, roof etc are controlled by hydraulic system. Ladle furnace is

used either to keep the liquid steel for sequence casting or for further refining of the

liquid steel to make better quality steel.

Cranes: Electric Over-head (EOT) cranes of various capacities are used to carry the

ladles/materials at different places. Cranes are used in Melting hall to charge melting

scrap, remove the ladles to the LRF, further to place it over the Tundish of the

Continuous Caster, to remove billets from the cooling bed and store at designated places,

and also for other petty use. Accordingly the sizes, capacity and numbers of cranes are

decided.

Continuous Casting Machine (CCM): CCM is used to continuously cast the liquid steel

in required cross section and in length. It consists of Tundish, Mould, Bow with

Withdrawal mechanism, straightening mechanism and cooling bed, hydraulic system for

withdrawal mechanism, water umps and cooling towers for water spray on the withdrawn

section as well as on the cooling bed. Dummy bar is provided to start the casting.

Tundish is a rectangular vessel, lined with refractory and having discharge nozzle with

pneumatically operated gate. A stand is erected over it where the ladle is stationed for

discharging the liquid in it. Mould is of copper with water cooled jacked. Its cross-

section in the bottom is of the size of which billet is to be drawn. Initially the dummy for

of the same size is kept inserted. When the liquid steel is poured in the mould the dummy

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bar is drawn slowly, so that the liquid steel in partially frozen state comes out of the

mould. Water spray nozzles are installed to spray water over the just drawn billet to cool

it further and to harden the skin of the drawn billet.

2.5.5.3 ROLLING MILL:

Process description

Reheating furnace

A pusher type furnace has been envisaged for the heating of billets. The furnace will be

end charging and side discharging. It will have single row as well as double row charging

facility. The furnace will be heated with FO. The furnace combustion system will

comprise of air blowers, FO storage, supply and preheating system and other associated

facilities. The product of combustion will leave the furnace at charging end and

exhausted through under ground flue tunnel and passed through a metallic tubular

recuperator before finally let off to a self supporting steel chimney of sufficient height.

A set of instrument will be used for smooth operation of the furnace.

Bar and round mill

A cross country type mill has been envisaged for the plant. The stands have been

grouped into roughing, intermediate and finishing groups. Roughing group will have 4

(four) stands, intermediate group will have 8 (eight) stands and finishing mill will have 8

(eight) stands. Roughing group of stands will be driven by one motor. 4 nos. of

intermediate stands will be driven by two motors and balance 4 nos. will be driven by a

separate motor. Each stand of finishing group will be driven by single motor. Necessary

guides and troughs will be provided at entry and exit of mill stands.

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One wire rod out let has been provided in the mill. The wire rod line will have 4 stand

block driven by a single motor through gear box. Coil forming and handling of coil is

provided.

Automated tilting, drop type tilter and feeding arrangement will be provided in roughing

group of stands. Repeaters have been provided in roughing / intermediate stands as

necessary.

Design provision has been made for introduction of slit rolling facility in future to roll 8

mm, 10 mm & 12 mm rebars in two strands. The rebars discharged from the mill will

pass through a water cooling system comprising cooling pipes with high pressure water

nozzles for rapid water quenching. At the cooling pipes the bar skin temperature will be

reduced to about 600oC. The core of the bar still remains hot. This entrapped heat

tempers the bar. This thermo-mechanical treatment of the bars increases tensile strength

without adversely effecting weldability and elongation properties. This process

eliminates requirement of cold twisting of bars for production of rebars.

A dividing shear, to cut the products to cooling bed length, will be located immediately

after the water cooling system. This shear will divide all products to cooling bed lengths.

Rake type cooling beds have been envisaged to receive the rolled product. Cooling bed

will be provided with incoming and out going roller tables. One cold shear has been

provided to cut the bars coming out of cooling bed into commercial length of 6 to 12 m.

The bar products will be formed into bundles and will be strapped by strapping machine

manually.

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The finished products will be removed by overhead EOT crane and stored in the storage

area or dispatched through road vehicles. One rolling mill of 350 TPD capacity is

proposed in the expansion project.

2.5.5.4 FERRO ALLOYS

The company is in the process of installation of a Ferro Alloys project with 1 no. of 6

MVA and 9 MVA submerged arc furnaces.

The HIGH CARBON SILICO MANGANESE is an alloy of Manganese and Iron with

additions of Silicon, Carbon and several other various elements. The silicon manganese

can be divided into various grades depending upon the carbon content in the alloy.

Manganese ore is the basic material having the major constituents of the alloy viz. iron

and manganese. Different types of manganese ores are blended to achieve an appropriate

manganese iron ratio used for the furnace charges. Coke is used as reductant and quartz

as an addition agent. The raw materials are charged into a furnace where they are smelted

by electric power supplied through three carbon electrodes. The alloy and the slag

produced in the furnace are tapped at regular intervals. The specifications of silicon

manganese produced will conform to Indian standards.

ELECTRODE PASTE, CASING, OXYGEN LANCE AND REFRACTORIES :

The soderberg electrodes are formed in situ by charging electrode paste of suitable

compressive strength, electrical conductivity, porosity and apparent density, into mild

steel cylindrical shell provided with inner ribs for reinforcement. There is a continuous

consumption of both electrode paste and casing sheets.

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The other consumables of the process include oxygen lancing pipes and oxygen used for

opening the furnace tap-holes, and the refractory for the lining of pans / runners used for

alloy collection.

PROCESS DESCRIPTION: -

Standard Silico Manganese is smelted at about 1700 – 1800 ºC. This is achieved by a

conventional Submerged Arc Electric Furnace. The three carbon electrodes, partially

submerged in the charge, are supported on hydraulic cylinders for upward and downward

movements to maintain the desired electrical conditions in the furnace.

The body of the furnace is cylindrical in shape, and is lined with firebricks, silicon

carbide bricks and carbon tamping paste. Two tap-holes are provided at 120º. Apart form

draining out both the molten alloy and the slag. During the repair works of one of the tap

holes the other will function as standby. The raw materials are thoroughly mixed in the

proper proportion before being charged into the furnace. Manual poking rods or stoker

car are used for stoking the charge on the furnace top. As the charge enters the smelting

zone, the alloy formed by chemical reactions of the oxides and the reductant, being heavy

gradually settles at the bottom. The slag produced by the unreduced metal oxides and the

flux, being relatively lighter, floats on the alloys surface. At regular intervals the furnace

is tapped.

The tap hole is opened by Oxygen lancing pipe and after tapping is completed, it is

closed by clay plug. The liquid Silico manganese and the slag flow into the C.I. Pan. The

slag being lighter overflow from the C.I. Pan and is taken into the sand mould.

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The alloy cake from C.I. Pan is removed and broken manually with hammer to required

lump size.

The slag produced in the process, generally free from metal, after cooling is removed by

lorry to the slag dump.

2.5.5.5 POWER GENERATION: (TOR # 21)

Waste Heat Recovery Boilers will be installed behind the ABC of DRI kiln in bypass

configuration. The flue gases after ABC will be taken to unifired furnace chamber and

then flow over banks of super heater, convective evaporator and economizer before being

discharged to atmosphere through ESP, ID fan and stack. 12 MW electricity will be

generated from WHRB. In the Fluidized Bed Combustion boiler envisaged, combustion

of fuel particles is achieved in suspension with an inert aggregate i.e. sand. Combustion

air will be fed through air nozzles from underneath into the sand fuel bed. Oil burner will

be provided for start up and low load flame stabilization. The fuels proposed in FBC

Boiler are Char & Coal. The flue gases will pass over various heat transfer surfaces to

ESP and then finally discharged through ID fan and stack. 36 MW of Power generation

proposed through FBC Boiler.

The condensate after condenser of STG will be pumped to a common deaerator by

condensate extraction pumps. Feed water from the deaerator will be pumped to the waste

heat recovery boiler as well as FBC boiler by boiler feed pumps.

The steam generated from both the WHRB and FBC boilers will drive the steam turbine

through a common steam header to generate 48 MW of Electricity. The power generated

will be used for captive consumption.

Process flow diagram is shown as figure 2.1.

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2.6 ENVIRONMENTAL MITIGATION MEASURES

1. AIR POLLUTION CONTROL

(A) Sponge Iron plant

Ø After Burning Chamber will be provided to control the CO emissions.

Ø In the proposed plant the exhaust gases from the rotary kiln will pass

through a Waste Heat Recovery Boiler (WHRB) and after heat recovery the

gases will pass through a state-of-the-art Electro Static Precipitator to bring

down the particulate matter in the exhaust gases to less than 50 mg/Nm3.

Then the treated gases will be let out through a combined stack (with twin

flues) of 60 m height for effective dispersion of emissions into the

atmosphere.

Ø Dust extraction system with Bag filters will be provided at material transfer

points, crusher area, cooler discharge, product separation area, etc. to

control dust emission. All the material handling systems will be connected

with de dusting system. All the discharge points and feed points wherever

the possibility of dust generation is there a de dusting suction point will be

provided to collect the dust.

Ø Water sprinklers will be provided for dust suppression during unloading of

raw materials.

Ø All conveyors will be covered with GI sheets.

Ø Major raw materials will be stored in covered sheds.

(B) Steel Melting Shop

The Fugitive emissions from the Induction furnaces will be sucked through hoods

and will pass through a fume extraction system comprising of bagfilters and then

let out through a common stack of 30m height. The outlet dust emission will be

less than 50 mg/Nm3. The dust will be pneumatically carried to covered storage

bins.

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(C) AFBC Based Power Plant

The flue gases from the boiler will be treated in a state-of-the-art Electro Static

Precipitator to bring down the particulate emission to less than 50 mg/Nm3 and

will be let out through a stack of 72 m height for effective dispersion of emissions

into the atmosphere.

(D) Rolling Mill

The flue gases from the Rolling Mill will be let out through a stack of 45 m

height for effective dispersion of emissions into the atmosphere.

(E) Ferro Alloys

The emissions from each of the Submerged Electric Arc Furnaces will be

controlled by providing a fume extraction system with bag filters for each unit

and then let out into the atmosphere through two nos stacks each of 30 m height.

The out let dust emission will be less than 50 mg/Nm3.

Whenever Air pollution control systems fail, production in that unit will be

stopped till that air pollution control system is rectified.

2. WATER POLLUTION

Closed circuit cooling system will be provided in the process & cooling of SMS, Rolling

mill and Ferro alloys plants. Hence there will not be any waste water generation from

process and cooling. Boiler blowdown & DM plant regeneration waste water will be

treated in Neutralization tanks and will be mixed with CT blowdown and will be stored

in a Central Monitoring Basin (CMB). The treated effluent from CMB will be partly used

for dust suppression, partly for ash conditioning and the remaining will be utilized for on

land for irrigation. Sanitary waste will be treated in septic tank by soak pit.

3. NOISE POLLUTION

The turbine will be of internationally reputed make and will be manufactured as per

MOEF/OSHA standards on Noise. Acoustic enclosures will be provided to STG. The

major noise levels will be confined to the working zones of the plant. Ear plugs will be

provided to all employees who will enter into the noise prone areas.

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4. SOLID WASTE

• Dolochar generated will be utilized in FBC boiler for Power generation

• Slag from SMS will be used in road construction.

• Mill scales from Rolling mill will be used in Induction furnace.

• Ash & dust from bag filters will be given to cement plants/ brick

manufacturers/self brick making.

• Slag from Ferro alloys unit will be used in road construction.

Hence there will not be any adverse impact on land environment due to the solid waste

generation. 15 M wide greenbelt around the plant will be developed around the plant. All

Internal roads will be asphalted to prevent the fugitive dust emission due to vehicular

movement.

2.8 ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR THE RISK OF

TECHNOLOGICAL FAILURE

Sponge Iron, Billet & TMT bar & Ferro alloys manufacturing technologies are well

proven all over the world. Hence there will not be any risk of technological failure from

this plant.

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CHAPTER – III

BASELINE ENVIRONMENTAL STATUS

This chapter gives an idea and description of environmental status of the study area with

reference to the prominent environmental attributes. The general study area covers 10km.

radius of the plant. Monitoring was conducted from December, 2007 to February, 2008.

The impact identification always commences with the collection of baseline data such as

ambient air quality, ground water quality, surface water quality, noise levels, land

environment, land use pattern, flora & fauna and socio economic aspects with in the

study zone of 10 km. radius.

3.1 AIR ENVIRONMENT (TOR # 3)

3.1.1 Meteorology

Meteorology of the study area plays an important role in the air pollution studies. The

prevailing micro meteorological conditions at the proposed Project site will regulate the

dispersion and dilution of air pollutants in the atmosphere. The predominant wind

directions and the wind speed will decide the direction and distance of the most affected

zone from the proposed activity. The meteorological data collected during the monitoring

period is very useful in interpretation of baseline as input for dispersion models for

predicting the Ground Level Concentrations (GLC).

Rainfall

The average annual rainfall based in 10 years data collected from the nearest

meteorological center is found to be 1143 mm.

3

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3.1.2 Meteorological data recorded at site (Winter season (Dec ’07 – Feb ’08))

The predominant winds from NE direction were observed for 22.5 % of the total time,

with wind speeds (with % frequencies) in the range of 1-5 kmph (20.7 %), 6-11 kmph

(1.8 %), 12-19 kmph (0 %) and >19 kmph (0 %). The winds from NW direction were

observed from 18.9 % of the total time, with wind speeds (with % frequencies) in the

range of 1-5 kmph (17.7 %), 6-11 kmph (1.2 %), 12-19 kmph (0 %) and >19 kmph (0

%). The winds from SW direction were observed from 12.3 % of the total time, with

wind speeds (with % frequencies) in the range of 1-5 kmph (10.8 %), 6-11 kmph (1.5 %),

12-19 kmph (0 %) and >19 kmph (0 %). Winds from N, NEE, E, SEE, SE, S, SW,

SWW, W, NWW and NNW directions were observed for 2.7 %, 1.8 %, 2.1 %, 1.0 %, 8.1

%, 1.5%, 12.3 %, 2.2 %, 1.2 %, 2.1, and 1.5 % of the total time respectively. Calm

conditions prevailed for 22.1 % of the total time.

A Temporary Weather Monitoring Station was installed at the site and temperature,

relative humidity, wind direction, wind speed, and rainfall were recorded for one season

(winter season).

Temperature

The mean maximum temperature recorded was 29.9ºC and the mean minimum

temperature was 8.9º C at the Project site.

Wind direction and speed are recorded at site every hour.

The wind rose diagram of winter season is shown in fig 3.1

The wind rose shows that winds are predominantly blowing from NE and NW direction.

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WINDROSE AT SITE

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3.1.3 Air Quality (TOR # 7)

The ambient air quality with respect to the study zone of 10 km. radius around the plant

forms the baseline information. The study area represents mostly rural environment. The

various sources of air pollution in the region are vehicular traffic, dust arising from

unpaved village roads & domestic fuel burning. The Prime objective of baseline air

quality survey is to assess the Existing air quality of the area. This will also be useful is

assessing the conformity to standards of the ambient air quality during the plant

operation.

3.1.3.1 Selection of Sampling Stations

The base line status of the ambient air quality can be assessed through scientifically

designed Ambient Air Quality Monitoring Network.

The selection of sampling locations in the air quality surveillance programme is based on

the following.

(a) Representation of Project site.

(b) Representation of cross sectional distribution in the down wind direction.

(c) Representation of residential areas.

(d) Representation of regional background levels.

Eight nos. of Ambient Air Quality Monitoring Stations were established with in the study

zone of the plant.

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The sampling locations and their distances are shown in Table 3.1.1 and in fig 3.2. The

Max. Min., Avg., and 98th percentile values for all the sampling locations for RSPM,

SPM, SO2 and NOX are shown in Table 3.1.2 to 3.1.9.

3.1.3.2 Parameters Monitored

At each Monitoring Station Respirable Suspended Particulate Matter (RSPM),

Suspended Particulate Matter (SPM), SO2 and NOX are monitored. SPM was analysed

for PAH. The sampling was carried out for 2 days in a week for winter monsoon season

(December, 2007 – February, 2008) to assess the existing status of air pollution and

pollution dispersion pattern over the whole air basin of project site. RSPM, SPM, SO2

and NOX were sampled as per MOEF guidelines.

TABLE - 3.1.1 AMBIENT AIR QUALITY MONITORING STATIONS (TOR # 7)

S. No STATION DIRECTION DISTANCE (in kms.)

1. Existing Plant --- --- 2. Gerwani S 4.5 3. Taraimal SE 2.5 4. Punjipathra N 2.5 5. Ratrot NE 5.0 6. Gaurmuri SW 3.0 7. Ujalpur SE 5.0 8. Jamadbari W 3.0

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Fig. 3.2: AMBIENT AIR QUALITY MONITORING STATIONS

Monitoring Stations

PROJECT SITE

PROJECT SITE

Gourmuri

Taraimal

Punjipathara

Ratrot

Jamadbari

Gerwani

Ujalpur

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TABLE - 3.1.2

Sampling Location: Existing plant Sampling period: December, 2007-February 2008

Unit : µg/m3 Parameter Maximum Minimum Average 98th percentile RSPM 44.9 33.2 39.6 44.7 SPM* 135.6 112.8 122.2 135.2 SO2 10.4 8.5 9.5 10.2 NOx 12.7 10.6 11.5 12.5 * PAH in SPM is BDL TABLE - 3.1. 3 Sampling Location: Gerwani Sampling period:

December, 2007-February 2008 Unit : µg/m3 Parameter Maximum Minimum Average 98th percentile RSPM 38.1 29.0 33.1 38.0 SPM* 123.4 96.6 103.4 123.2 SO2 10.9 8.5 9.2 10.8 NOx 13.4 8.9 10.4 13.1 * PAH in RSPM is BDL TABLE - 3.1.4 Sampling Location: Taraimal Sampling period:

December, 2007-February 2008

Unit : µg/m3 Parameter Maximum Minimum Average 98th percentile RSPM 39.9 29.3 33.4 39.8 SPM* 125.3 98.7 106.9 125.0 SO2 11.1 8.7 9.6 10.9 NOx 13.8 9.4 10.7 13.6 * PAH in SPM is BDL TABLE - 3.1.5 Sampling Location: Punjipathra Sampling period:

December, 2007-February 2008 Unit : µg/m3 Parameter Maximum Minimum Average 98th percentile RSPM 40.2 31.3 36.5 40.0 SPM* 132.1 105.7 116.7 131.7 SO2 12.0 8.3 9.3 11.9 NOx 14.2 10.3 11.4 13.9 * PAH in SPM is BDL

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TABLE - 3.1. 6 Sampling Location: Gaurmuri Sampling period:

December, 2007-February 2008 Unit : µg/m3 Parameter Maximum Minimum Average 98th percentile RSPM 43.7 36.1 39.8 43.5 SPM* 141.4 114.3 128.6 141.0 SO2 9.7 7.8 8.6 9.6 NOx 12.9 10.2 11.4 12.8 * PAH in SPM is BDL TABLE - 3.1.7 Sampling Location: Ratrot Sampling period:

December, 2007-February 2008 Unit : µg/m3 Parameter Maximum Minimum Average 98th percentile RSPM 35.8 23.7 26.9 35.5 SPM* 113.4 84.0 89.9 112.9 SO2 10.9 7.8 8.7 10.8 NOx 13.4 8.9 9.7 13.1 * PAH in SPM is BDL TABLE - 3.1. 8 Sampling Location: Ujalpur Sampling period:

December, 2007-February 2008 Unit : µg/m3 Parameter

Maximum Minimum Average 98th percentile

RSPM 36.1 24.4 27.5 35.9 SPM* 114.9 84.9 90.5 114.6 SO2 11.1 7.9 8.6 11.0 NOx 13.9 9.1 10.2 13.8 * PAH in SPM is BDL TABLE - 3.1. 9 Sampling Location: Jamadbari Sampling period:

December, 2007-February 2008

Unit : µg/m3 Parameter Maximum Minimum Average 98th percentile RSPM 39.9 35.8 37.8 39.8 SPM* 125.6 103.9 114.8 125.2 SO2 9.1 7.6 8.1 9.0 NOx 11.0 9.1 10.2 11.0

* PAH in SPM is BDL

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The avg. SPM concentration at the Project site is 122.2 µg/m3. The avg. RPM

concentration at the Project site is 39.6 µg/m3. The avg. SO2 & NOX concentrations

recorded at the Project site are 9.5 & 11.5 µg/m3 respectively.

