bhushan steels or

BHUSHAN STEEL AND STRIP LIMITED

EIA / EMP FOR 3.1 MTPY INTEGRATED STEEL PLANT AT

AT MERAMANDALI, DIST. DENKANAL (ORISSA)

MECON LIMITED

RANCHI – 834 002

BHUSHAN STEEL AND STRIP LIMITED

EIA / EMP FOR 3.1 MTPY INTEGRATED STEEL PLANT AT

AT MERAMANDALI, DIST. DENKANAL (ORISSA)

MECON LIMITED

RANCHI – 834 002

11.S2.Q6BK September’ 2007

Bhushan Steel & Strips Limited EIA/ EMP Study for Modification-cum-Expansion

of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa)

© 2007 MECON Limited. All rights reserved (i)

CONTENTS Sl. No.

Description Page No.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

INTRODUCTION

PROJECT DESCRIPTION & ANNEXURES

PRESENT ENVIRONMENTAL STATUS & ANNEXURES

ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION

MEASURES

ENVIRONMENTAL MANAGEMENT PLAN (EMP)

EMP IMPLEMENTATION AND MONITORING.

DISASTER MANAGEMENT PLAN (DMP)

SOCIO-ECONOMIC IMPACT ASSESSMENT

ORGANISATION AND MANPOWER

ENVIRONMENTAL COST & PROJECT BENEFITS

CONSULTANT CREDENTIALS

1 – 1 to 1 – 8

2 – 1 to 2 – 31

2 sheets

3 – 1 to 3 – 22

7 sheets

4 – 1 to 4 – 28

5 – 1 to 5 – 30

6 – 1 to 6 – 8

7 – 1 to 7 – 24

8 – 1 to 8 – 15

9 – 1 to 9-4

10 – 1to 10 - 4

11-1 to 11-4



© 2007 MECON Limited. All rights reserved (ii)

LIST OF FIGURES

Fig. No.

Description Chapter No.

2-1 3-1 4-1 4-2

PROCESS FLOW DIAGRAM WIND ROSE DIAGRAM (3 SHEETS) FLOW CHART OF IRON MAKING PROCESS ISOPLETH OF SPM, SO2 & NOx

2 3 4 4

LIST OF DRAWINGS Sl. No.

Description Drawing No.

1. GENERAL LAYOUT OF PLANT DRG.No.MEC/11/14/Q6AT/DE/GN/50/0001

2. WATER BALANCE DIAGRAM DRG.No.BSSL/0/ISP/7-1 REV.-1

3. THE MATERIAL FLOW SHEET DRG.No.MEC/Q671/11/18/01

4. LOCATOR MAP SHOWING

MONITORING STATIONS

Drg. No. MEC/Q6BK/11/S2/01



© 2007 MECON Limited. All rights reserved 1 - 1

1.0 INTRODUCTION

1.1 General The Indian steel industry has recorded remarkable performance in recent years.

The industry is now capable of producing high quality materials to stringent

international specification for high-end applications. 21st century is widely

perceived to be the century of Asia and India is looked upon as one of the

economies with most promising prospects. This possesses a formidable

challenge as well as an opportunity to the Indian corporate sector. Bhushan Steel

& Strips Limited (BSSL) as the leading steel maker is in position to fulfill its role in

the nation’s quest for higher growth and development in the new millennium.

BSSL is the dominant player in steel producer in the country having its plants at

Shahibabad (UP) and Khapoli in Maharastra state etc. The national steel policy

has set a target of 60 million tonnes (MT) of steel production by 2010 and to

increase it to a level of 100 million tonnes by 2018. The major steel producers in

India are planning to expand their capacities in the tune with the national steel

policy formulation. BSSL is also not exception to that and therefore intends to

increase the capacity of its Steel Plant at Meramandali, Dhenkanal (Orissa) from

its present capacity of 1.5 MT per annum to 3.1 MT per annum of steel products.

The developments of industrial projects play a key role in the economic growth of

any country. Industrial process is invariably involving the conversion of raw

materials and resources into semi finished and / or finished products. During this

process, residues in the form of wastes will be formed. If the residues are not

recycled/ re-utilised they become waste and have to be discharged into

environment as pollutants. The degree to which the pollutants affect the physical

environment depends upon their quantitative and qualitative characteristics as

well as the receiving media.




Iron is perhaps the most important metal to the mankind and its principal alloy,

steel, is widely used for domestic, agricultural, industrial and defense purposes.

Per capita steel consumption is a major indicator of economic status of any

country. The growth of the steel industry significantly contributes to economic

growth as it generates employment both directly and also due to development of

downstream industries.

However, any industrial development process is accompanied by some

environmental problems. Proper planning at the conceptual stages can minimize

many of these problems. Once an industry is commissioned it becomes difficult

and expensive to retrofit pollution control equipment, as such incorporation of the

same at conceptual stage is the best alternative.