The maximum average RPM concentration was recorded at Gaurmuri with a value of

39.8 µg/m3.

The maximum average SPM concentration was recorded at Gaurmuri with a value of

128.6 µg/m3.

The maximum average SO2 concentration was recorded at Taraimal with a value of 9.6

µg/m3.

The maximum average NOx concentration was recorded at Punjipathra & Gaurmuri with

a value of 11.4 µg/m3.

3.2 NOISE ENVIRONMENT

The physical description of sound concerns its loudness as a function of frequency. Noise

in general is sound, which is composed of many frequency components of various

loudness distributed over the audible frequency range. Various noise scales have been

introduced to describe, in a single number, the response of an average human being to a

complex sound made up various frequencies at different loudness levels. The most

common and heavily favoured of those scales is the A weighted decibel (dBA). This is

more suitable for audible range of 20 to 20,000 Hertz. The scale has been designed to

weigh various components of noise according to the response of a human ear.

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The impact of noise sources on surrounding community depends on:

Ø Characteristics of noise sources (instantaneous, intermittent or continuous in nature).

It is well known that steady noise not as annoying as one that is continuously varying

in loudness.

Ø The time at which noise occurs, for example loud noise levels at night in residential

areas are not acceptable because of sleep disturbance.

Ø The location of the noise source, with respect to noise sensitive area, which

determines the loudness and period of noise exposure.

The environmental impact of noise can have several effects varying from Noise Induced

Hearing Loss (NIHL) to annoyance depending on loudness of Noise levels.

The environmental impact assessment of noise from the plant can be carried out by

taking into consideration of various factors: potential damage to hearing, potential

physiological responses, annoyance and general community responses.

The main objective of noise level monitoring is to assess the background noise levels in

different zones viz., industrial, commercial, residential and silence zones within the study

area. The basic studies conducted were

a. Assessment of background noise levels.

b. Identification and monitoring the major noise generating sources in the study area.

c. Impact of noise on general population in the study zone of 10 kms. radius.

3. 2. 1 Reconnaissance

Noise levels were measured at different locations within 10 Km. radius of the proposed

Project such as villages, bus stands etc.

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3.2.1.1 Background noise

Baseline noise data has been measured at different locations using A-weighted sound

pressure level meter. The equivalent day-night noise levels in the study zone are ranging

from 44.10 dBA to 51.65 dBA.

3.2.1.2 Sources of noise

Typical considerations in environmental noise assessment can be divided into two

categories, one is related to noise sources and the other related to potential receiver.

Two quantities are needed to describe completely the strength of the source. They are

sound Power level and directivity. Sound Power levels measures the total sound Power

radiated by the source in all directions where as directivity is a measure of difference in

radiation with direction. This concept of sound Power level and directivity index makes it

possible to calculate the sound pressure level created by the source.

3.2.2 Community noise

The ambient noise level is characterized by significant variations above a base or a

residual noise level. The residual noise level is that level below which the ambient noise

does not seem to drop during a given time interval and is generally caused by the

unidentified distant sources. It differs in rural and urban areas. At night, its level is low

due to lesser elements of noise. The annoyance that people experience depends upon the

number of noise elements that produce noise concurrently at a given time that occur

during a time interval.

The noise rating developed by EPA for specification of community noise from all

sources is the day night sound level, Ldn. It is similar to a 24 hour equivalent sound level

except that during the night period, which extends from 09.00 p.m. to 6.00 a.m. A 10

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dBA weighing penalty is added to the account for the fact that noise at night when people

are trying to sleep is judged more annoying than the same noise during the day time.

The Ldn for a given location in a community is calculated from an hourly equivalent

sound level given by the following equation.

Ldn =10 log (1/24 [15 (10(Ld/10) + 9 (10(Ln+10)/10 )] )

Where Ld is the equivalent noise level during day time (6A .M. to 9 P.M.)

Ln is the equivalent noise level during night time (9 P.M. to 6 A.M.)

3.2.2.1 Occupational exposure

To assess the magnitude of impact due to noise sources, it is essential to know the

following.

a. The duration of sound.

b. Distribution through the working day.

c. Overall noise levels.

d. It's composition including frequency and intensity at various intervals of time.

Other factors regarding receiver include:

a. The age of the individual.

b. The sensitivity of the individual.

c. The efficiency of the protective devices used.

After characterizing the noise sources noise at receiver's location, the impact must be

assessed. The environmental impact of noise can lead to the following effects.

a. Damages the hearing capacity.

b. Interference in communication.

c. Interference with work.

d. Interference with sleep.

e. Causes annoyance.

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3. 2. 3. Noise level observations in the study area

Baseline noise levels have been monitored at different locations within the study zone of

the plant 8 no's of stations have been selected for measurement of noise levels and their

distance with respect to site are shown in table 3. 2.1 and Fig. 3.3

Fig. 3.3: Noise Monitoring Stations

Monitoring Stations

PROJECT SITE

PROJECT

Gourmuri

Taraimal

Punjipathara

Ratrot

Jamadbari

Gerwani

Ujalpur

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TABLE 3.2.1

NOISE LEVEL MONITORING STATIONS S. No STATION DIRECTION DISTANCE (in kms.)

1. Existing plant --- --- 2. Gerwani S 4.5 3. Taraimal SE 2.5 4. Punjipathra N 2.5 5. Ratrot NE 5.0 6. Gaurmuri SW 3.0 7. Ujalpur SE 5.0 8. Jamadbari W 3.0

TABLE 3.2.2

EQUIVALENT DAY NIGHT NOISE LEVELS

NOISE LEVELS dBA S. No. LOCATION Day Night Day-Night

1. Existing Plant 52 41 51.65 2. Gerwani 48 34 46.89 3. Taraimal 50 36 48.89 4. Punjipathra 46 33 45.10 5. Ratrot 45 32 44.10 6. Gaurmuri 50 37 49.10 7. Ujalpur 46 32 44.89 8. Jamadbari 47 33 45.89

3.3 WATER QUALITY IMPACTS (TOR # 18)

Water required for the proposed expansion will be met from the Chuikansa Nallah /

River Kelo which is about 2.5 Km from the plant. Water samples have been collected and

analysed for various parameters. The characteristics of water sample are shown in table

No. 3.3.1

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TABLE NO. 3.3.1 SURFACE WATER QUALITY ANALYSIS

Station: Chuikansa Nallah (60m upstream) S. NO. PARAMETER UNIT SAMPLE

PHYSICAL CHARACTERISTICS 1. Colour ----- 2. pH 7.8 3. Turbidity NTU 5 4. Electrical Conductivity ms/cm 140 5. Total Dissolved Solids mg/l 86 CHEMICAL CHARACTERISTICS

6. Total Hardness mg/l 67 7. Calcium Hardness mg/l 42 8. Magnesium Hardness mg/l 25 9. Alkalinity mg/l 44 10. Sulphates mg/l 12 11. Chlorides mg/l 31 12. Nitrates as NO3 mg/l 5 13. Fluoride as F mg/l 0.21 14. Sodium as Na mg/l 22 15. COD mg/l 5 16. Residual chlorine mg/l <0.01 17. Cyanides as CN- mg/l <0.01 18. Phenols as C6H5OH mg/l Absent 19. Hexavalent chromium as Cr mg/l <0.01 20. Iron as Fe mg/l 0.22 21. Copper as Cu mg/l <0.01 22. Arsenic as As mg/l <0.01 23. Selenium mg/l <0.01 24. Cadmium as cd mg/l <0.01 25. Boron as B mg/l <0.01 26. Mercury as Mg mg/l <0.001 27. Lead as Pb mg/l <0.01 28. Silica as SiO 2 mg/l 4.0 29. Mineral oil mg/l <0.01 30. Total coliforms (MPN/100 ml) 65

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TABLE NO. 3.3.2 SURFACE WATER QUALITY ANALYSIS Station: Chuikansa Nallah (60m downstream)

S. NO. PARAMETER UNIT SAMPLE PHYSICAL CHARACTERISTICS

1. Colour ----- 2. pH 7.7 3. Turbidity NTU 5 4. Electrical Conductivity ms/cm 141 5. Total Dissolved Solids mg/l 86 CHEMICAL CHARACTERISTICS

6. Total Hardness mg/l 68 7. Calcium Hardness mg/l 43 8. Magnesium Hardness mg/l 25 9. Alkalinity mg/l 44 10. Sulphates mg/l 13 11. Chlorides mg/l 30 12. Nitrates as NO3 mg/l 5 13. Fluoride as F mg/l 0.22 14. Sodium as Na mg/l 21 15. COD mg/l 5 16. Residual chlorine mg/l <0.01 17. Cyanides as CN- mg/l <0.01 18. Phenols as C6H5OH mg/l Absent 19. Hexavalent chromium as Cr mg/l <0.01 20. Iron as Fe mg/l 0.23 21. Copper as Cu mg/l <0.01 22. Arsenic as As mg/l <0.01 23. Selenium mg/l <0.01 24. Cadmium as cd mg/l <0.01 25. Boron as B mg/l <0.01 26. Mercury as Mg mg/l <0.001 27. Lead as Pb mg/l <0.01 28. Silica as SiO 2 mg/l 4.0 29. Mineral oil mg/l <0.01 30. Total coliforms (MPN/100 ml) 64

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SURFACE WATER QUALITY ANALYSIS Station: at other surface drains

S. NO. PARAMETER UNIT SAMPLE I SAMPLE II SAMPLE III SAMPLE IV

PHYSICAL CHARACTERISTICS 1. Colour ----- ----- ----- ----- 2. pH 7.6 7.7 7.6 7.7 3. Turbidity NTU 6 8 7 6 4. Electrical Conductivity ms/cm 131 122 128 133 5. Total Dissolved Solids mg/l 78 73 75 81 CHEMICAL CHARACTERISTICS 6. Total Hardness mg/l 73 68 70 74 7. Calcium Hardness mg/l 41 38 40 42 8. Magnesium Hardness mg/l 32 30 30 32 9. Alkalinity mg/l 48 43 45 49 10. Sulphates mg/l 8.1 7.5 7.7 8.5 11. Chlorides mg/l 23.3 22.4 22.8 23.9 12. Nitrates as NO3 mg/l 3.2 2.9 3.0 3.4 13. Fluoride as F mg/l 0.03 0.02 0.02 0.03 14. Sodium as Na mg/l 11.2 10.3 10.8 11.3 15. COD mg/l 5 4 4 5 16. Residual chlorine mg/l <0.01 <0.01 <0.01 <0.01 17. Cyanides as CN- mg/l <0.01 <0.01 <0.01 <0.01 18. Phenols as C6H5OH mg/l Absent Absent Absent Absent 19. Chromium as Cr+6 mg/l <0.01 <0.01 <0.01 <0.01 20. Iron as Fe mg/l 0.25 0.21 0.23 0.26 21. Copper as Cu mg/l <0.01 <0.01 <0.01 <0.01 22. Arsenic as As mg/l <0.01 <0.01 <0.01 <0.01 23. Selenium mg/l <0.01 <0.01 <0.01 <0.01 24. Cadmium as cd mg/l <0.01 <0.01 <0.01 <0.01 25. Boron as B mg/l <0.01 <0.01 <0.01 <0.01 26. Mercury as Mg mg/l <0.001 <0.001 <0.001 <0.001 27. Lead as Pb mg/l <0.01 <0.01 <0.01 <0.01 28. Silica as SiO 2 mg/l 5.0 4.1 4.6 5.2 29. Mineral oil mg/l <0.01 <0.01 <0.01 <0.01 30. Total coliforms (MPN/

100 ml) 82 70 74 84

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SURFACE WATER QUALITY ANALYSIS Station: at other surface drains

S. NO. PARAMETER UNIT SAMPLE V SAMPLE VI SAMPLE VII SAMPLE VIII

PHYSICAL CHARACTERISTICS 1. Colour ----- ----- ----- ----- 2. pH 7.8 7.4 7.4 7.6 3. Turbidity NTU 8 5 5 6 4. Electrical Conductivity ms/cm 131 122 128 129 5. Total Dissolved Solids mg/l 68 63 65 66 CHEMICAL CHARACTERISTICS 6. Total Hardness mg/l 59 52 52 57 7. Calcium Hardness mg/l 41 36 35 39 8. Magnesium Hardness mg/l 18 16 17 18 9. Alkalinity mg/l 38 33 33 36 10. Sulphates mg/l 8 7 7 7 11. Chlorides mg/l 21 19 18 20 12. Nitrates as NO3 mg/l 3 2 2 3 13. Fluoride as F mg/l 0.03 0.02 0.02 0.03 14. Sodium as Na mg/l 11.2 10.3 10.8 11.3 15. COD mg/l 5 4 4 4 16. Residual chlorine mg/l <0.01 <0.01 <0.01 <0.01 17. Cyanides as CN- mg/l <0.01 <0.01 <0.01 <0.01 18. Phenols as C6H5OH mg/l Absent Absent Absent Absent 19. Chromium as Cr+6 mg/l <0.01 <0.01 <0.01 <0.01 20. Iron as Fe mg/l 0.20 0.17 0.18 0.19 21. Copper as Cu mg/l <0.01 <0.01 <0.01 <0.01 22. Arsenic as As mg/l <0.01 <0.01 <0.01 <0.01 23. Selenium mg/l <0.01 <0.01 <0.01 <0.01 24. Cadmium as cd mg/l <0.01 <0.01 <0.01 <0.01 25. Boron as B mg/l <0.01 <0.01 <0.01 <0.01 26. Mercury as Mg mg/l <0.001 <0.001 <0.001 <0.001 27. Lead as Pb mg/l <0.01 <0.01 <0.01 <0.01 28. Silica as SiO 2 mg/l 4 3 3 3 29. Mineral oil mg/l <0.01 <0.01 <0.01 <0.01 30. Total coliforms (MPN/

100 ml) 75 67 65 72

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Ground Water Quality (TOR # 19)

Ground water samples have been collected and analyzed for various parameters like pH,

Suspended Solids, Total Dissolved Solids, Temperature, Total Hardness, Calcium

Hardness, Magnesium hardness, Alkalinity, Fluoride, Chloride, Sulphates, Nitrates,

Phenolic compounds, Heavy metals etc. and is compared with the standards to know the

water quality. Selection of sampling locations will be generally done based on the

following factors:

i) Proximity of the industries to the site. ii) Residential areas. iii) Representation of Project site.

Eight numbers of ground water samples from bore wells were collected from the near by

villages to assess ground water quality impacts. The ground water sampling locations and

their distances from the proposed Project site are shown in Table 3.3.3. These water

samples are analysed for various parameters as per IS: 10500. The ground water

characteristics were shown in table Nos. 3.3.4. to 3.3.11. The ground water monitoring

stations are shown in Fig. 3.4. There is no organic contamination of the ground water.

No heavy metals are present in ground water. The hardness in the water is slightly higher

which is due to the geological formation beneath the ground surface but this is less than

the maximum acceptable levels.

TABLE 3.3.3: GROUND WATER QUALITY MONITORING STATIONS Sr. No. STATION DIRECTION DISTANCE (in km)

1. Plant --- --- 2. Gerwani S 4.5 3. Taraimal SE 2.5 4. Punjipathra N 2.5 5. Ratrot NE 5.0 6. Gaurmuri SW 3.0 7. Ujalpur SE 5.0 8. Jamadbari W 3.0

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Fig. 3.4: Ground Water Quality Monitoring Stations

Monitoring Stations

PROJECT SITE

PROJECT SITE

Gourmuri

Taraimal

Punjipathara

Ratrot

Jamadbari

Gerwani

Ujalpur

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TABLE 3.3.4 GROUND WATER QUALITY ANALYSIS

Station : Plant Month: December, 2007 S. NO. PARAMETER UNIT SAMPLE PHYSICAL CHARACTERISTICS 1. Colour --- 2. pH 7.2 3. Turbidity NTU 1 4. Electrical Conductivity µs/cm 695 5. Total Dissolved Solids mg/l 440 CHEMICAL CHARACTERISTICS 6. Total Hardness mg/l 234 7. Calcium Hardness mg/l 148 8. Magnesium Hardness mg/l 86 9. Alkalinity mg/l 201 10. Sulphates mg/l 76 11. Chlorides mg/l 125 12. Nitrates as NO3 mg/l 2.0 13. Fluoride as F mg/l 0.51 14. Sodium as Na mg/l 89 15. Residual chlorine mg/l <0.01 16. Cyanides as CN- mg/l <0.01 17. Phenols as C6H5OH mg/l Absent 18. Total chromium as Cr mg/l <0.01 19. Iron as Fe mg/l 0.023 20. Copper as Cu mg/l <0.01 21. Arsenic as As mg/l <0.01 22. Selenium as Se mg/l <0.01 23. Cadmium as cd mg/l <0.01 24. Boron as B mg/l <0.01 25. Mercury as Hg mg/l <0.001 26. Lead as Pb mg/l <0.01 27. Silica as SiO 2 mg/l 3.0 28. Manganese as Mn Mg/l <0.01 29. Mineral oil Mg/l <0.01 30. Anionic detergents as MBAS Mg/l <0.01 31. Total coliforms (MPN/100 ml) Absent

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TABLE 3.3.5

GROUND WATER QUALITY ANALYSIS

Station : Gerwani Month: December, 2007 S. NO. PARAMETER UNIT SAMPLE PHYSICAL CHARACTERISTICS 1. Colour --- 2. pH 7.4 3. Turbidity NTU 2 4. Electrical Conductivity µs/cm 675 5. Total Dissolved Solids mg/l 442 CHEMICAL CHARACTERISTICS 6. Total Hardness mg/l 232 7. Calcium Hardness mg/l 167 8. Magnesium Hardness mg/l 65 9. Alkalinity mg/l 209 10. Sulphates mg/l 60 11. Chlorides mg/l 117 12. Nitrates as NO3 mg/l 2.7 13. Fluoride as F mg/l 0.54 14. Sodium as Na mg/l 88 15. Residual chlorine mg/l <0.01 16. Cyanides as CN- mg/l <0.01 17. Phenols as C6H5OH mg/l Absent 18. Total chromium as Cr mg/l <0.01 19. Iron as Fe mg/l 0.024 21. Copper as Cu mg/l <0.01 21. Arsenic as As mg/l <0.01 22. Selenium as Se mg/l <0.01 23. Cadmium as cd mg/l <0.01 24. Boron as B mg/l <0.01 25. Mercury as Hg mg/l <0.001 26. Lead as Pb mg/l <0.01 27. Silica as SiO 2 mg/l 3.0 28. Manganese as Mn mg/l <0.01 29. Mineral oil mg/l <0.01 30. Anionic detergents as MBAS mg/l <0.01 31. Total coliforms (MPN/100 ml) Absent

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TABLE 3.3.6 GROUND WATER QUALITY ANALYSIS

Station : Taraimal Month: December, 2007 S. NO. PARAMETER UNIT SAMPLE PHYSICAL CHARACTERISTICS

1. Colour --- 2. pH 7.2 3. Turbidity NTU 1 4. Electrical Conductivity µs/cm 630 5. Total Dissolved Solids mg/l 399 CHEMICAL CHARACTERISTICS

6. Total Hardness mg/l 204 7. Calcium Hardness mg/l 159 8. Magnesium Hardness mg/l 45 9. Alkalinity mg/l 187 10. Sulphates mg/l 55 11. Chlorides mg/l 105 12. Nitrates as NO3 mg/l 2.1 13. Fluoride as F mg/l 0.5 14. Sodium as Na mg/l 79 15. Residual chlorine mg/l <0.01 16. Cyanides as CN- mg/l <0.01 17. Phenols as C6H5OH mg/l Absent 18. Total chromium as Cr mg/l <0.001 19. Iron as Fe mg/l 0.018 20. Copper as Cu mg/l <0.01 21. Arsenic as As mg/l <0.01 22. Selenium as Se mg/l <0.01 23. Cadmium as cd mg/l <0.01 24. Boron as B mg/l <0.01 25. Mercury as Hg mg/l <0.001 26. Lead as Pb mg/l <0.01 27. Silica as SiO 2 mg/l 3.0 28. Manganese as Mn mg/l <0.01 29. Mineral oil mg/l <0.01 30. Anionic detergents as MBAS mg/l <0.01 31. Total coliforms (MPN/100 ml) Absent

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TABLE 3. 3 .7 GROUND WATER QUALITY ANALYSIS

Station : Punjipathra Month: December, 2007 S. NO. PARAMETER UNIT SAMPLE PHYSICAL CHARACTERISTICS

1. Colour --- 2. pH 7.5 3. Turbidity NTU 2 4. Electrical Conductivity µs/cm 755 5. Total Dissolved Solids mg/l 499 CHEMICAL CHARACTERISTICS

6. Total Hardness mg/l 249 7. Calcium Hardness mg/l 162 8. Magnesium Hardness mg/l 87 9. Alkalinity mg/l 225 10. Sulphates mg/l 74 11. Chlorides mg/l 125 12. Nitrates as NO3 mg/l 3.1 13. Fluoride as F mg/l 0.54 14. Sodium as Na mg/l 98 15. Residual chlorine mg/l <0.01 16. Cyanides as CN- mg/l <0.01 17. Phenols as C6H5OH mg/l Absent 18. Total chromium as Cr mg/l <0.01 19. Iron as Fe mg/l 0.019 20. Copper as Cu mg/l <0.01 21. Arsenic as As mg/l <0.01 22. Selenium as Se mg/l <0.01 23. Cadmium as cd mg/l <0.01 24. Boron as B mg/l <0.01 25. Mercury as Hg mg/l <0.001 26. Lead as Pb mg/l <0.01 27. Silica as SiO 2 mg/l 4.0 28. Manganese as Mn mg/l <0.01 29. Mineral oil mg/l <0.01 30. Anionic detergents as MBAS mg/l <0.01 31. Total coliforms (MPN/100 ml) Absent

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TABLE 3.3.8 GROUND WATER QUALITY ANALYSIS

Station : Ratrot Month: December, 2007 S. NO. PARAMETER UNIT SAMPLE PHYSICAL CHARACTERISTICS

1. Colour --- 2. pH 7.2 3. Turbidity NTU 1 4. Electrical Conductivity µs/cm 745 5. Total Dissolved Solids mg/l 475 CHEMICAL CHARACTERISTICS

6. Total Hardness mg/l 261 7. Calcium Hardness mg/l 172 8. Magnesium Hardness mg/l 89 9. Alkalinity mg/l 206 10. Sulphates mg/l 74 11. Chlorides mg/l 116 12. Nitrates as NO3 mg/l 2.0 13. Fluoride as F mg/l 0.51 14. Sodium as Na mg/l 95 15. Residual chlorine mg/l <0.01 16. Cyanides as CN- mg/l <0.01 17. Phenols as C6H5OH mg/l Absent 18. Total chromium as Cr mg/l <0.01 19. Iron as Fe mg/l 0.022 20. Copper as Cu mg/l <0.01 21. Arsenic as As mg/l <0.01 22. Selenium as Se mg/l <0.01 23. Cadmium as cd mg/l <0.01 24. Boron as B mg/l <0.01 25. Mercury as Hg mg/l <0.001 26. Lead as Pb mg/l <0.01 27. Silica as SiO 2 mg/l 3.0 28. Manganese as Mn mg/l <0.01 29. Mineral oil mg/l <0.01 30. Anionic detergents as MBAS mg/l <0.01 31. Total coliforms (MPN/100 ml) Absent

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TABLE 3.3.9 GROUND WATER QUALITY ANALYSIS

Station : Gaurmuri Month: December, 2007 S. NO. PARAMETER UNIT SAMPLE PHYSICAL CHARACTERISTICS 1. Colour --- 2. pH 7.4 3. Turbidity NTU 1 4. Electrical Conductivity µs/cm 635 5. Total Dissolved Solids mg/l 406 CHEMICAL CHARACTERISTICS 6. Total Hardness mg/l 211 7. Calcium Hardness mg/l 162 8. Magnesium Hardness mg/l 49 9. Alkalinity mg/l 190 10. Sulphates mg/l 59 11. Chlorides mg/l 110 12. Nitrates as NO3 mg/l 2.5 13. Fluoride as F mg/l 0.51 14. Sodium as Na mg/l 83 15. Residual chlorine mg/l <0.01 16. Cyanides as CN- mg/l <0.01 17. Phenols as C6H5OH mg/l Absent 18. Total chromium as Cr mg/l <0.01 19. Iron as Fe mg/l 0.022 20. Copper as Cu mg/l <0.01 21. Arsenic as As mg/l <0.01 22. Selenium as Se mg/l <0.01 23. Cadmium as cd mg/l <0.01 24. Boron as B mg/l <0.01 25. Mercury as Hg mg/l <0.001 26. Lead as Pb mg/l <0.01 27. Silica as SiO 2 mg/l 3.0 28. Manganese as Mn mg/l <0.01 29. Mineral oil mg/l <0.01 30. Anionic detergents as MBAS mg/l <0.01 31. Total coliforms (MPN/100 ml) Absent

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TABLE 3.3.10 GROUND WATER QUALITY ANALYSIS

Station : Ujalpur Month: December, 2007 S. NO. PARAMETER UNIT SAMPLE PHYSICAL CHARACTERISTICS 1. Colour --- 2. pH 7.3 3. Turbidity NTU 1 4. Electrical Conductivity µs/cm 612 5. Total Dissolved Solids mg/l 387 CHEMICAL CHARACTERISTICS 6. Total Hardness mg/l 201 7. Calcium Hardness mg/l 132 8. Magnesium Hardness mg/l 69 9. Alkalinity mg/l 181 10. Sulphates mg/l 58 11. Chlorides mg/l 99 12. Nitrates as NO3 mg/l 2.5 13. Fluoride as F mg/l 0.53 14. Sodium as Na mg/l 83 15. Residual chlorine mg/l <0.01 16. Cyanides as CN- mg/l <0.01 17. Phenols as C6H5OH mg/l Absent 18. Total chromium as Cr mg/l <0.01 19. Iron as Fe mg/l 0.019 20. Copper as Cu mg/l <0.01 21. Arsenic as As mg/l <0.01 22. Selenium as Se mg/l <0.01 23. Cadmium as cd mg/l <0.01 24. Boron as B mg/l <0.01 25. Mercury as Hg mg/l <0.001 26. Lead as Pb mg/l <0.01 27. Silica as SiO 2 mg/l 3.0 28. Manganese as Mn mg/l <0.01 29. Mineral oil mg/l <0.01 30. Anionic detergents as MBAS mg/l <0.01 31. Total coliforms (MPN/100 ml) Absent

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TABLE 3.3.11 GROUND WATER QUALITY ANALYSIS

Station : Jamadbari Month: December, 2007 S. NO. PARAMETER UNIT SAMPLE PHYSICAL CHARACTERISTICS

1. Colour --- 2. pH 7.2 3. Turbidity NTU 1 4. Electrical Conductivity µs/cm 749 5. Total Dissolved Solids mg/l 490 CHEMICAL CHARACTERISTICS

6. Total Hardness mg/l 291 7. Calcium Hardness mg/l 195 8. Magnesium Hardness mg/l 96 9. Alkalinity mg/l 238 10. Sulphates mg/l 79 11. Chlorides mg/l 135 12. Nitrates as NO3 mg/l 2.2 13. Fluoride as F mg/l 0.50 14. Sodium as Na mg/l 105 15. Residual chlorine mg/l <0.01 16. Cyanides as CN- mg/l <0.01 17. Phenols as C6H5OH mg/l Absent 18. Total chromium as Cr mg/l <0.01 19. Iron as Fe mg/l 0.022 20. Copper as Cu mg/l <0.01 21. Arsenic as As mg/l <0.01 22. Selenium as Se mg/l <0.01 23. Cadmium as cd mg/l <0.01 24. Boron as B mg/l <0.01 25. Mercury as Hg mg/l <0.001 26. Lead as Pb mg/l <0.01 27. Silica as SiO 2 mg/l 4.0 28. Manganese as Mn mg/l <0.01 29. Mineral oil mg/l <0.01 30. Anionic detergents as MBAS mg/l <0.01 31. Total coliforms (MPN/100 ml) Absent

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3.3.1 Water Requirement:

Water is generally required for cooling, domestic and is used as CT make-up, Boiler

make-up, D.M. Plant regeneration, service water etc., in the power plant. Water required

for the plant will be met from the Chhuikansa Nallaha / Kelo river. The water

requirement for the expansion project will be 3700 M3/day and the total water

requirement after the expansion will be 3800 cum/day

3.3.2 WATER CLEARANCES

Permission from the concerned department will be taken before operation of the

expansion project.

3.3.3 WASTE WATER

The total wastewater generation after expansion will be 391 cum/day.

3.4 LAND ENVIRONMENT

3.4.1 LAND USE PATTERN (TOR # 1)

The following is the land use pattern within 10 Km radius of the plant.

Land use pattern

Irrigated Area : 19.5 %

Forest Area : 20.2

Un Irrigated Area : 31.8 %

Built up Area : 2.2%

Open & Waste land : 26.3 %

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3.4.2 MINERAL RESERVES

There are no mineral reserves in the study area.

3.4.3 SEISMIC EFFECT

The project site falls in zone-II of seismic zone classification of India.

3.5.1 BASELINE DATA ON SOIL QUALITY

Eight soil samples were collected and for analyzed for various parameters like texture,

infiltration rate, bulk density, pH, Ca, Mg, Na, K, Zn, Mn etc. The soil sampling

locations are shown in Fig 3.5. The soil characteristics are shown in Table No. 3.5.1 to

3.5.8. The topography of the plant is more or less flat without many undulations.

TABLE: 3. 5.1

SOIL CHARACTERISTICS

Station : Plant Month : December, 2007

S. No. Parameter Unit Value

1. Bulk Density g / cc 1.8

2. Infiltration rate Cm/hr 1.7

3. pH -- 7.5

4. Soil type -- Sandy loam

5. Calcium mg/100 gm 924

6. Magnesium mg/100 gm 58

7. Sodium mg/100 gm 66

8. Potassium mg/100 gm 41

9. P2O5 mg/100 gm 25

10. Mn mg/100 gm <0.001

11. Zn mg/100 gm <0.001

12. Pb mg/100 gm <0.001

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Fig. 3.5: Soil Sampling Location

Monitoring Stations

PROJECT SITE

PROJECT SITE

Gourmuri

Taraimal

Punjipathara

Ratrot

Jamadbari

Gerwani

Ujalpur

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TABLE 3.5. 2 SOIL CHARACTERSTICS

Station : Gerwani Month : December, 2007 S. No. Parameter Unit Value 1. Bulk Density g / cc 1.72 2. Infiltration rate cm/hr 1.91 3. pH -- 7.5 4. Soil type -- Sandy loam 5. Calcium mg/100 gm 890 6. Magnesium mg/100 gm 68 7. Sodium mg/100 gm 72 8. Potassium mg/100 gm 40 9. P2O5 mg/100 gm 26 10. Mn mg/100 gm <0.001 11. Zn mg/100 gm <0.001 12. Pb mg/100 gm <0.001

TABLE 3.5.3 SOIL CHARACTERISTICS

Station : Taraimal Month : December, 2007

S. No. Parameter Unit Value

1. Bulk Density g / cc 1.71

2. Infiltration rate cm/hr 1.96

3. pH -- 7.6

4. Soil type -- Sandy loam

5. Calcium mg/100 gm 965

6. Magnesium mg/100 gm 67

7. Sodium mg/100 gm 60

8. Potassium mg/100 gm 41

9. P2O5 mg/100 gm 24

10. Mn mg/100 gm <0.001

11. Zn mg/100 gm <0.001

12. Pb mg/100 gm <0.001

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TABLE 3.5. 4

SOIL CHARACTERSTICS

Station : Punjipathra Month : December, 2007 S. No. Parameter Unit Value 1. Bulk Density g / cc 1.9

2. Infiltration rate cm/hr 2.09

3. pH -- 7.6

4. Soil type -- Loamy

5. Calcium Mg/100 gm 968

6. Magnesium Mg/100 gm 74

7. Sodium Mg/100 gm 69

8. Potassium Mg/100 gm 45

9. P2O5 Mg/100 gm 21

10. Mn Mg/100 gm <0.001

11. Zn Mg/100 gm <0.001

12. Pb Mg/100 gm <0.001

TABLE 3.5.5

SOIL CHARACTERISTICS

Station : Ratrot Month : December, 2007

S. No. Parameter Unit Value

1. Bulk Density g / cc 1.8

2. Infiltration rate cm/hr 2.0

3. pH -- 7.4

4. Soil type -- Sandy loam

5. Calcium Mg/100 gm 898

6. Magnesium Mg/100 gm 62

7. Sodium Mg/100 gm 65

8. Potassium Mg/100 gm 27

9. P2O5 Mg/100 gm 19

10. Mn Mg/100 gm <0.001

11. Zn Mg/100 gm <0.001

12. Pb Mg/100 gm <0.001

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TABLE 3.5. 6 SOIL CHARACTERSTICS

Station : Gaurmuri Month : December, 2007 S. No. Parameter Unit Value 1. Bulk Density g / cc 1.8

2. Infiltration rate cm/hr 2.13

3. pH -- 7.3 4. Soil type -- Sandy loam

5. Calcium Mg/100 gm 897 6. Magnesium Mg/100 gm 74

7. Sodium Mg/100 gm 69

8. Potassium Mg/100 gm 42 9. P2O5 Mg/100 gm 30

10. Mn Mg/100 gm <0.001 11. Zn Mg/100 gm <0.001

12. Pb Mg/100 gm <0.001

TABLE 3.6.7

SOIL CHARACTERSTICS

Station : Ujalpur Month : December, 2007

S. No. Parameter Unit Value

1. Bulk Density g / cc 1.8

2. Infiltration rate cm/hr 1.9

3. pH -- 7.6

4. Soil type -- Sandy loam

5. Calcium Mg/100 gm 915

6. Magnesium Mg/100 gm 61

7. Sodium Mg/100 gm 69

8. Potassium Mg/100 gm 46

9. P2O5 Mg/100 gm 28

10. Mn Mg/100 gm <0.001

11. Zn Mg/100 gm <0.001

12. Pb Mg/100 gm <0.001

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TABLE 3.5. 8 SOIL CHARACTERSTICS

Station : Jamadbari Month : December, 2007 S. No. Parameter Unit Value

1. Bulk Density g / cc 1.85

2. Infiltration rate cm/hr 2.02

3. pH -- 7.2

4. Soil type -- Sandy loam

5. Calcium Mg/100 gm 902

6. Magnesium Mg/100 gm 70

7. Sodium Mg/100 gm 63

8. Potassium Mg/100 gm 44

9. P2O5 Mg/100 gm 30

10. Mn Mg/100 gm <0.001

11. Zn Mg/100 gm <0.001

12. Pb Mg/100 gm <0.001

3.6 BIOLOGICAL ENVIRONMENT The Flora and Fauna in the study area is shown in Table 3.6.

TABLE 3.6

Flora 1. Shorea Robusta ( Sal) 2. Anogeissus Latifolia (Dhaura) 3. Terminalia Tomentosa (Soja) 4. Terminalia Arjuna ( (Arjuna) 5. Diospyrose Melanoxylone (Tendu) 6. Madhuka Indica (Mahua) 7. Pterocarpus Marsupium (Bija) 8. Buchanania Lanzan 9. Cliestanthus Collinus 10. Char 11. Harad 12. Bahera 13. Amla 14. Mango 15. Black Berry

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DISCRIPTION OF FAUNA 1. Carnivorous Animals 1. Felis Pardus (Tendva) 2. Hyaena Striata 3. Felis Pardus (Tendva) 4. Hyaena Striata 2. Herbivorous Animals Gavaevs Gaurvs (Bisons) Bubalous Arni (Buffalos) Rusa Unicolor (Sambhars) Boselaphvs Tragocamelvs (Nilgai) Cervus Muntijack (Bherki) Tetracesus Quadricornis (Fourhorned Deer) Axis Axis (Chital) Gavaevs Gaurvs (Bisons) Bubalous Arni (Buffalos) Rusa Unicolor (Sambhars) Boselaphvs Tragocamelvs (Nilgai) Cervus Muntijack (Bherki) Tetracesus Quadricornis (Fourhorned Deer) Axis Axis (Chital) 3. Other Animals Melursus Ursinus (Slot Bear) Lepus Reficaudatus (Hares) Semnopithews entellus (Langurs) Sciurus indicus (Porcupine) Sus Scorpa (Wild Boar) Gazella gazella (Chinkara) Funambulus Pennanti (Five stripped Squirrel) Rats Banadicoots Mice Felis Chaus Vivericula Indica Herpestes Edwards Vulpes bengelensis 4. Birds Gallvs Ferrugineus Gallus Sonneratii Pterocies Excustus Francolinus Pictus Crocopus Chlorogestor Columba Liva Perdicula Sp. House Sparrow Crow Myna Bulbul Weaver Bird Ghagar Cuckoo Nilkanth Papeeha Great Horned OWL Duskey Horned Owl

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Night Jars Swifts Bee Eaters Swalloes Shrikes Pegions Fairy Birds Wegtails Podicipitidae Anatidae Accpitridae Paria Kite Haliasur Indus Nasiaetus Fasciatus HaliaetusL eucorypus Longbill Vultures Neophron Percnopterus Sarus Crane Anteropoides Virgo 5. Snakes 1. Cobras 2. Vipers 3. Kraits 4. Rat Snake 5. Wolf Snakes 6. Checkered Keet Back 7. Buff Strippes keel Back 8. Charvsopelea Ornata. 66.. AAQQ UUAATTIICC FFAAUUNNAA 1. Labeo Rohita 2. Catla Catla 3. Cirrhina mrigala 4. Kalbaus 5. Silondio Silondia 6. Wallago Attu 7. Mystus Seenghala 8. Catfish 9. Murral 10. Tilapia 11. Punti 12. Magur 13. Tangra 14. Sol.