Setting up of an industry has both positive and negative impacts on the

environment. The negative impacts include environmental degradation and

adverse socio economic changes. It is the responsibility of scientists and

environmentalists to document the likely impacts so that they can be identified

and attempts are made to minimise the effects due to negative impacts and

maximise benefits due to the positive impacts. In this regards Environmental

Impact Assessment (EIA) and Environmental Management Plan (EMP) has been

considered as one of the most important documents for utilisation by all the

concerned to understand the environmental implications due to the proposed

development activity and take decisions in the best interest of the Environment.

1.2 Purpose of the Report

The purpose of EIA study report is to take stock of the prevailing quality of

environment, to assess the impacts of proposed industrial activity on

environment and to plan appropriate environmental control measures to minimise




adverse impacts and to maximise beneficial impacts. The following major

objectives have been considered:

Assess the existing status of environment.

Assess the impacts due to the modification-cum-expansion of project.

Suggest pollution control and ameliorative measures.

Prepare an action plan for implementation of suggested ameliorative

measures.

Suggest a monitoring programme to assess the efficacy of the various

adopted environmental control measures.

Assess financial considerations for environmental control plans.

In pursuance of Government of India Policy, under ‘The Environment (Protection)

Act 1986’ and Orissa State Pollution Control Board (OSPCB), the proposed

modification-cum-expansion will require clearance from environmental angle.

Bhushan Steel & Strips Limited entrusted MECON LIMITED (MECON) to prepare

an Environmental Impact Assessment and Environmental Management Plan

(EIA/EMP) report for their proposed modification-cum-expansion plant at

Meramandali, Dhenkanal in Orissa. The present report, an EIA/EMP report is

prepared based on monitored data for one season covering three months

(summer season). The present report is prepared in accordance with the

guideline of MOE&F & OSPCB.

For carrying out the Environmental Impact Assessment (EIA) study, the area

falling within 7 km radius of project site at Meramandali area has been

considered for generation of base line data with respect to present air quality,

water quality, noise level, soil quality, ecology, socio-economic and meteorology

etc. The site studies were carried-out during summer season in April, 2006 to

June 2006.




This EIA report has been prepared on the basis of environmental data generated

in and around the existing plant site during the summer season in the month of

April 2006 to June 2006. The data regarding meteorological conditions, air

quality, water quality, noise levels, soil quality, ecology and socio-economic

environment were generated in the study area falling within 7km radius with the

plant site as center.

An in-depth analysis of the baseline environmental data generated by actual field

monitoring and collected from various secondary sources has been carried out

for identifying and predicting the probable environmental impacts due to the

expansion of project. Reasonable assumptions have been made, wherever data

is found lacking. Based on the findings a suitable environmental management

plan has been suggested.

1.3 Project & Project Proponent

Bhushan Steel & Strips Limited (BSSL) is the project proponent. M/s Bhushan

Steel & Strips Limited (BSSL) is a reputed producer in the secondary steel

sector, with consumption of more than a million tonnes of HR steel coils without

themselves producing any HR steel coil. Therefore, depending on the availability

of funds, BSSL can plan to go for an integrated 3.1 Mt/yr HR steel coils plant as

backward integration without the botheration on the marketability of the products.

With the sound financial status of BSSL, the expected growth in consumption of

iron and steel in the country and no problem in marketability of HR coils, as

mentioned above, M/s BSSL have decided to install an integrated HR coils plant

and be in the primary steel sector. Hence, BSSL is contemplating to modify and

expand the existing 1.5 Mtpy integrated steel plant to 3.1 Mtpy level at

Meramandali in Dhenkanal district (Orissa).




1.4 Nature, Size, Location of the Project

The nature of project is ferrous metallurgical industries and fall under the

category of primary metallurgical industry including sponge iron manufacturing

and further processing to secondary metallurgical industry for HR coil product in

flat category.

The size of the project is 3.1 Mtpy of steel product through DR-BF-EAF-Rolling

mill route. M/s Bhushan Steel & Strips Limited (BSSL) is intending to modify the

existing 1.5 Mtpy integrated steel plant to 3.1 Mtpy level at Meramandali in

Dhenkanal (Orissa). This steel plant is based on the Directly Reduced Iron (DRI)

- Electric Arc Furnace (EAF), Blast Furnace –Ladle Furnace & RH-OB -

continuous casting – rolling mill route with waste heat recovery based captive

power plant(CPP).

The site is located between latitude 20°46’41” to 20°49’20” N and longitudes

85°15’22” to 85°16’21” E at Meramandali block of Dhenkanal district of Orissa.

Land measuring about 1664 acres falling under villages Sibpur, Narendrapur,

Itapo, and Asanabani in district Dhenkanal in Orissa had been selected for steel

plant. The plant is situated about 5 km from Meramanadali Railway Stations (on

Angul – Cuttack broad gauze main railway line). The National Highway no. 42

touches northern side of plant. The plant is 18 km from Angul and 42 km from

Dhenkanal. Nearest Railway station is Meramanadali on Eastcoast railway and

nearest port is Paradeep, which is more than 215 km away.