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CHAPTER – IV ENVIRONMENT MONITORING PROGRAMME

4.0 INTRODUCTION Impact prediction is a very important phenomenon in evaluating the environmentally

potential adverse impacts for any proposed industrial project. The impact prediction is

always carried out under worst possible conditions so as to mitigate or to eliminate the

environmental hazards. These predictions thus calculated are superimposed over the

baseline data to calculate the net impact on the environment after the expansion project

comes into production.

4.1 AIR ENVIRONMENT

It is possible that increase in the background concentration of even a minor constituent of

the atmosphere may lead to significant changes in the atmospheric properties. So these

changes are essential in understanding potential climatic changes due to air pollutants. For

example under strongly stable condition, disturbances are highly damped and mixing of

pollutants is strongly suppressed. It is under such conditions that the worst air pollution

episodes have occurred.

Prediction of impacts is the most important component in the environmental impact

assessment studies. Several scientific techniques and methodologies are available to

predict impacts of developmental activities on physico, ecological and socioeconomic

environments. Such predictions are superimposed over the baseline (pre project) status of

environmental quality to derive the ultimate (post project) scenario of environmental

conditions. The prediction of impacts helps to identify the environmental management

plan required to be executed during and after commissioning the proposed expansion

project to minimize the adverse impacts on environmental quality.

The mathematical models are the best tools to quantitatively describe cause -effect

relationships between sources of pollution and different components of environment. In

4

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case, mathematical models are not available or it is not possible to identify / validate

through models for particular situation, prediction could be arrived at through available

scientific knowledge and judgments.

The mathematical model used for predictions in the present study include, steady state

Gaussian Plume dispersion model designed for multiple point sources for air quality,

Wave divergence and Federal Highway Administration (FHWA) models for noise levels.

In case of water, land, biological and socio-economic environments the prediction have

been made based on available scientific knowledge and judgments.

4.1.1 IMPACT ON TOPOGRAPHY AND CLIMATE

4.1.1.1 IMPACT ON TOPOGRAPHY

The major envisaged topographical changes would be limited to the immediate vicinity of

the plant. The change in topography will be only due to man made structures like

Industrial complex and Administrative building. Similarly, it will invite positive benefits

in the form of land leveling and green belt development in the plant vicinity.

4.1.1.2 IMPACTS ON CLIMATE

As the temperature of the effluent gases will not be high, generally this will not cause any

thermal imbalance as extensive greenbelt will be developed within the plant premises.

However, there will be natural dispersion of heat due to unstable conditions during day

and as such there would be no significant micro / macro climatological changes of any

consequence.

4.1.2 PREDICTION OF IMPACTS ON AIR ENVIRONMENT (TOR # 11)

It is absolutely essential to study the impacts of air pollution on its environs due to the

proposed Plant. These impacts are predicted with the help of Gaussian Mathematical

model. These models stimulate the relationship between air pollutant emissions from the

stack and the resultant impact on the air quality within the study zone. The pollutants

emitted into the atmosphere get diluted immediately and is transported and mixed with the

surrounding air. The basic purpose of these mathematical models are to represent these

processes mathematically. Computer models are used for predicting the Ground Level

Concentrations (GLC) for spatial variations.

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In the present case, computation of 24 hour average Ground Level Concentrations are

carried out using ATDM (All Terrain Dispersion Model). This model is based on the

algorithms of two USEPA dispersion models, ISCST2 and COMPLEX 1 and also

incorporates the procedure used in POSTIT post processor to calculate the concentrations

in intermediate terrain.

ATDM is based on Guassian dispersion, which incorporates the Pasquill Gifford

dispersion parameters for estimating the horizontal cross wind and vertical dispersion.

ALL TERRAIN DISPERSION MODEL

The All Terrain Dispersion Model (ATDM) is a Gaussian Dispersion model that calculates

the concentration from point, area and volume source emissions in simple, intermediate

and complex terrain.

v For receptors located in simple terrain (terrain below stack top) ATDM uses the

dispersion algorithms from ISCST2 model.

v For receptors located in complex terrain (terrain above plume centre line). ATDM

uses the dispersion algorithm from the COMPLEX 1 model.

v For receptors located in intermediate terrain, ATDM uses both ISCST2 and

COMPLEX1 algorithms to estimate the 24 hourly average concentration at each

receptor location and reports the larger of the two values as the calculated

concentration.

ATDM calculates the plume rise and plume and plume centre line elevation for a given

source to determine whether a receptor is located in a simple terrain, complex terrain or in

intermediate terrain w.r.t. source. Depending upon the terrain regime of the receptor, the

model then uses on of the three approaches described below to calculate the one-hour

average concentration at that receptor resulting from the emissions from the sources.

Simple Terrain

For receptors located in simple terrain (terrain below stack top), ATDM uses the

dispersion algorithms form the ISCST2 model. The ISCST2 model is a Gaussian

dispersion model that calculates concentrations using the pasquill – Gifford dispersion

coefficients (Rural mode) and the Briggs urban dispersion coefficients (Urban mode). As

in ISCST2, ATDM accounts for the effects of building down wash.

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User specified terrain stack base elevations are used in the ISCST2 dispersion calculations

according to EPA recommended approach for simple terrain. In this approach, the final

plume rise is calculated to determine the plume centerline elevation above the sea level

and this elevation is used for all downwind distances from the stack. Therefore, the plume

centerline remains parallel to sea level without regard to changes in the underlying terrain.

Complex terrain

For receptors located in complex terran (above plume centreline), ATDM uses the

dispersion algorithm from the COMPLEX1model. This algorithm is similar to that of the

ISCST2 model in that it uses the same Gaussian dispersion equation and plume rise

equations.

Intermediate Terrain

A receptor is said to be located in intermediate terrain if its elevation is greater that the

stack top elevation but less than that plume centreline elevation. For such receptors, EPA

recommends that both the ISCST 2 and COMPLEX dispersion algorithms be used to

estimate the 24 hourly average concentration at the receptor location and the larger of the

two values be used as the calculated concentration.

Multiple sources

When modeling multiple sources, ATDM sums the calculated one hour average

concentrations from each source to estimate the total concentration at a given receptor

location.

Model Input

Emissions

The emission data from the stacks is shown in Table 4.1.3

Receptor Locations

The software is capable of generating a polar receptor grid at every 10 radial

angles at specified distances (in Kms).

Meteorological data

For the prediction of rise in Ground Level concentrations of pollutants, the actual

meteorological data recorded at the site during the study period (December, 2007 -

February 2008) is used

For each hour the following meteorological information required

- Wind direction

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- Wind speed

- Ambient Temperature

- Stability class

- Mixing Height

Predictions have been carried out for these emissions considering the following points.

- Predictions have been carried out for 100% load where the maximum emissions

are emitted and which would be the worst environmental scenario.

- Predictions have been carried out for SPM, SO 2 and NOx.

- The emissions from other industries in the area are considered for modeling.

• Pasquill Stability Class Through Sigma Theta Method

Hourly meteorological data recorded hourly, at the continuous weather monitoring station

on wind speed and direction, has been used for calculating the stability by using Sigma

Theta method (Ref: On site meteorological program guidance for regulatory modeling

applications, US-EPA).

Calculation of standard deviation of wind direction:

Hourly wind direction has been recorded. The one hourly wind direction data (standard

deviation; σA) in degrees has been used for determining the hourly stability.

Lateral Turbulence (σA) and Wind Speed or Sigma Theta Method:

The hourly σA values calculated by the data logger are used for arriving at the hourly

stability's by the following procedure:

The following section describes the method of estimating stability categories in terms of

standard deviation of the lateral wind direction fluctuations (σA) and the scalar mean wind

speed (us). The lateral wind direction turbulence criteria for initial estimate of PG stability

category are given in Table - 4.1.1. The wind speed adjustments for determining final

estimate of PG stability category from σA is given in Table - 4.1.2. The criteria laid down

in the tables below are for the data collected at 10m and roughness length of 15 cm. Night

time is defined as the period from one hour before sunset to one hour after sunrise. The

method specifies that the data need to be collected at 10 m height. The relationship

employed in the estimation methods assumes conditions are of steady state.

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TABLE - 4 .1.1 LATERAL TURBULENCE CRITERIA FOR INITIAL ESTIMATE OF STABILITY

Initial estimate of Pasquill Stability

Category Standard deviation of horizontal wind direction fluctuations, σ A, in degrees

A 22.5 = σA

B 17.5 = σA < 22.5

C 12.5 = σA < 17.5

D 7.5 = σA < 12.5

E 3.8 = σA < 7.5

F σA < 3.8

TABLE - 4 .1.2

WIND SPEED ADJUSTMENTS FOR DETERMINING FINAL ESTIMATE OF PG STABILITY CATEGORY FROM σA

Initial Estimated

Category 10 m Scalar Wind Speed (US) (m/s)

Final Estimate of Stability Category

Day time A US<3 3<US<4 4<US<6

6<US

A B C D

B US<4 4<US<6

6<US

B C D

C US<6 6<US

C D

D, E or F ANY D Night time A US<2.9

2.9<US<3.6 3.6<US

F E D

B US<2.4 2.4<US<3.0

3.0<US

F E D

C US<2.4 2.4<US

E D

D ANY D E US<5.0

5.0<US E D

F US<3.0 3.0<US<5.0

5.0<US

F E D

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As site specific mixing heights are not available, the following mixing heights are

assumed. (TOR # 11)

STABILITY CLASS MIXING HEIGHT (M)

A 1300 B & C 900 D 750 E & F 400 Model Output

The output is same as that of ISCST2 model. The output contains the first through sixth

highest concentration values at each receptor, Maximum concentration tables and daily

concentration tables for each averaging period.

4.1.3 STACK HEIGHT CALCULATION

4.1.3.1 Stack Height Calculation For 2 X 100 TPD Kilns (Combined Stack )

STACK HEIGHT BASED ON SO2 EMISSION

Total coal consumption for 2 x 100 TPD kilns : 200 TPD

Max. Sulphur content in coal : 0.45% (By mass)

SO2 emission (Q) : 200 x 1000 x (0.45/100) x 2/24

: 75 kg/hr

: 14 (Q)0.3

: 14 (75)0.3

: 5.12 m or say 52 m

As 4 x 100 TPD kilns are proposed in the expansion, there will be two nos. of

combined Stacks (each with twin flues) of 60 m height will be provided for effective

dispersion of sulphur dioxide emissions into the atmosphere.

4.1.3.2 STACK HEIGHT CALCULATION (AFBC BOILER)

Consumption of Coal : 558 TPD

Sulphur content in Coal : 0.5 % (by mass, Max.)

SO2 emission : 558 X 1000 X 0.5 X 2/24 x 100

: 232.5 Kg/hr

Stack Height, H : 14(Q)0.3

: 14 (232.5)0.3 = 71.8 m

Say 72 m

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Hence a stack of 72 m height will be provided to the AFBC boiler stack for effective

dispersion of emissions into the atmosphere.

4.1.3.3 STACK HEIGHT CALCULATION (ROLLING MILL)

FO Consumption per Rolling mill : 11.9 TPD

Sulphur content in FO : 4.5 % (by mass, Max.)

SO2 emission : 11.9 X 1000 X 4.5 X 2/24x100

: 44.625 Kg/hr

Stack Height H, : 14 (Q)0.3

: 14 (44.625)0.3 = 43.75 m or say 45 m

Hence stack of 45 m height will be provided for effective dispersion of emissions into

the atmosphere.

Sources of Air Emissions :

The main sources of fugitive emissions are raw material unloading, raw material handling,

crushers of coal, material transfer points, storage bins, etc. Dust generated from raw

material unloading areas is controlled by providing dust suppression system. In other

areas specified above dust extraction system with bag filters will be provided to control

the particulate emission.

The waste flue gases from kilns will be allowed to pass through a Waste Heat Recovery

Boiler (WHRB) and then after heat recovery the gases will pass through an Electrostatic

Precipitator (ESP) to bring down the particulate matter to less than 50 mg/Nm3 and will be

let out into the atmosphere through two nos. of combined stacks (each with twin flues)

each of 60 m height for effective dispersion of emissions into the atmosphere.

Fumes will be evacuated directly from both the Induction Furnaces through a swiveling

type of hoods with an air-cooled ducting. The duct carrying fumes from the Induction

furnace and CCM will join a mixing chamber from where the gases will be led to the Bag

House by means of an ID fan. Clean gases having less than 50 mg/Nm3 of particulates will

be let out through two common stacks (with two flues) each of 30 m height.

In Reheating Furnace the fuel proposed to be used is FO. Stack of 45 m height will be

provided for effective dispersion of SO2 emissions into the atmosphere.

The primary & secondary fugitive emissions from submerged Electric arc furnaces from

Ferro alloys unit will be treated in Fume extraction & cleaning system comprising of

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suction hoods, bag filters etc . The outlet dust emissions in the exhaust gases will be less

than 50 mg/Nm3. The treated gases will be discharged into the atmosphere through stacks

of 30 m height (2 nos).

The waste flue gases from AFBC boiler will pass through an Electrostatic Precipitator

(ESP) to bring down the particulate matter to less than 50 mg/Nm3 and will be let out into

the atmosphere through a stack of 72 m height for effective dispersion of emissions into

the atmosphere.

The predicted max. incremental rise in SPM concentrations (24 hourly) will be 0.6µg/m3 at

a distance of 1100 m from the origin stack in the down wind direction over the baseline

concentrations.

The predicted max. incremental rise in SO 2 concentrations (24 hourly) will be 8.9 µg/m 3 at

a distance of 1100 m from the origin stack in the down wind direction over the baseline

concentrations.

The predicted max. incremental rise in NOx concentrations (24 hourly) will be 4.7 µg/m3

at a distance of 1100 m from the origin stack in the down wind direction over the baseline

concentrations.

The net resultant concentrations (Maximum baseline conc. + predicted incremental rise in

conc.) of SPM, SO2 and NOX are shown in Table No. 4.1.4. The net resultant

concentrations of SPM, SO2 and NOX are well within the National Ambient Air Quality

Standards (NAAQS) when the plant commences the operation. Hence there will not be

any adverse impact on air environment due to the proposed expansion project.

TABLE 4.1.3 STACK EMISSIONS

S. No. Stack attached to Dia (m)

Height (m)

Temp. of flue gas

(0C)

Velocity of flue gas (m/sec)

SPM (g/s)

SO2 (g/s)

NOx (g/s)

1.

Kilns(2 x 100 TPD) with WHRB (Stack # 1 with twin flues)

1.16 per flue

60 (Combined stack

with twin flues)

180 16

0.6 (< 50

mg/Nm3) per flue

15.1 per flue

6.0 per flue

2.

Kilns(2 x 100 TPD) with WHRB (Stack # 2 with twin flues)

1.16 per flue

60 (Combined stack

with twin flues)

180 16

0.6 (< 50

mg/Nm3) per flue

15.1 per flue

6.0 per flue

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2.

Induction Furnace & LRF (Common Stack) (Stack # 3 & 4)

1.0 30 100 15.0 0.5 --- ---

3. Reheating Furnace (Stack # 5) 1.0 45 180 15.0 0.4 0.8 2.3

4. AFBC Boiler (Stack # 6) 3.0 72 180 16.0 3.8 64.6 38

5. EAF (Stack # 7,8) 1.0 30 180 15.0 0.4 - -

6. DG Set (500 KVA) (Stack # 9)

0.25 7

(above building)

90 2.5 0.01 2.1 1.8

TABLE 4.1.4 NET RESULTANT MAXIMUM CONCENTRATIONS DUE TO THE

PROJECT

SPM (µg/m 3) SO2 (µg/m 3) NOX (µg/m 3) Maximum baseline conc. in the study area 141.4 12.0 14.2

Maximum predicted incremental rise in concentration

0.6 8.9 4.7

Incremental rise in Ground Level concentrations due to the proposed expansion of the other plants in the area

3.1 18.2 8.9

Net resultant concentrations during operation of the plant

145.1 39.1 27.8

National Ambient Air Quality Standards

200 80 80

4.2 PREDICTION OF IMPACTS ON WATER ENVIRONMENT

The proposed expansion project requires about 3700 cum/day of water. The total water

requirement after the expansion will be 3800 cum/day. This includes cooling water make

up for DRI, SMS, Rolling Mill, SEAF and in Power Plant Make-up water for Cooling,

make-up water for Boiler, DM Plant regeneration, service water and for domestic water.

The water requirement for the proposed expansion will be met from Chhuikansa Nallah /

Mahanadi River. The permission for withdrawal of water will be taken before operation of

the expansion project. There will not be any waste water generation from process and

cooling from the existing plant. The only waste water from the existing plant will be

sanitary waste water of 8 cum/day. The total effluent quantity expected from the proposed

expansion will be 383 cum/day and 391 cum/day inclusive of the existing plant. Closed

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circuit cooling system will be implemented and this will result in lower water consumption

and there will not be any effluent generation from the process & cooling in the steel plant.

The details of total water consumption, it's breakup and total waste water generation and

it's breakup are show in Table 4.2.1. & 4.2.2. Characteristics of waste are shown in Tables

4.2.3 to 4.2.6. The sanitary waste water will be treated in septic tank followed by soak pit.

Rain water Harvesting structures have been constructed in the existing plant and similarly it

will be continued with the help of Central Ground Water Board.. The depth of ground

water table will certainly increase. Hence there will not be any adverse impact on water

environment due to the proposed expansion.

TABLE 4.2.1

WATER REQUIREMENT FOR EXPANSION

S.No SOURCE QUANTITY (cum/day)

Existing Expansion Total

1. Cooling water make-up for DRI Plant 90 192 282 2. Cooling water make-up for SMS -- 120 120 3. Cooling water make-up for Rolling mill -- 75 75 4. Cooling water make-up for Ferro alloys plant -- 30 30 5. For Power Plant a. Cooling Tower Make-up -- 2880 2880 b. Boilers make-up -- 320 320 c. D.M. plant regeneration water -- 15 15 d. Service water -- 48 48 6. Domestic 10 20 30

Total 100 3700 3800

TABLE 4.2.2 WASTE WATER GENERATION FROM EXPANSION

SOURCE QUANTITY (cum/day)

Cooling tower blowdown 280

Boilers blowdown 24

DM plant regeneration 15

Service water 48

Sanitary waste water 24

Total 391

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TABLE 4.2.3

CHARACTERISTICS OF SANITARY WASTE WATER (UNTREATED)

PARAMETER CONCENTRATION

pH 7.0 – 8.5

BOD 200 – 250 mg/l

COD 300 – 400 mg/l

TDS 800 – 900 mg/l

TABLE 4.2.4

CHARACTERISTICS OF BOILER BLOWDOWN

PARAMETER CONCENTRATION

pH 9.5 – 10.5

TDS 1000 mg/l

TABLE 4.2.5

CHARACTERISTICS OF COOLING TOWER BLOWDOWN

PARAMETER CONCENTRATION

pH 7.0 - 8.0

TDS 1000 mg/l

TABLE 4.2.6

CHARACTERISTICS OF DM PLANT REGENERATION WATER

PARAMETER CONCENTRATION

pH 4 – 10

TDS 5000 – 6000 mg/l

4.3 PREDICTION OF IMPACTS DUE TO NOISE

4.3.1 PREDICTION OF IMPACT DUE TO THE PROPOSED ACTIVITY

The sound pressure level generated by noise source decreases with increasing distance

from the source due to wave divergence.

An additional decrease in sound pressure level with distance from the source is expected,

due to atmospheric effect or its interaction with objects in the path of transmission. For

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hemispherical sound wave propagation through homogeneous loss free medium, one can

estimate noise levels at various locations, due to different sources using model based on

first principle, as per the following equation:

Lp2 = Lp1 – 20 Log (r2/r1) - Ael.2

Where Lp1 and Lp2 are sound pressure levels at points located at distance r1 and r2 from

the source and Ae1.2 is the excess attenuation due to environmental conditions. Combined

affect of all the sources then can be determined at various locations by logarithmic

addition.

It is first approximation one can assume that for all general population in the villages, every

noise source in the plane is a point source. The average equivalent sound power level of

such a point source can be estimated for different distances and directions from

hypothetical source by applying following equation:

Lp = Lw - 20 Log r – Ae – 8

Where Lw is the sound power level of the source, Lp is sound pressure level at a distance r

and Ae is environmental attenuation factor. A combined noise level Lp (total) of all the

sources at a particular place is given by:

Lp(total) = 10 Log (10Lp1/10) + 10(Lp2/10) + ---------)

Major noise generating sources were identified from the proposed activity for prediction

purposes. The major noise generating sources are STG, DG set & compressors. The

predictions have been made to represent the worst case. The noise levels at various

distances were calculated using wave divergence model.

The model was run for ascertaining the areas where we could get the noise levels of 35,

45, 50,55,60,65, and considering the other noise generating sources from the plant.

Silencers will be provided to the DG Sets. All machinery will be manufactured keeping in

view of the MOEF/OSHA standards on Noise levels. The Ambient Noise levels will be

within the standards prescribed by MOE&F, GOI vide Notification dated 14-02-2000 under

the Noise pollution (regulation & control) Rules, 2000.

4.3.2. PREDICTION OF IMPACTS ON COMMUNITY Day and Night sound pressure levels, Ldn is often used to describe the community noise

exposure which include 10 dBA night time penalty. As the nearest human settlement is

about 2.5 Km. from the plant, the impact of noise on general population would be

insignificant.

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As per the WHO recommendation, there is no identified risk and damage of hearing due to

the noise levels (Leq = 8 hours) less than 75 dBA. Most of the international damage risk

criteria for hearing loss permit (Leq = 12 hours) upto 87 dBA. Further, WHO

recommendation on community noise annoyance, permits day time out door noise levels

of 55 dBA. Leq and night time outdoor noise level of 45 dBA leq to meet sleep criteria

i.e. Leq (24 hours) = 52.2. dBA and Ldn = 5.5 dBA.

4.3.3. PREDICTION OF IMPACT ON OCCUPATIONAL HEALTH

The damage risk criteria as enforced by OSHA (Occupation Safety and Health

Administration) to reduce hearing loss, stipulates that noise level upto 85 dBA are

acceptable for 8 hour working shift per day. Plant authorities will provide ear plugs to the

employees and will be enforced to be used by the employees.

4.4 PREDICTION OF IMPACTS ON LAND ENVIRONMENT 90 acres of land is in the possession of the management. As there are no endangered

species in the vicinity of the proposed activity, there should not be any concern for the loss

of important germoplasm that needs conservation.

The flue gases from the kilns will pass through Waste Heat Recovery Boiler & then

through ESP to bring down the particulate emission to less than 50 mg/NM3 and will be

discharged through two nos. of combined stacks (each stack with twin flues) each of 60m

height for effective dispersion of emissions into the atmosphere.

To control the fugitive emissions dust extraction system and dust suppression syste m will

be installed at all the possible dust emanating areas. All required pollution control systems

will be installed in the proposed expansion project. Hence it will not have any impact on

nearby top soil.

There will not be any process waste water & cooling water blowdown from the steel plant

as closed circuit cooling system is proposed in the expansion. The boiler blowdown, DM

plant regeneration water from the power plant will be treated in a neutralization tank and

utilized for onland for irrigation within the premises. Zero effluent discharge will be

maintained after expansion also. Hence there will not be any adverse impact on land

environment due to the proposed expansion project. Solid waste generated from the plant

will be disposed / utilized as per the norms. Hence there will not be any adverse impact on

land environment due to the proposed expansion project.

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The land use pattern of the study area will certainly improve due to the proposed activity.

Land price in the area will increase and will benefit the local people. This industry may

attract some ancillary works also which will also help in improving the land use pattern of

the area. Greenbelt is considered essential for maintaining the stability of the environment

of the area. 30 Acres of extensive greenbelt will be developed in the plant including

existing Greenbelt.

4.5 PREDICTION OF IMPACTS DUE TO VEHICULAR MOVEMENT (TOR # 10)

All the trucks used for transportation of raw materials will be covered. Hence there will

not be any fugitive dust generation during transportation of raw materials. Pucca road exist

upto the site. The existing road is capable of absorbing this additional truck movement.

Hence there will not be any adverse impact on vehicular traffic due to the proposed

expansion project.

4.6 PREDICTION OF IMPACTS ON SOCIO ECONOMIC ENVIRONMENT

The local areas will be benefited by way of generation of employment opportunities,

increased demand for local products and services. There will be an overall improvement

in the income level of the local people.

The project creates employment to about 250 persons once the plant is commissioned and

for 500 persons during construction stage. Priority will be given to locals for Semi-Skilled

and Unskilled jobs. With the implementation of the proposed expansion project, there will

be lot of scope for more industrial investments which in turn will benefit the nation.

The project authorities intend to provide welfare activities recreational facilities in the

surrounding villages once the expansion plant commences production. The project

authorities intend to conduct regular health checkups in the surrounding villages.

Therefore there will be a certain enhancement of educational and medical standards of

people in the study area. There will be generally positive and beneficial impacts by way of

economic improvements, transportation, aesthetic environment and business generation.

There will be an overall upliftment of socio-economic status of people in the area.

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CHAPTER – V

Analysis of Alternatives

(Technologies and Site)

5.1 ALTERNATIVE TECHNOLOGIES Production of sponge iron, Induction Furnace with Concast to produce Billets, Rolling

Mill to produce TMT bars Ferro alloys by Submerged Electric Arc Furnace are well

proven technologies all over the world. Hence no technological failures are anticipated.

Hence no alternative technologies are considered.

5.2 ALTERNATIVE SITES EXAMINED FOR SETTINGUP OF

STEEL PLANT BY M/S B.S. SPONGE PRIVATE LIMITED. M/s B.S. Sponge Private Limited is an operating a 200 TPD sponge Iron plant in

Taraimal Village, Gharghoda Tehsil, Raigarh District, Chhattisgarh. The existing plant

site is in accordance with MOEF guidelines.

Ø There is no habitation within 2.5 km. radius of the plant.

Ø There are no National Parks/Sanctuaries within 10 Km. radius.

Ø There are no historical places/places of tourist importance within 10 Km. radius

The proposed expansion will be taken-up in the existing plant premises only which is in

accordance with MOEF guidelines. Hence no alternative sites are considered.

5

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CHAPTER –VI ENVIRONMENT MONITORING PROGRAMME

6.1 TECHNICAL ASPECTS 6.1.1 METHODOLOGIES To know the effectiveness of environmental mitigation measures post project

environmental monitoring program will be strictly followed as per statutory requirement.

• Online monitors will be installed to rotary kilns to monitor particulate matter from

the exhaust gases after treatment in Electro Static Precipitator (ESP).

• Always particulate matter in the exhaust gas will be maintained below 50

mg/Nm3.

• In case if the stack emission is more than the stipulated standard, the interlocking

system proposed will stop the feed to the kiln and eventually there will not be any

production in the unit. Production in the unit will be restarted only when the Air

pollution control systems are able to achieve the norms.

• Energy meters will be provided to all air pollution control systems to ensure

effective operation of the control systems.

• The Fugitive emissions from the Induction furnaces will be sucked through hoods

and will pass through a fume extraction system & cleaning system with bag filters

and discharged into the atmosphere through a stack of 30m height. The outlet dust

emission will be less than 50 mg/NM3.

• The emissions from each of the Submerged Electric Arc Furnaces will be

controlled by providing a fume extraction system with bag filters and discharged

into the atmosphere through a stack of 30 m height. The outlet dust emission will

be less than 50 mg/Nm3.

6

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• Energy meters will be provided to all air pollution control systems to ensure

effective operation of the control systems.

• Fugitive emissions will be monitored and CPCB regulation in this regard will be

followed.

• All air pollution control systems will be taken-up for maintenance as per

prescribed dates and always ensure compliance with norms.

• CECB will also carry out stack monitoring and ambient air quality at regular

intervals. This will also help in cross checking the performance of Pollution

control systems implemented in the plant.

6.1.2 FREQUENCY & LOCATIONS OF ENVIRONMENTAL MONITORING A comprehensive monitoring programme is given under. This environmental monitoring

will be entrusted to a third party.

MONITORING SCHEDULE FOR ENVIRONMENTAL PARAMETERS

S. No. Particulars Frequency of Monitoring

Duration of sampling

Parameters required to be monitored

1. Water & Waste water quality A. Water quality in the

area Once in a month except for heavy metals which will be monitored on quarterly basis.

Composite sampling (24 hourly)

As per IS: 10500

2. Air Quality A.

Stack Monitoring

Online monitor (for major stacks) Once in a month

SPM SO2 & NOx

B. Ambient Air quality

Twice a week 24 hours continuously

RPM, SPM, SO2 & NOx

C. Fugitive emission monitoring

Once in a month Particulate matter.

3. Meteorological Data Meteorological data to be

monitored at the plant. Daily Continuous

monitoring Temperature, RH, rainfall, wind direction & speed.

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6.1.3 DATA ANALYSIS All the parameters will be analysed as per IS procedures specified for those parameters.

All water samples will be analysed for various parameters as per IS: 10500 with the

specified procedures.

The methodology adopted for monitoring & analysis of RPM & SPM is as per IS: 5182

Part IV SO2 & NOx as per IS: 5182 Part II & Part VI respectively. Samples were analysed

for SO2 using improved West-Gaeke method for air samples using a spectrophotometer at

a wavelength of 560 nm.

Samples were analysed for NOx using Jacob and Hocheiser modified (Na-As) method,

for Air samples using a spectrophotometer at wavelength of 540 nm.

RPM & SPM in ambient air are found by using Respirable Dust Sampler (RDS).

6.1.4 REPORTING SCHEDULE After completion of analysis copies of all the analysis reports will be sent to the Ministry

of Environment & Forests and CECB on monthly basis. A copy of the report will be

maintained in the plant and will be made available to the concerned inspecting

authorities.

6.1.5 EMERGENCY PROCEDURES Whenever the Electro Static Precipitators fail to comply with the norms, then interlocking

system will immediately cut-off the supply of raw materials. The production will be re-

started after ensuring compliance with norms.

6.1.6 DETAILED BUDGET & PROCUREMENT SCHEDULES The budgetary allocation for Environmental monitoring is Rs. 20 Lakhs. Online monitors

will be installed prior to commissioning of the kilns proposed. A third party will be

engaged to monitor all the environmental parameters as per CPCB/CECB norms.

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Chapter – 7

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CHAPTER –VII

ADDITIONAL STUDIES

7.1 RISK ASSESSMENT (TOR # 22)

7.1.1 INTRODUCTION

Risk analysis deals with the identification and quantification of risks, the plant equivalent and

personnel are exposed to, due to accidents resulting from the hazards present in the factory.

Hazard analysis involves the identification and quantification of the various hazards that likely

to occur in the factory.

Both hazard and risk analysis very extensive studies, and require a very detailed design and

engineering information.

The various hazard analysis techniques that may be applied are Hazard and Operability

(HAZOP) studies, Fault - Tree Analysis (FTA), event tree analysis, failure and effects mode

analysis. Risk analysis follows an extensive hazard analysis. It involves the identification and

assessment of risks the neighboring populations are exposed to as result of hazard present. This

requires a through knowledge of failure probability, credible accident scenario, vulnerability of

populations etc. Much of this information is difficult to get or generate. Consequently, the risk

analysis is often confined to maximum creditable accident studies.

7.1.2 SCOPE OF THE STUDY

The scope of study includes the study of proposed operations, storage and handling of raw

materials with respect to Hazard Identification. Risk Assessment and preparation of Disaster

Management plan. Based on the Hazard Identification and analysis, the major disaster scenarios

would be worked out to estimate the consequence of failure. A Disaster Management Plan

(DMP) would also be evolved to meet the emergency situation including the occupational

health and safety.

7

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7.1.3 FIRE PROTECTION SYSTEM

The following Fire Protection system will be provided in the plant.

- Hydrant system covering the entire plant including all important auxiliaries and buildings.

The system will be complete with piping, valves instrumentation, hoses, nozzles and

hydrants, valves etc.

− Sprinkler system for cable galleries / vaults / spreader room etc.

− Portable extinguisher such as pressurized water type, carbon dioxide type and foam type

will be located at strategic locations through out the plant.

− Modular type carbon dioxide panel injection fire extinguishing system will be provided in

control equipment room, cable space below control room and at other unmanned electrical

and electronic equipment room.

The following pumps will be provided in the fire protection system.

Fire water pumps.

(Fire water reservoir is part of the main water reservoir)

a) AC motor driven fire water pumps for hydrant, medium velocity water spray system and

foam system.

b) AC motor driven fire water pumps for high velocity water spray system.

c) Diesel engine driven pump as stand by for the above.

d) Jackey pump 1 no. (AC motor driven) for maintaining pressure.

7.1.4 FIRE ALARM SYSTEM The fire alarm system proposed is given as following.

Cable areas, control room will be provided with Ionization and photo electric smoke detectors.

The above system will be designed as per the requirements of Tariff Advisory Committee

(TAC) of Insurance companies of India.

Suitable number of electric motor driven and diesel engine operated hydrant and spray pumps

with automatic starting will be provided for the above systems. The fire water pumps will take

suction from the fire water reservoir to be created in the plant area.

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7.1.5 METHODOLOGY OF MCA ANALYSIS

The MCA Analysis involved ordering and ranking of various sections in terms of potential

vulnerability. The following steps were involved in MCA Analysis.

• Preparation of an inventory of major storages and rank them on the basis of their hazard

properties.

• Identification of potentially hazardous storage sections and representative failure cases from

the vessels and the pipelines.

• Visualization of chemical release scenarios.

• Effect and damage calculation from the release cases through mathematical modeling.

• Inventory Analysis and Fire & Explosion and Toxicity Index (FETI) are the two techniques

employed for hazard identification process.

7.1.6 FIRE & EXPLOSION AND TOXICITY INDEX The role of Fire & Explosion Index (FEI) aids quantitative hazard identification. The FEI is

calculated by evaluating the loss potential of all the units in the storage area and the hazardous

areas were classified accordingly. The role of FEI is

• Identification of the equipment/areas that could likely contribute to the creation or escalation

of incident and relatively rank the incidents.

• Quantification of the expected damage of potential fire and explosion incidents.

• Preparation of guidelines for mitigating fire hazards.

The loss potential which could actually be experienced under the most adverse operating

conditions is quantitatively evaluated. The FEI is used for any operation in which a flammable,

combustible or reactive material is stored, handled or processed.

FEI = MF * GPH * SPH

Where MF : Material factor

GPH : General Process Hazard

SPH : Special Process Hazard

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TOXICITY INDEX

The Toxicity Index is calculated using the Nh, Ts, GPH and SPH. TI is calculated by the

following formula.

(Nh + Ts) * (1 + GPH + SPH)

TI = -------------------------------------------

100

7.1.7 ASSESSMENT OF RISK AT M/s. BSPL

Based on the storage inventory the following areas are identified as potential safety risk areas

are shown in table 7.1

TABLE 7.1

POSSIBLE RISKS FROM THE PROPOSED STEEL PLANT

S. No. Area Capacity / quantity Hazards identified 1. Coal handling plant - Fire and or dust explosion 2. Coal storage 20,000 tones Fire, spontaneous combustion 3. FO storage 2 x 35 KL Fire

7.1.7.1 COAL HANDLING PLANT - DUST EXPLOSION

Coal dust when dispersed in air and ignited will explode. Crusher houses and conveyor systems

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 any warning with

maximum explosion pressure upto 6.4 bars. Another dangerous characteristic of dust explosions

is that it sets off secondary explosions after the occurrence of initial dust explosion.

Stock pile area shall be provided with automatic garden type sprinklers for dust suppression as

well as to reduce spontaneous ignition of coal stock piles, necessary water distribution net work

will be provided for distributing water at all transfer points, crusher house, control room, etc.

A centralized control room with microprocessor based control system has been envisaged for

operation of the coal handling plant. Except locally controlled equipment like travelling tripper,

dust extraction / dust suppression / ventilation equipment, sump pumps, water distribution

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system all other in line equipment will have provision for local control as well. All necessary

inter local control panels 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 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 at normal rise

in temperature inside the stock pile to be enable to control the same.

7.1.8 RISK & CONSEQUENCE ANALYSIS OF FIRE

The principle objective of this study is to identify the potential hazards estimate the effects of

hazards to people both with in and outside the plant premises.

− Identification of possible failure cases of the facilities which might affect the population and

property within the plant boundary.

− Assessment of consequential effect on surrounding population, property etc., due to onset of

such failures.

− Suggest recommendations based on consequence analysis relevant to the situations.

7.1.8.1 METHODOLOGY

The hazards expected from this plant include the pool fire situation due to the leakage of FO

from the storage tank. There will be two nos. of FO storage tanks each of 35 KL capacity. The

tank will be made of Mild steel and will be provided with dyke around the tanks. The most

credible failure is due to the rupture of the pipe connecting the storage tank. The worst case can

be assumed as when the entire contents leak out into the dyke forming a pool, which may catch

fire on finding source of ignition.

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FO STORAGE TANK - POOL FIRE SCENARIO

The maximum quantity of FO stored at site will be 2 x 35 m3 capacity. In the event of tank

spilling its contents through a small leakage or due to rupture of pipeline connecting the tank

and on ignition fire will ensue. As the tanks are provided with dyke, the fire will be confined

within the dyke. Threshold limit for first degree burns is 4.5 kw/m2. Based on these results it

may be concluded that the vulnerable zone in which the thermal fluxes above the threshold limit

for first degree burns (4.5 kw/m2) is restricted to 17 m.

The hazard distances for various radiation intensities are shown in table 6.4

TABLE 6.4

HAZARD DISTANCES (Two Tanks on fire - scenario)

FO Quantity: 2 x 35 m3

Radiation intensity HAZARD DISTANCES

37.5 kw/m2 (100% lethality) 3 m

25.0 kw/m2 (50% lethality) 6 m

12.5 kw/m2 (1% lethality) 11 m

4.5 kw/m2 (1st degree burns) 17m

The hazard distances for Thermal radiation are confined to the plant premises only. Hence there

will not be any thermal radiation impact on outside the popula tion due to the pool fire scenario.

The thick green belt to be developed will help to further mitigate the radiation intensity level

outside plant boundary.

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7.1.8.2 GENERAL FIRE HAZARDS WITHIN THE PROPOSED

EXPANSION ACTIVITY

The potential hazardous operations and processes in the system are listed below.

1. Cable Galleries

For containment 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 would 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 avoid spreading of fire, all cable entries / openings in

cable galleries, channels, barriers etc. Will be sealed with non inflammable /fire resistant sealing

material. Instrument cables will be fire Resistant low smoke type.

7.1.8.3 EFFECTIVE CONTROLS

Ignition sources in the vicinity. Pressurisation of buildings not having explosion - proof fittings,

switching off power supply from a central place, blanket ban on smoking, proper maintenance

of flame proof fittings.

The thick green belt to be developed will help to mitigate the radiation intensity level outside

plant boundary.

7.2 DISASTER MANAGEMENT PLAN

7.2.1 DISASTERS

A disaster is catastrophic situation in which suddenly, people are plunged into helplessness and

suffering and as a result, need protection, clothing, shelter, medical and social care and other

necessities of life.

Disasters can be divided into two main groups. In the first, are Disasters resulting from natural

phenomena like earthquakes, volcanic eruptions, cyclones, tropical storms, floods, avalanches,

landslides etc. The second group includes disastrous events occasioned by man, or by man's

impact upon the environment. Examples are industrial accidents, radiation accidents, factory

fires, explosions and escape of toxic gases or chemical substances, river pollution, mining or

other structural collapses, air, sea, rail and road transport accidents and can reach catastrophic

dimensions in terms of human loss.

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There can be no set criteria for assessing the gravity of a disaster in the abstract it depends to a

large extent on the physical, economic and social environment in which it occurs. What would

be considered a major disaster in developing country, will be equipped to cope with the

problems involved, may not mean more than temporary emergency elsewhere. However all

disasters bring in their wake similar consequences that call for immediate action, whether at the

local, national or international level, for the rescue and relief of the victims. This includes the

search for the dead and injured, medical and social care, removal of the debris, the provision of

temporary shelter for the homeless food, clothing and medical supplies, and the rapid

reestablishment of essential services.

7.2.2 OBJECTIVES OF DISASTER MANAGEMENT OF PLAN

The disaster Management Plan is aimed to ensure safety of life, protection of environment,

protection of installation, restoration of production and salvage operations in this same order of

priorities. For effective implementation of Disaster Management Plan, it will be widely

circulated and personnel training through rehearsals.

The Disaster Management Plan would reflect the probable consequential severity of undesired

event due to deteriorating conditions or through knock on effects. Further the management

should be able to demonstrate that their assessment of the consequences uses good supporting

evidence and based on currently available and reliable information, incident data from internal

and external sources and if necessary the reports of out side agencies.

To tackle the consequences of a major emergency inside the factory or immediate vicinity of the

factory, a Disaster Management Plan has to be formulated and this planned emergency is called

Disaster Management Plan. The objective of the Industrial Disaster Management Plan is to

make use of the combined resources of the Plant and the outside services to achieve the

following:

− Pool fire scenario due to FO storage

− Minimise damage to property and the environment.

− Effect the rescue and medical treatment of causalities.

− Provide for the needs of relatives.

− Provide authoritative information to news media.

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− Secure the safe rehabilitation of affected areas.

− Safeguard other people.

Initially contain and then ultimately bring the situation under the control.

Preserve subsequent records and equipment for subsequent enquiry the cause and circumstances

leading to emergency.

7.2.3 EMERGENCIES

7.2.3 1 GENERAL, INDUSTRIAL, EMERGENCIES

The emergencies that could be envisaged in the Plant are as follows:

− Pool fire scenario at FO storage tank

− Contamination of food / water.

− Sabotage / social disorder.

− Structural failures.

− Slow isolated fires.

7.2.3.2 SPECIFIC EMERGENCIES ANTICIPATED

During the study of risk assessment, the probability of occurrence of hazards are worked out

along with the nature of damage. This is the reason why one should study risk assessment in

conjunction with DMP.

7.2.3. 3 EMERGENCY ORGANISATION

It is recommended to setup an Emergency Organisation. A senior executive who has control

over the affairs of the Plant would be heading the Emergency Organisation. He would be

designated as Site Controller. In the case of stores, utilities, open areas which are the not under

the control of production heads, executive responsible for maintenance of utilities would be

designated as Incident Controller. All the Incident Controllers would be reporting to the site

controller.

Each Incident Controller, for himself, organises a team responsible for controlling the incident

with the personnel under his control. Shift in-charge would be the reporting Officer, who would

bring the incident to the notice of the Incident Controller and the Site Controller.

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Emergency Coordinators would be appointed who would undertake the responsibilities like fire

fighting, rescue, rehabilitation, transport and support services. For this purposes, Security in-

charge, Personal Department, Essential services personnel would be engaged. All these

personnel would be designated as key personnel.

In each shift, electrical supervisor, electrical fitters, pump house incharge and other maintenance

staff would be drafted for emergency operations. In the event of Power communication system

failure, some of staff members in the office/ Plant offices would be drafted and their services

would be utilised as messengers for quick passing of communications. All these personnel

would be declared as essential personnel.

7.2.3.4 EMERGENCY COMMUNICATION

Whoever notices an emergency situation such as fire, growth of fire, leakage etc. would inform

his immediate superior and Emergency Control Center. The person on duty in the Emergency

Control Centre, would appraise the site controller. Site controller verifies the situation from the

Incident Controller of that area or the shift incharge and takes a decision about implementing on

Site Emergency. This would be communicated to all the Incident Controllers, Emergency

Coordinators. Simultaneously, the emergency warning system would be activated on the

instructions of the Site Controller.

7.2.3.5. EMERGENCY RESPONSIBILITIES

The responsibilities of the key personnel are appended below 7.2.3.5.1 SITE CONTROLLER

On receiving information about emergency he would rush to Emergency Control Centre and

take charge of ECC and the situation and assesses the magnitude of the situation on the advice

of incident controller and decides.

• Whether affected area needs to be evacuated.

• Whether personnel who are at assembly points need to be evacuated.

• Declares Emergency and orders for operation of emergency siren.

• Organises announcement by public address system about location of emergency.

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• Assesses which areas are likely to be affected, or need to be evacuated or to be

altered.

• Maintains a continuous review of possible development and assesses the situation in

consultation with Incident Controller and other key personnel whether shutting down

the Plant or any section of the Plant required and if evacuation of persons is required.

• Directs personnel of rescue, rehabilitation, transport, fire brigade, medical and other

designated mutual support systems locally available for meeting emergencies.

• Controls evacuation of affected areas, if the situation is likely to go out of control or

effects are likely to go beyond the premises of the factory, informs to District

Emergency Authority, Police, Hospital and seeks their intervention and help.

• Informs Inspector of factories, Deputy Chief Inspector of factories, CECB and other

statutory authorities.

• Gives public statement if necessary.

• Keeps record of chronological events and prepares an investigation report and

preserves evidences.

On completion of on site Emergency and restoration of normalcy, declares all clear and orders

for all clear signal.

7.2.3.5.2 INCIDENT CONTROLLER

− Assembles the incident control team.

− Directs operations within the affected areas with the priorities for safety to

personnel, minimise damage to the Plant, property and environment and minimise

the loss of materials.

− Directs the shutting down and evacuation of Plant and areas likely to be adversely

affected by the emergency.

− Ensures that all-key personnel help is sought.

− Provides advice and information to the Fire and Security officer and the local Fire

Services as and when they arrive.

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− Ensures that all non-essential workers / staff of the effected areas evacuated to the

appropriate assembly points and the areas are searched for causalities.

− Has regard to the need for preservation of evidence so as to facilitate any enquiry

into the cause and circumstances, which caused or escalated the emergency.

− Coordination on with emergency services at the site.

− Provides tools and safety equipments to the team members.

− Keeps in touch with the team and advise them regarding the method of control to be

used.

− Keep the site Controller of Emergency informed of the progress being made.

7.2.3.5.3 EMERGENCY COORDINATO R - RESCUE, FIRE FIGHTING

− On knowing about emergency, rushes to Emergency Control Centre.

− Helps the incident controller in containment of the emergency.

− Ensure fire pumps in operating conditions and instructs pump house operator to be

ready for any emergency.

− Guides the fire fighting crew i.e. Firemen trained Plant personnel and security staff.

− Organises shifting the fire fighting facilities to the emergency site, if required.

− Takes guidance of the Incident Controller for fire fighting as well as assesses the

requirements of outside help.

− Arranges to control the traffic at the gate and the incident area / Directs the security

staff to the incident site to take part in the emergency operations under his guidance

and supervision.

− Evacuates the people in the Plant or in the near by areas as advised by site controller.

− Searches for casualties and arranges proper aid for them.

− Assembles search and evacuation team.

− Arranges for safety equipments for the members of his team.

− Decides which paths the evacuated workers should follow.

− Maintains law and order in the area, and if necessary seeks the help of police.

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7.2.3.5.4 EMERGENCY COORDINATOR - MEDICAL, MUTUAL AID,

REHABILITATION, TRANSPORT AND COMMUNICATION

− The event of failure of electric supply and there by internal telephone, sets up

communication point and establishes contact with the Emergency Control Center

(ECC).

− Organises medical treatment to the injured and if necessary will shift the injured to

near by hospitals.

− Mobilises extra medical help from outside, if necessary

− Keeps a list of qualified first aiders of the factory and seek their assistance.

− Maintains first aid and medical emergency requirements.

− Makes sure that all safety equipment are made available to the emergency team.

− Assists Site Controller with necessary data and to coordinate the emergency

activities.

− Assists Site Controller in updating emergency plan.

− Maintains liaison with Civil Administration.

− Ensure availability of canteen facilities and maintenance of rehabilitation centre.

− He will be in liaison with Site Controller / Incident Controller.

− Ensures availability of necessary cash for rescue / rehabilitation and emergency

expenditure.

− Controls rehabilitation of affected areas on discontinuation of emergency.

− Makes available diesel petrol for transport vehicles engaged in emergency operation.

7.2.3.5.5 EMERGENCY COORDINATOR – ESSENTIAL SERVICES

He would assist Site Controller and Incident Controller

− Maintains essential services like Diesel Generator, Water, Fire Water, Compressed

Air / Instrument Air, Power Supply for lighting.

− He would plan alternate facilities in the event of Power failure, to maintain essential

services such as lighting, etc.

− He would organize separate electrical connections for all utilities and during

emergency be coordinates that the essential services and utilities are not effected.

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− Gives necessary instructions regarding emergency electrical supply, isolation of

certain sections etc to shift incharge and electricians.

− Ensure availability of adequate quantities of protective equipment and other

emergency materials, spares etc.

7.2.3.5.6 GENERAL RESPONSIBILITIES OF EMPLOYEES DURING AN EMERGENCY

During an emergency, it becomes more enhanced and pronounced when an emergency warning

is raised, the workers if they are incharge of process equipment, should adopt safe and

emergency shut down and attend any prescribed duty as an essential employee. If no such

responsibility is assigned, he should adopt a safe course to assembly point and await

instructions. He should not resort to spread panic. On the other hand, he must assist emergency

personnel towards objectives of DMP.

7.2. 3.6. EMERGENCY FACILITIES

7.2.3.6.1 EMERGENCY CONTROL CENTRE

For the time being office block is identified as Emergency control centre. It would have external

Telephone, Fax, facility. All the Incident controller officers, senior personnel would be located

here.

The following information and equipment are to be provided at the Emergency control centre

(ECC).

- Intercom, telephone

- P&T telephone

- Fire suit / gas tight goggles / gloves / helmets

- Factory layout, site plan

- Emergency lamp / torchlight

- Plan indicating locations of hazard inventories, Plant control room, sources of safety

equipment, work road plan, assembly points, rescue location vulnerable zones,

escape routes.

- Hazard chart

- Safe contained breathing apparatus

- Hand tools, wind direction, wind velocity indications

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- Public Address Megaphone, Hand bell, Telephone directories (Internal,

P&T).

− Address with telephone numbers and key personnel, Emergency coordinator.

− Important addresses, telephone numbers such as experts from outside, government

agencies neighboring industries etc.

− Emergency shut down procedures.

− Nominal roll of employees.

7.2.3.6.2 EMERGENCY POWER SUPPLY

Plant facilities would be connected to Diesel Generator and would be placed in auto mode.

7.2.3.6.3 FIRE FIGHTING FACILITIES

First Aid Fire Fighting equipment suitable for emergency should be maintained as per statutory

requirements per TAC Regulations. Fire hydrant line converting major areas would be laid. It

would be maintained as 6 kg / sq.cm. pressure.

7.2.3.6.4 LOCATION OF WIND SOCK

On the top of production block and on the top of administrative block wind socks would be

installed to indicate direction of wind during emergency period.

7.2.3.6.5 EMERGENCY MEDICAL FACILITIES

Gas masks and general first aid materials for dealing with chemical burns, fire burns etc. would

be maintained in the medical centre as well as in the emergency control room. Private medical

practitioners help would be sought. Government hospital would be approached for emergency

help.

Apart from Plant first aid facilities, external facilities would be augmented. Names of Medical

Personnel, Medical facilities in Raigarh will be prepared and updated. Necessary specific

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medicines for emergency treatment of Burns patients, and for those affected by toxicity would

be maintained.

Breathing apparatus and other emergency medical equipment would be provided and

maintained. The help of near by industrial managements in this regard would be taken on

mutual support basis.

7.2.3.7 EMERGENCY ACTIONS

7.2.3.7.1 EMERGENCY WARNING

Communication of emergency would be made familiar to the personnel inside the plant and

people outside. An emergency warning system would be established.

7.2.3.7.2 EMERGENCY SHUTDOWN

There are number of facilities which can be provided to help in dealing with hazard conditions.

The suggested arrangements are

# Stop feed

# Deluge contents

# Remove heat

# Transfer contents

Methods of removing additional heat include removal the normal cooling arrangements or use

of an emergency cooling system. Cooling facilities which is vaporising liquid may be

particularly effective, since a large increase in vaporisation can be obtained by dropping

pressure.

7.2.3.7.3 EVACUATION OF PERSONNEL

The area would have adequate number of exits and staircases. In the event of an emergency,

unconnected personnel have to escape to assembly point. Operators have to take emergency

shutdown procedure and escape. Time office maintains a copy of deployment of employees in

each shift at Emergency Communication Centre. If necessary, persons can be evacuated by

rescue teams.

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7.2.3.7.4 ALL CLEAR SIGNAL

At the end of emergency, after discussing with Incident Controllers and Emergency

Coordinators, the site controller orders an all clear signal.

7.3 OCCUPATIONAL HEALTH AND SURVEILLANCE (TOR # 23) Large industries where multifarious activities are involved during construction, erection,

testing, commissioning, operation and maintenance, the men, materials and machines are the

basic inputs. Along with the booms, the industrialization generally brings several problems

like occupational health and safety.

7.3.1 OCCUPATIONAL HEALTH

Occupational health needs attention both during construction and operation phases. However

the problem varies both in magnitude and variety in the above phases.

7.3.2 CONSTRUCTION & ERECTION

The occupational health problems envisaged at this stage can mainly be due to constructional

and noise.

To overcome these hazards, in addition to arrangements required to reduce it within TLV'S,

personnel protective equipments should also be supplied to workers.

7.3.3 OPERATION & MAINTENANCE

The working personnel should be given the following appropriate personnel protective

equipments.

• Industrial Safety helmets

• Crash helmets

• Face shield with replacement acrylic vision

• Zero power plain goggles with cut type filters on both ends

• Zero power goggles with cut type filters on both sides and blue colour glasses

• Welders equipment for eye and face protection

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• Cylindrical type earplug

• Ear plugs

• Canister gas masks

• Self contained breathing apparatus

• Leather apron

• Boiler suit

• Safety belt / line man's safety belt

• Leather hand gloves

• Asbestos hand gloves

• Canvas cum leather hand gloves with leather palm

• Industrial safety shoes with steel toe

• Electrical safety shoes without steel toe and gum boots

7.3.4 OCCUPATIONAL HEALTH

Pre employment medical examination shall be conducted. Full fledged hospital facilities shall be

made available round the clock for attending emergency arising out of accidents, if any. All

workers shall be medically tested once in a year and at the end of his term of employment.

Medical records of all employees will be maintained.

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7.4 SAFETY PLAN

Safety of both men and materials during construction and operation phases is of concern. The

preparedness of an industry for the occurrence of possible disasters is known as emergency

plan. The disaster in Project is possible due to collapse of structures and fire / explosion etc.

The details of fire fighting equipments to be installed are given below.

• Carbon dioxide

• Foam type

• DCP

• Soda acid type

• Fire buckets

• Fire hydrants

Keeping in view the safety requirement during construction, operation and maintenance phases,

M/s B.S. Sponge Private Limited has formulated safety policy with the following regulations.

− To take steps to ensure that all known safety factors are taken into account in the

design, construction, operation and maintenance of Plants, machinery and

equipment.

− To allocate sufficient resources to maintain safe and healthy conditions of work.

− To ensure that adequate safety instructions are given to all employees.

− To provide where ever necessary protective equipment, safety appliances and

clothing and to ensure their proper use.

− To inform employees about materials, equipments or processes used in the their

work which are known to be potentially hazardous to health and safety.

− To keep all operations and methods of work under regular review for making

necessary changes from the safety point of view in the light of experience and up to

date knowledge.

− To provide appropriate facilities for first aid and prompt treatment of injuries and

illness at work.

− To provide appropriate instructions, training and supervision to employees health

and safety, first aid and to ensure that adequate publicity is given to these matters.

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− To ensure proper implementation of fire preventive methods and an appropriate fire

fighting service along with training facilities for personnel involved in this service.

− To publish / notify regulations, instructions and notices in the common language

employees.

− To prepare separate safety rules for each type of process involved.

− To ensure regular safety inspection by a competent person at suitable intervals of all

buildings, equipments, work places and operations.

7.4.1 SAFETY ORGANISATION

7.4.1.1 CONSTRUCTION AND 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

advise on corrective actions, conduct safety audit, organise 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.

7.4.1.2 OPERATION & MAINTENANCE PHASE

When the construction is completed the posting of safety officers should be in accordance with

the requirement of factories act and their duties and responsibilities should be as defined there

of.

7.4.1.3 SAFETY CIRCLE

In order to fully develop the capabilities of the employees in identification of hazardous

processes and improving safety and health, safety circles would be constituted in each area of

work. The circle would consist of 5-6 employees from that area. The circle normally should

meet for about an hour every week.

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7.4.2 SAFETY TRAINING

A full fledged training centre will be established at M/s B.S. Sponge Private Limited. Safety

training will be provided by the safety officers with the assistance of faculty members called

from professional safety institutions and universities. In addition to regular employees, limited

contractor labours will also given safety training.

To create safety awareness safety films will be shown to workers and leaflets etc. will be

distributed.

− Compartmentation of the cable galleries, use of proper sealing techniques of cable

passages and crevices in all directions would help in localising and identifying the

area of occurrence of fire as well as ensure effective automatic and manual fire

fighting operations.

− Spread of fire in horizontal direction would be checked by providing fire stops for

cable shafts.

− Reliable and dependable type of fire detection system with proper zoning and

interlocks for alarms are effective protection methods for conveyor galleries.

− Housekeeping of high standard helps in eliminating the causes of fire and regular

fire watching system strengthens fire prevention and fire fighting.

7.4.3 HEALTH AND SAFETY MONITORING PLAN

All the potential occupational hazardous work places will be monitored regularly. The health of

employees working in these areas will be monitored once in a year

7.5 SOCIAL IMPACT ASSESSMENT (TOR #25) The local areas will be benefited by way of generation of employment opportunities, increased

demand for local products and services. There will be an overall improvement in the income

level of the local people.

The project creates employment to about 250 persons once the expansion project is

commissioned and for 500 persons during construction stage of expansion project. Priority will

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be given to locals for Semi-Skilled and Unskilled workers. With the development of this Plant

there will be lot of scope for more industrial investments which in turn will benefit the nation.

The project proponent intends to provide welfare activities recreational facilities in the

surrounding villages once the plant commences production. The project proponent intends to

conduct regular health checkups in the surrounding villages. Therefore there will be a certain

enhancement of educational and medical standards of people in the study area. There will be

generally positive and beneficial impacts by way of economic improvements, transportation,

aesthetic environment and business generation. There will be an overall upliftment of socio-

economic status of people in the area.

7.6 R & R ACTION PLAN The proposed expansion will be taken-up in the existing plant premises only. There is no

habitation in the proposed site for the expansion activity. Hence no Rehabilitation &

Resettlement Action Plan has been envisaged in the proposed expansion project.

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CHAPTER –VIII

PROJECT BENEFITS

8.1 PHYSICAL INFRASTRUCTURE

Once the expansion activity is commissioned, the socio-economic status of the local people will

improve and there by infrastructure facilities like communication systems will improve. There

will be improvement in infrastructure due to the proposed expansion project.

8.2 SOCIAL INFRASTRUCTURE (TOR # 25)

With the implementation of the expansion project, the socio-economic status of the local people

will improve substantially. The land rates in the area will improve in the nearby areas due to the

proposed expansion activity. This will help in upliftment of the social status of the people in the

area. Educational, medical facilities will certainly improve due to the proposed expansion

project.

8.3 EMPLOYMENT POTENTIAL

The proposed project creates employment to 500 people during construction and 250 people

during operation of the expansion project.

8.3.1 SKILLED

Total skilled employment in the proposed plant will be 35.

8.3.2 SEMI-SKILLED

Total Semi-skilled employment in the proposed expansion project will be 65. Priority will be

given to local people for semi-skilled jobs.

8

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8.3.3 UNSKILLED

Total Unskilled employment in the proposed expansion project will be 150. Top priority will be

given to local people for unskilled jobs.

8.4 OTHER TANGIBLE BENEFITS

The following are the other benefits to the area due to the proposed expansion project.

• Educational status will improve in the area

• Periodic Medical check-up will be carried out.

• Overall economic upliftment of socio-economic status of people in the area.

• Ancillary developmental activities will be created due to the establishment of the

proposed unit.

SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES PROPOSED

The following welfare measures have been proposed

Ø Supply of street lights

Ø Supply of furniture to school .

Ø Supply of free books to poor school children.

Ø Supply of computers to school

Ø Merit scholarships for school children.

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CHAPTER –IX

ENVIRONMENTAL COST BENEFIT ANALYSIS

At scoping stage Environmental Cost Benefit analysis is not recommended. All required

environmental protection measures will be implemented to comply with norms.

9

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CHAPTER –X ENVIRONMENT MANAGEMENT PLAN

10.0 INTRODUCTION The major objective and benefit of utilizing Environmental Impact Assessment in project

planning stage itself, is to prevent avoidable losses of environmental resources and values as a

result of Environmental Management. Environmental Management includes protection /

mitigation / enhancement measures as well as suggesting post project monitoring programme.

Environmental management may suggest revision of project site or operation to avoid adverse

impacts or more often additional project operations may have to be incorporated in the

conventional operation.

The industrial development in the study area needs to be intertwined with judicious utiliztion of

non-renewable resources of the study area and with in the limits of permissible assimilative

capacity. The assimilative capacity of the study area is the maximum amount of pollution load

that can be discharged in the environment without affecting the designated use and is governed

by dilution, dispersion, and removal due to physico-chemical and biological processes. The

Environment Management Plant (EMP) is required to ensure sustainable development in the

study area of the proposed plant site, hence it needs to be an all encompassive plan for which the

proposed industry, Government, Regulating agencies like Pollution Control Board working in

the region and more importantly the affected population of the study area need to extend their

cooperation and contribution. It has been evaluated that the study area has not been affected

adversely and is likely to get new economical fillip. The affected environmental attributes in the

region are air quality, water quality, soil, land use, ecology and public health.

10

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The Management Action Plan aims at controlling pollution at the source level to the possible

extent with the available and affordable technology followed by treatment measures before they

are discharged.

Environmental Management aims at the preservation of ecosys tem by considering the pollution

abatement facilities at the plant inception. In the upcoming modern steel plants, pollution

abatement has become an integral part of planning and design along with Techno economic

factors.

10.1 MANAGEMENT DURING CONSTRUCTION PHASE

Environmental pollution is inevitable during the construction phase. The project proponent

should take appropriate steps to control pollution during construction phase. The following are

the factors requiring control during construction phase.

10.1.1 SITE PREPARATION

At the time of construction there will be some quantity of soil and debris and produce unstable

material. The disturbed slopes shall be well stabilized before the on set of the monsoon. The

leveling operation will also involve piling up of backfill materials. Use of dust suppressant

spraying to minimize fugitive dust during construction activities is recommended.

10.1.2 WATER SUPPLY AND SANITATION

The employees at the plant shall be provided with water for their requirement and for the

construction activities. The existing shall be provided with sufficient and suitable toilet facilities

to allow proper standards of hygiene. These facilities would preferably be connected to a septic

tank and shall be maintained properly to have least environmental impact.

10.1.3 NOISE

Noise pollution is anticipated during the construction phase due to the usage of various

construction equipment such as mechanical vibrator, mixers etc. The noise effect on the nearest

inhabitations due to construction activity will be negligible. However, it is advisable that onsite

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workers working near the noise generating equipment shall be provided with noise protection

devices like earplugs.

10.1.4 MAINTENANCE OF VEHICLES

One should be very careful in selecting the site for vehicle maintenance, so as to prevent the

ground water contamination due to the spillage of oil. Both diesel and petrol engine vehicles

shall be maintained properly. Unauthorized dumping of waste oil should be prohibited. Wastes

should be disposed off to the CECB approved vendors.

10.1.5 WASTE

The solid waste shall be collected and disposed off as per norms.

10.1.6 STORAGE OF HAZARDOUS MATERIAL

The following hazardous materials need to be stored at the site during construction.

a. Gas for welding purpose

b. LDO

c. Painting materials

All these materials would be stored as per international safety standards.

10.1.7 LAND ENVIRONMENT

The proposed expansion will not create any major impact on land environment. As soon as the

construction activity is over the surplus earth will be utilised to fill up low lying areas, the

rubbish will be cleared and all in built surfaces will be reinstated. Appropriate vegetation will be

planned and all such areas shall be landscaped. 30 acres of extensive greenbelt will be

developed (inclusive of existing greenbelt) within the premises.

10.2 POST CONSTRUCTION PHASE

10.2.1 AIR EMISSION MANAGEMENT

The main sources of dust pollution are crushing operations of raw materials (such as, Iron ore/

Coal) and their transfer points. A separate dedusting system will be provided to control the dust

from various material transfer points by means of suitable ducting connected to an Induced

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Draught fan. The dust that is drawn from various points will be passed through bag filters. The

following table shows the various control systems proposed in the expansion project and their

outlet dust emissions. (TOR # 12)

S.

No. Stack attached to Control Equipment Particulate emission at the

outlet

1. Kilns(4 x 100 TPD) with WHRB

Electro Static Precipitators < 50 mg/Nm3

2. Induction Furnace & LF (common Stack)

Fume Extraction system with Bagfilters

< 50 mg/Nm3

3. AFBC Boiler Electro Static Precipitator < 50 mg/Nm3 4. Rolling Mill --- < 50 mg/Nm3

5. SEAF Fume Extraction system with Bagfilters

< 50 mg/Nm3

The gases from the kiln will pass through Waste Heat Recovery Boiler (WHRB) and after heat

recovery the gases will pass through state of the- art ESP. The particulate emission at the outlet

of Electro Static Precipitator will be less than 50 mg/Nm3. The flue gases after treatment in ESPs

will be let out through a combined stack (Twin flues) of height of 60 m.

10.2.1.2 DUST EXTRACTION SYSTEM

Dust extraction system with Bag filters will be provided at the following locations.

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10.2.1.1.2 BAG FILTER SPECIFICATIONS

SL. NO

Description Product House Cooler Discharge Intermediate Bin Stock House Coal Scr& Crusher House

Iron Ore Crushing

1 2 3 4 5 6 7 8 9 10

Type Gas Volume Gas Temperature Dust Dust Load at Inlet Material of Bags Max. Design Temp Treatment For Bag Stack Emission Filtration Area

Draft Forced Filter Type 20000 Cu-M/hr Ambient Sponge Iron, Char, Dolomite 10-15 gms/Cm.Mtr. Polyester Needled Felt Having A weight of 550 GSM. 130 Deg. Celsius Anti-adhesive Silicon Treatment 50 mg/Cu. Mtr. 205 Sq.m

Draft Forced Filter Type 20000 Cu-m/hr 100 Deg CelCius Sponge Iron, Char, Dolomite 12-30 gms/Cm.Mtr. Polyester Needled Felt Having A weight of 550 GSM. 130 Deg. Celsius Anti-adhesive Silicon Treatment 50 mg/Cu. Mtr 205 Sq.m

Draft Forced Filter Type 16000 Cu-m/hr 80Deg .CelCius Sponge Iron, Char 25-30 gms/Cm.Mtr. Polyester Needled Felt Having A weight of 550 GSM. 130 Deg. Celsius Anti-adhesive Silicon Treatment 50 mg/Cu. Mtr. 164 Sq.m

Draft Forced Filter Type 12000 Cu-m/hr Ambient . Coal, Dolomite, Iron Ore Fines 10-15 gms/Cu.Mtr. Polyester Needled Felt Having A Weight of 550 SM. 130 Deg. Celsius Anti-adhesive Silicon Treatment 50 mg/Cu. Mtr. 123 Sq.m

Draft Forced Filter Type 16000 Cu-m/hr Ambient Coal Dust 10-15 gms/Cu.Mtr. Polyester Needled Felt Having A Weight of 550 SM 130 Deg. Celsius Anti-adhesive Silicon Treatment 50 mg/Cu. Mtr. 164 Sq .m

Draft Forced Filter Type 16000 Cu-m/hr Ambient Iron ore Dust 10-15 gms/Cm.Mtr . Polyester Needled Felt Having A weight of 500 GSM 130 Deg.Celcius Anti-adhesive Silicon Treatment 50 mg/Cu. Mtr. 164 Sq .m

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10.2.1.1.3 TECHNICAL SPECIFICATIONS OF ELECTROSTATIC

PRECIPITATORS

APPLICATION: ESP FOR 100 TPD SPONGE IRON KILN (4 nos.)

ESP MAKE M/S. THERMAX LIMITED Design volume Am3/hr 70,000 Design Temperature Deg C 180 - 220 Maximum Inlet dust Load Gm/Nm3 18 Outlet Emission Mg/Nm3 50 Moisture in gas %w/w 17(at Heat Exchanger)

36 to 40 (at ESP) Collection area m 2 2600 Specific Collection Area m2/m 3/s 69.1 No. of gas passages 11 Velocity through ESP m/s 0.73 Residence Time sec 21.04 Migration velocity cm/s 7.08 Note: An interlocking system will be provided to each of the ESPs in such a way that

whenever the emission in the exhaust exceeds the standard, then the raw material feed to the kiln will be stopped. The unit will be restarted only when the pollution control systems are able to comply with Norms.

10.2.1.1.4 CONTROL OF EMISSIONS FROM DRI PLANT

Sl.No AREA OF AIR

POLLUTION Measures adopted for control

1.

RAW MATERIAL PLANT

1. All vibrating screens will be totally covered, to prevent the leakages of dust. 2.Through out the length, the conveyor is covered with G.I.Sheets to prevent the dust pollution 3. All the material handling systems will be connected with de dusting system. All the discharge points and feed points wherever the possibility of dust generation is there a de dusting suction point will be provided to collect the dust. 4. DUST SUPPRESSION SYSTEM- It is the most effective and successful system to prevent the fly-off of dust. Dust suppression system will be adopted to control the fugitive dust emanated during raw material unloading operations.

2. RAW MATERIAL STORAGE SYSTEM

1. All conveyors will be covered with G.I.Sheets to control the dust. 2. All bins will be totally packed and covered, so that there will not be any chance of dust leakage.

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i) Weigh feeders will be kept below the hopper and used to feed the known quantity of raw material per hour ; it also seals the discharge area. ii) All discharge and feed points wherever the possibility of dust generation is there, will be provided with dust suppression system. iii) All material transfer points will be connected with dust suppression water nozzles to avoid the pollution.

3. KILN FEED SYSTEM

The raw material will be fed into the kiln through a double pendulum valve, which seals the false air entry into the rotary kiln and gas leakage from the kiln. The chute will be sealed with a double pendulum flap.

4. MAIN PROCESSING SYSTEM KILN

Sealed system to avoid false air entry as well as exit. So that the desired quality can be produced. Hence there will not be any chance for pollution in this area.

5. KILN COOLER TRANSFER BUILDING -

The transfer point between kiln to coolers is completely sealed to avoid the false air entry and gas leakages.

6. ROTARY COOLER

1. The water will be circulated again and again. Hence there will not be any water pollution problem

2. There will be slip seals at cooler inlet & cooler outlet.The seals are also being lubricated to avoid falls air entry and gas leakages.

3. Cooler discharge and feed points wherever the possibility of dust generation is there will be provided with de dusting system.

7. WASTE GAS CLEANING SYSTEM

AFTER BURNING CHAMBER Then the gas passes through the After Burning Chamber (ABC) in which the combustion of carbon monoxide and un burnt carbon takes place by supplying required air .The basic purpose of after burning chamber is to eliminate the carbon monoxide content in waste flue gases. WHRB & ELECTRO STATIC PRECIPITATOR The gases from the kiln will pass through Waste Heat Recovery Boiler and after heat recovery, the gases will pass through an Electro Static Precipitator and the outlet dust emission in the exhaust gases will be <50 mg/Nm3. The clean gases will be emitted into the atmosphere through a combined stack of 60m for proposed Kilns.

8. PRODUCT SEPARATION SYSTEM:

1. All conveyors will be covered with G.I.Sheets, to control the dust emission.

2. All bins will be totally packed and covered. so that there will not be any chance for dust leakage.

3. Telescopic chutes will be provided below the hopper to

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discharge the product directly into the truck for dispatch to avoid the pollution.

4. All the above materia l handling systems will be connected with de-dusting system

5. All discharge points and feed points wherever the possibility of dust generation is there, a de-dusting system with Bag filter s will be provided .

6. The collected dust will be taken by pneumatic conveying system and stored in a dust storage bin.

7. Bag housing system In the bag house the dry dust will be collected in an enclosed housing containing fabric filter bags which are suspended inside the unit. The dust ladden air will be pushed or pulled through the filter bags, forming a dust cake to separate the particulate from the clean air. The collected dust will be taken by a pneumatic conveying system and stored in a dust storage bin.

Good House keeping: Good house keeping practices will be maintained in all sections of

the plant.

10.2.1.1.5 FUGITIVE EMISSIONS (TOR # 13)

Fugitive dust emissions are likely in the unloading areas, material transfer point, cooler

discharge area, product separation area, etc. Fugitive emission in the material unloading

area can be avoided by providing dust suppression system. More over the raw material

will be stored in covered sheds. Fugitive emission from material unloading operations,

material transfer points will be controlled fully with total enclosure and all the transfer

emission will be connected with extractor inlet point and will pass through a high

efficiency Bag Filter before discharging into the atmosphere. Fugitive emissions will be

regularly monitored in the plant area and CPCB stipulations regarding fugitive emission

control and monitoring will be strictly followed.

10.2.1.2 STEEL MELTING SHOP (TOR # 13) 10.2.1. 2.1 CONTROL OF SECONDARY FUGITIVE EMISSIONS The secondary emissions from the Induction furnaces, laddle furnace continuous casting

machine area will be extracted and treated in a fume extraction system.

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Fumes will be evacuated directly from induction furnaces through hoods with swiveling

mechanism and ducting. The fumes from LRF will be collected through a water cooled

hood and duct work. The duct carrying fumes from Induction furnaces and LRF will join

in a mixing chamber from where the gases will be led to the bag house by means of ID

fan. Clean gases having less than 50 mg/Nm3 of dust content will be exhausted through a

two common stacks (with 2 flues) each of 30 m height. A line diagram showing the fume

extraction system is enclosed as Fig.10.1.

Whenever Air pollution control systems fail, production in that unit will be stopped till

that air pollution control system is rectified.

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Water Cooled Duct Dust ID Fan Chimney Pneumatic System Dust Storage Bin

FUME EXTRACTION & CLEANING SYSTEM FOR SECONDARY FUGITIVE EMISSIONS (Fig 10.1)

Laddle Refining Furnaces – 2

Nos

F.D. Cooler

Bag House Induction

Furnace - II

Induction Furnace - I

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SPECIFICATIONS OF FUME EXTRACTION SYSTEM

FOR INDUCTION FURNACES

Volumetric Flow rate : 42400 m3 /hr

Inlet dust load : 10 gms/Nm3

Guaranteed outlet dust emission : <50 mg/Nm3

Type of bag filters : Pulse jet Pressure drop across bag filters : 25 mm wg

10.2.1.3 CONTROL FUGITIVE EMISSION FROM FERRO ALOYS PLANT

The emissions from each of the Submerged Electric Arc Furnaces will be controlled by

providing a fume extraction & cleaning system with bag filters and then let out into the

atmosphere through a stack of 30 m height. The out let dust emission will be less then 50

mg/Nm3.

Specifications Of Bagfilters

Description Details

Application Fume extraction system for furnace Gas Volume 42400 m3 / hr Gas Temperature 160-180o C Resistance 350 mm WC Inlet Dust Load 2.6 g / Nm3 Outlet Dust load < 50 mg/ Nm3 Dust Handled Fumes coming during the manufacturing

process of ferro alloys Bags size 160 mm x 5625 mm No. of Bags 600

Control Unit Solid state electric supply sequential

The primary & secondary fugitive emissions from each of submerged Arc Furnaces will be

extracted through similar type of hoods and these gases will then pass through a bag house

and after treatment these gases will be discharged into the atmosphere through a stack of 30 m

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height. 2 nos of stacks each of 30 m will be provided. The outlet dust emission from the

exhaust flue gases will be <50 mg/Nm3. A copy of the Fume extraction & cleaning system

shown as Fig: 10.2

Fume Extraction System: Fig – 10.2

Monitoring of Secondary fugitive emissions

The fugitive emissions of suspended particulate matter (SPM) will not exceed 1000 ug/m3 at a

distance of 10 m (approx.) from the sources mentioned below, where fugitive dust emissions

are anticipated. The measurement will be done preferably on 8- hour basis with high volume

sampler.

S. No. Area Monitoring Location

1. Raw material handling area

Wagon tippler, Screen area, Transfer Points, Stock Bin area

2. Crusher area Crushing plant, vibrating screen, transfer points

3. Raw material feed area Feeder area, Mixing area, transfer points 4. Cooler discharge area Over size discharge area, Transfer Points 5. Product processing area Intermediate stock bin area. Screening plant,

Magnetic Separation unit, Transfer Points, Over size discharge area, Product separation area, Bagging area

10.2.1. 4 POWER PLANT The flue gases from the FBC boiler will be treated in a state-of-the-art ESP and the outlet dust

emission will be less than 50 mg/Nm3 and after treatment the gases will be let out into the

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atmosphere through a stack of 72 m height for effective dispersion of emissions into the

atmosphere.

The specifications of ESP for the FBC Boiler will be as following TECHNICAL SPECIFICATIONS OF ESP (FBC BOILER)

Gas flow rate, m3/hr : 559832

Flue gas temperature (0C) : 170

Inlet dust concentration, gm/nm3 : 35

Guaranteed outlet dust

Concentration, mg/nm3 : 50 (at max. flow conditions)

Design pressure, mm wg : 300

Number of fields : Two

Pressure drop across the

ESP, mm wg : 25 (max)

Collection efficiency : 99.90%

10.2.1.5 DUST SUPPRESSION SYSTEM

Water sprinklers will be provided at the unloading areas of the raw materials for dust

suppression. Dust suppression system with plain water - comprising piping network, valves

pumps, instrumentation & control, water tank etc. will be provided.

10.2.1.6 INTERNAL ROADS

Internal roads will be asphalted to prevent the fugitive dust emission due to vehicular

movement.

10.2.1.7 COMPLIANCE ON CREP RECOMMENDATIONS (TOR # 17, 27)

All the CREP recommendations will be implemented & followed strictly. The following will

be the compliance of CREP recommendations.

Ø Continuous stack monitoring system is proposed for major stacks.

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Ø Energy meters will be installed for all the pollution control systems.

Ø Rain water harvesting pits are being constructed as per the guidelines issued by

CGWB.

Recommendations

a) The proposed air pollution control equipment will be installed prior to commissioning

the expansion plant.

b) Continuous monitoring system for particulate matter in the stacks will be provided.

c) Pressure drop measuring system will be installed to measure the pressure drop across

the bag filters.

d) All the internal roads shall be asphalted to reduce the fugitive dust due to truck

movement.

10.2.2 WATER POLLUTION MANAGEMENT

10.2.2.1 SMS, ROLLING MILL & FERRO ALLOYS

Closed circuit cooling system will be provided in DRI plant, cooling of Billets, TMT bars &

Ferro alloys. Hence there will not be any waste water generation from process and cooling in

the steel plant.

10.2.2.2 POWER PLANT

Total waste water generation from the proposed 12 MW WHRB based Power plant and 36

MW FBC based power plant is 367 cum/day (including sanitary waste water). The boiler

blowdown & DM Plant regeneration water will be treated in a neutralization tank and after

treatment it will be mixed with CT Blow down and treated service water. The treated effluent

will be stored in a Central Monitoring Basin (CMB). The treated effluent will be used for

onland for irrigation within the premises after ensuring compliance with CPCB/CECB

standards.

Total effluent generated (exc luding sanitary waste water) : 367 cum/day

Effluent to be used for Ash Conditioning & dust suppression : 75 cum/day

Effluent to be used for greenbelt development : 292 cum/day

Zero effluent discharge is being maintained in the existing plant and will be continued in the expansion also.

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Sanitary waste will be treated in septic tank by soak pit. ETP flow diagram is shown in fig 10.3

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10.2.3 SOLID WASTE (TOR # 20)

The solid wastes generated from the existing plant, expansion and after expansion are

shown below.

S. No Type of Solid waste

Existing Quantity (in TPD)

Expansion Quantity (in TPD)

After expansion Quantity (in TPD)

Disposal Proposed

1. Ash 60 434 494 Cement plants/Fly ash product manufacturers/brick manufacturers.

2 Slag (from SMS)

- 54 54 Used in Road construction

3 Wet scraper sludge

9.2 18.4 27.6 Given to brick manufacturers

4 Char 60 120 180 Completely utilized in FBC Boiler as fuel

5 Accretion slag

1.8 3.6 5.4 Used as sub base material in road construction

6. Ferro Manganese

- 55 55 To be reused in manufacture of Silico Manganese as it contains high MnO2 and Silicon

7. Ferro Silicon - 4.7 4.7 To be used in cast iron foundries.

8. Silico Manganese

- 27.5 27.5 To be used for road construction.

10.2.3 NOISE LEVEL MANAGEMENT

The major noise generating sources in the plant are STG, Boilers , Rolling mill and DG

set. The turbines will be of internationally reputed make and will be manufactured as per

OSHA & other international guidelines. Acoustic enclosure will be provided to STG. The

major noise levels will be confined to the working zones of the plant . The Leq of eight

hours will be within the prescribed standards. Community noise levels are not likely to be

effected due to the proposed thick green belt and attenuation due to the physical barriers.

The ambient noise levels will be less than 75 dBA during day time & less than 70 dBA

during night time. As the nearest habitation is about 2.5 Km. from the plant, there will not

be any adverse impact on habitations due to the proposed expansion activities.

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Recommendations

a) Acoustic enclosures to Turbine

b) The impact can reduced by adopting shock absorbing techniques.

c) The Noise absorption will improve by using hollow concrete blocks in the

construction of the proposed Plant.

d) Ear plugs shall be provided to the workers and this shall be enforced strictly.

e) Extensive greenbelt shall be developed for further attenuating the noise levels.

10.2.5 LAND ENVIRONMENT All the required Air pollution Control systems will be provided in the proposed

expansion project. The treated effluent will confirm to the CECB standards for onland for

irrigation. Hence there will not be any impact on land environment due to the proposed

expansion project. The solid waste generated from the project will be utilized as per

norms. Hence there will not be any adverse impact on land environment due to the solid

waste generated from the proposed expansion activities. Extensive greenbelt

development will have positive impact on land environment. Land prices in the area will

increase due to the proposed expansion project.

Recommendations

a) Land scaping can be done around the Administrative building, raw material storage

sheds etc. This will help in preserving the ecological conditions.

10.2.6. MEASURES FOR IMPROVEMENT OF ECOLOGY

There are no Wild life sanctuaries, Bird sanctuaries, National Parks within 10 Km. radius

of the plant. No significant vegetation occurs in and around the project site. No

significant fauna exists in the area. Hence there will not be any adverse impact on flora &

fauna due to the proposed expansion project.

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Recommendations

Plantation programme should be undertaken at several areas. They should include

plantation, along the internal and external roads and along the administrative buildings

and the stacking yards.

People should be educated and trained in social forestry activities by local governmental

and non-governmental organizations.

10.2.6.1 GREEN BELT DEVELOPMENT (TOR # 24)

Extensive greenbelt will be developed in addition to the existing greenbelt. The greenbelt

shall be developed simultaneously with the plant construction. This will further mitigate

the pollution impacts. 15 m wide greenbelt will be developed all around the plant. A

detailed greenbelt plan will be developed in as per CPCB guidelines in consultation with

local DFO.

Greenbelt plantation

Greenbelt will be developed in a set of rows of trees planted in such a way that they form

an effective barrier between the plant and the surroundings. The main purpose of

greenbelt development is to contribute to the following factors.

• To maintain the ecological homeostatus.

• To attenuate the air emissions from the kiln and the fugitive dust emissions.

• To prevent the soil erosion.

• To attenuate the noise levels.

.Plantation of grass, flowers, bushes and trees will be taken up to reduce the generation of

dust from the bare earth and to enhance the aesthetic value.

Plantation species

Plantation species will be considered based on the following.

• Suitable to the Geo-climatic conditions of the area.

• Mix of round, spreading, oblong and conical canopies.

• Ever green trees.

• Different heights ranging from 4m to 20m.

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Plantation for Arresting dust

Trees particularly having compact branching closely arranged leaves of simple elliptical

and hairy structure, shiny or waxy leaves and hairy twigs are efficient filters of dust. The

following species are suggested to arrest the dust

Alstonia Scholaris

Bauhinia purpurea

Cassia siamea

Peltoferrum ferrugineum

Butea monosperma

Tamarindus indica

Azadirachta indica

Plantation to absorb SO2 emissions

The following plants are suggested for plantation to absorb SO2 in the air.

Azadirachta indica

Albizia lebbeck

Alstonia scholaris

Lagerstroemia flosregineae

Melia azedarach

Minusops elangi

Poloyalthia longifloia

Plantation to reduce noise pollution

Trees having thick and flushy leaves with petioles are suitable. Heavier branches and

trunks of trees also deflect the sound waves. The following plant species are suggested to

reduce noise pollution.

Alstonia scholaris

Azadirachta indica

Melia monosperma

Grevillea peridifolia

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Tamarindus indica

Greavillea robusta

Plantation along the roads (Avenue plantation)

Alstonia scholaris

Cassia fistula

Bauhinia purpurea

Mimusops elangi

Pongamia pinnata

Polyalthia longifolia

Poluferrum ferrugineum

Lagerstroemia flosreginea

Cassia siamea.

Greenbelt development plan (TOR # 24)

• Local DFO will be consulted in developing the green belt.

• A greenbelt of 10 acres will be developed in the plant premises in addition to the

existing 20 acres of greenbelt. Hence total greenbelt after expansion will be 30

acres.

• A 15 m wide greenbelt will be developed all around the plant after

implementation of the expansion project.

• The tree species to be selected for the plantation are pollutant tolerant, fast

growing, wind firm, deep rooted. A three tier plantation is proposed comprising of

an outer most belt of taller trees which will act as barrier, middle core acting as air

cleaner and the innermost core which may be termed as absorptive layer

consisting of trees which are known to be particularly tolerant to pollutants.

• Greenbelt will be developed simultaneously with the construction of the plant as

per CPCB guidelines.

• 600 plants will be planted per acre.

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10.2.7. RAINWATER HARVESTING (TOR # 24)

Rainwater harvesting structures will be constructed to harvest the run-off water from roof

tops by laying a separate storm water drainage system for recharging of ground water.

4 nos. of rain water harvesting structures each of size 10m x 5m x 1.5 m will be provided

in the plant to recharge the precious ground water. Rain harvesting pits are being

constructed as per guidelines of State Ground Water Board.

10.3 POST PROJECT MONITORING STRATEGY

The monitoring of various environmental parameters is necessary which is part of the

environmental protection measures. Monitoring is an important feature because the

efficiency of control measures can only be determined by monitoring. A comprehensive

monitoring programme is given under.

Locations and frequency of monitoring as per the guidelines of CECB and MOEF are

tabulated below.

MONITORING SCHEDULE FOR ENVIRONMENTAL

PARAMETERS

S. No. Particulars Frequency of Monitoring

Duration of sampling

Parameters required to be monitored

1. Water & Waste water quality

A. Water quality in the area

Once in a month except for heavy metals which will be monitored on quarterly basis.

Composite sampling (24 hourly)

As per IS: 10500

2. Air Quality A. Stack Monitoring Online monitors

(major stacks) Once in a month

SPM SO2 & NOx

B. Ambient Air quality

Twice a week 24 hours continuously

RSPM, SPM, SO2 & NOx

C. Fugitive emissions Once in three months

8 hourly Particulate matter

3. Meteorological Data Meteorological data to be

monitored at the plant. Daily Continuous

monitoring Temperature, RH, rainfall, wind direction & speed.

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Infrastructure for Environmental Protection

Man Power

The project proponent shall provide a fully equipped laboratory to carry out the analysis.

The following manpower shall be provided on regular basis.

1. Environmental Engineer / Safety Officer

He should be a graduate engineer with adequate experience. He will be responsible for

implementing and monitoring the environmental impacts and all the safety aspects. He

should be a liasioning officer between the proposed plant and with regulatory agencies

like CECB, CPCB etc.

2. Chemist

He should be a qualified chemist to carry out the analysis of various samples.

3. Monitoring equipment and Consumables

Environmental monitoring during the operation phase of the plant will be entrusted to a

third party. Monitoring will be carried out as per CPCB/CECB norms. A budgetary

allocation of Rs 20 Lakhs will be earmarked for Environmental monitoring.

Noise levels

A sound level meter shall be purchased to record noise levels in different scales like A, B

and C with slow and fast response options at various generating source from D.G set

which will be used only when there is an interruption in the power supply.

10.4 COSTS FOR ENVIRONMENTAL PROTECTION (TOR # 26)

§ Capital Cost for Environment Protection for expansion project: Rs. 20 Crores

§ Recurring Cost for Environmental protection: Rs. 1 Crore per annum

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CHAPTER –XI SUMMARY

1. This expansion project envisages setting up of 120,000 TPA Sponge Iron, 1,62,000 TPA

Ingots/ Billets, 1,05,000 TPA Rolled products, Ferro alloys of 25000 TPA and 48 MW

electricity through WHRB & FBC routes. The proposed expansion will be taken-up in the

existing plant premises only.

2. The flue gases from the rotary kilns will be pass through Waste Heat Recovery Boiler and

after heat recovery the flue gases will pass through state-of-the-art ESP to bring down the

particulate matter in the exhaust gases to within 50 mg/Nm3 and will be discharged into the

atmosphere through a combined stack (Twin flues) of 60 m height. The secondary fugitive

emissions from the SMS will be treated in a fume extraction system and will be discharged

into the atmosphere through a stack of 30 m height. The gases from the FBC boiler will be

treated in an ESP to achieve < 50 mg/Nm3 and will be discharged into the atmosphere

through a stack of 72 m height for effective dispersion of emissions into the atmosphere The

resultant Ground Level Concentrations of SO2, NOX & SPM in the post expansion project

scenario are within the National Ambient Air Quality Standards (NAAQS). Hence there will

not be any adverse impact on air environment due to the proposed expansion project.

3. Interlocking system will be provided to ESP in such a way that , when the particulate matter

in the exhaust gas exceeds the norms the feed to raw material will stop and thereby no

production in the unit. The unit will restarted only when the air pollution control system is

able to comply with the norms.

4. Energy meters will be provided to air pollution control systems to ensure continuous

operation of the control systems.

11

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5. Dust extraction system with bag filters will be provided at material trans fer points, crushers,

junction towers, cooler discharge area, product separation area, etc.

6. Raw material unloading areas will be provided with water sprinklers to suppress the fugitive

dust.

7. All internal roads will be asphalted.

8. As closed circuit cooling system is proposed, there will not be any waste water generation

from process & cooling of steel plant activities. Boiler blowdown, DM plant regeneration

water will be neutralized and mixed with CT blowdown to Sanitary waste will be treated in

septic tank followed by soak pit. Hence there will not be any adverse impact on water

environment due to the proposed expansion project.

9. Dolochar generated from existing and expansion will be completely utilized in the FBC

based power plant in the same premises. Slag from SMS will be used sub base course

material in road construction. Ash/Dust from Bagfilters will be given to near by brick

manufacturers Hence there will not be any adverse impact on land environment due to the

proposed project.

10. 30 acres of extensive greenbelt (inclusive of existing greenbelt) will be developed in

consultation with local DFO.

11. Adequate fire protection & safety systems as per NFPA / TAC will be provided.

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Annexure - II DATA ON EXISTING PLANT (TOR # 15)

1. AIR EMISSIONS Analysis report of Stack issued by CECB is enclosed

2. WASTE WATER GENERATION Closed circuit system is being implemented in the existing plant hence there will not be any waste water generation from process and cooling Only source of waste water generation is sanitary waste water. This is treated by septic tank followed by soak pit.

3. SOLID WASTE MANAGEMENT

The quantities of the solid waste generated are as follows

S. No Type of Solid waste

Quantity (in TPD)

1. Ash 60

2 Slag (from SMS) -

3 Wet scraper sludge 9.2

4 Char 60

5 Accretion slag 1.8

These solid wastes generated are being disposed as per the norms.

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TOR COMPLIANCE S.No TERMS OF REFERENCE (ISSUED BY MoEF) Pg. No

1. Present land use should be prepared based on satellite imagery. Location of national parks / wildlife sanctuary / reserve forests within 10 km. radius should specifically be mentioned.

3-25

2. Permission and recommendations of the State Forest Department regarding impact of proposed expansion on the Taraimal forest located at 1 km.

Annexure - I

3. Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall should be collected.

3-1 to 3-2

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

2-4

5. List of raw material required, quantity and source should be included.

2-5

6. Design details of all the plants with manufacturing process and capacity along with quantity of final product to be manufactured should be included.

2-8 to2-18

7. Ambient air quality 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.

3-5 to 3-9

8. Residential colony should be located in upwind direction. Not applicable as Residential colony is

not proposed 9. The suspended particulate matter present in the ambient air must

be analyzed for the presence of poly-aromatic hydrocarbons (PAH), i.e. Benzene soluble fraction. Chemical characterization of RSPM and incorporating of RSPM data.

3-7 to 3-9

10. Impact of the transport of raw material and finished product on the transport system should be assessed and provided.

4-15

11. Determination of atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack based on site-specific meteorological features.

4-7

12. Plant-wise air pollution control measures proposed for the control of emissions from all the sources

10-4 to 10-13

13. Control of fugitive emissions as per CPCB guidelines for DRI plants and secondary emissions from blast furnace, primary and secondary emissions from Sinter plant.

10-8 to 10-13

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

3-7 to 3-9

15 Data on air emissions, wastewater generation and solid waste management for the existing plant should be incorporated

Annexure – II

16 Point-wise compliance to the specific and general conditions stipulated in the environmental clearance for the existing plant.

Not applicable as existing plant was not

under purview of MoEF.

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17 Permission for the drawl of 3,800 m3/day water from Mahanadi River/Chuinkansa nallah from the concerned department.and water balance data including quantity of effluent generated, recycled and reused and discharged is to be provided. Methods adopted/to be adopted for the water conservation.

3-29, 10-13

18 Surface water quality of nearby rivers (60 m upstream and downstream) and other surface drains at eight locations must be ascertained.

3-13 to 3-15

19 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.

3-18 to 3-26

20 Action plan for solid/hazardous waste generation, storage, utilization and disposal particularly char, fly ash and ferro alloy slag. Assurance that 100 % char will be used in the FBC boiler and copies of MOU regarding utilization of ash should be included

10-16

21 Generation and utilization of waste/fuel gases and their utilization in the CPP have to be set out.

2-18

22. Risk assessment and damage control needs to be addressed 7-1 to 7-17 23 Occupational health of the workers needs elaboration 7-17 to 7-21 24 Green belt development plan in 33 % area and a scheme for

rainwater harvesting have to be put in place. 10-19 to 10-22

25 Socio-economic development activities need to be elaborated upon

7-21 to 7-22

26 Total capital cost and recurring cost / annum for environmental pollution control measures.

10-22

27 Plan for the implementation of the recommendations made for the Steel Plants in the CREP guidelines must be prepared

10-13