1.5 Project Importance to the Country/Region

The integrated steel plant is being set up with capital outlay of 6330 crores. This

will help the local economy directly as well as indirectly. The project will continue




to contribute to state as well as to national exchequer by way of taxes in the form

of excise duty, custom duty as most of the products are going to be exported.

Therefore project is having great importance to national economy.

In the state the project will generate jobs in the form of direct as well as indirect

employment for local people and local economy will flourish due to income

expenditure in the local market.

1.6 Scope of Study

This report shall contains various information’s on the existing environmental

attributes, including air, water, noise, solid waste, soil quality, ecology and socio-

economic patterns etc. The report evaluates the predicted impact of the

proposed plant activities on the environment. It also cover the various remedial

measures considered by plant management like air pollution control systems,

complete recycling of process cooling water, green belt development plans and

reuse of solid waste and other environmental management system which are

useful for control of environmental degradation due to the proposed steel plant. A

detailed coverage of the emission sources, emission control equipment,

background air quality levels, predicted air quality levels, meteorological

measurements, dispersion model and all other aspects of pollution have been

provided in this report. The draft Draft EIA/EMP has been discussed for the

adequacy and completeness in its the 69th Meeting of the Expert Appraisal

Committee (Industry) held during 4th – 6th July, 2007 for preparation of final

EIA/EMP. The EAC (I) recommended the following additional TORs for inclusion

in the revised EIA/EMP:

1. Point-wise compliance to the conditions stipulated for the existing 1.5 MTPA

plant by the MoEF.




2. Permission for the drawl of 1,29,600 m3/day water from Brahmani river 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. Action plan for the development of green belt in 33 % area.

4. Action plan for the utilization of 100 % char and coal washery rejects in FBC

boiler for the power generation and long term management plan for SMS slag

utilization should be incorporated.

5. An action plan to control and monitor secondary fugitive emissions as per

CPCB guidelines should be included

6. APCS for the control of emissions from the kiln and WHRB and utilization of

kiln gases in WHRB.

7. Use of BOD effluent for quenching should be included.

8. A plan for the adoption of dry coke quenching instead of wet quenching within

5 years should be incorporated.

9. Plan for the implementation of the recommendations made for the steel

plants in the CREP guidelines must be prepared.

The report includes the general structure of EIA given in Appendix III and IIIA in

the EIA Notification, 2006. The reply of point 1 shall be submitted separately

while other points are suitably incorporated in different chapters of EIA report.

The EIA report is structured as follows:

• Introduction

• Project Description

• Present Environmental Status

• Anticipated Environmental Impacts




• Environmental Management Plan(EMP)

• EMP Implementation and Monitoring.

• Disaster Management Plan(DMP)

• Social Impact Assessment

• Cost considerations and project benefits

• Consultant credentials etc

1.7 Acknowledgment

MECON wishes to place on record its deep appreciation for the trust reposed in

MECON by BHUSAN STEEL & STRIPS LIMITED (BSSL) for the EIA/EMP study

and also for the active interest and the help extended by the concerned officials

of BSSL. The Co-operation extended by the officials of various State and Central

Government agencies is also gratefully acknowledged.




2.0 PROJECT DESCRIPTION

2.1 General M/s Bhushan Steel & Strips Limited (BSSL) is proposing to modify and expand

1.5 Mtpy integrated steel plant to 3.1 Mtpy level at Meramandali in Dhenkanal

(Orissa). The steel plant is based on the Directly Reduced Iron (DRI) - Electric

Arc Furnace (EAF), Blast Furnace –Ladle Furnace & RH-OB - continuous casting

– rolling mill route with waste heat recovery based captive power plant(CPP).

The land measuring 1664.56 acres had been acquired by Orissa Industrial

Infrastructure Development Corporation (IDCO) and was transferred to Bhushan

Steel & Strips limited to set up integrated steel plant. A detailed report was

prepared earlier for selection of plant site at Meramandali and was the best site

as per the availability of Water, Power, infrastructure facilities and raw materials

particularly coal. Coal is one of the major raw materials for steel and power

generation and is available in Talcher coalfield within 45-50 km of Meramandali

site. This was one of the major factors for deciding this site for the steel plant.

2.2 Type of Project

The proposed project is an expansion–cum-modification of existing 1.5 Mtpy

integrated steel project at Meramandali, Dist Dhenkanal (Orissa). The plant is in

implementation stage and after the detailed analysis and economy of scale has

given impetus for modifying some of the facilities earlier proposed during 1.5

Mtpy stage and adding few other facilities to reach the level of 3.1 Mtpy

integrated steel plant.

2.3 Need for the Project The steel industry in India is poised for faster growth in the decades ahead as the

industrial and economic development of the country gains pace. Indian Steel




industry is also emphasizing its presence in the global market. The domestic

market growth outlook for finished steel has been estimated and is given below. Domestic Market Growth Outlook

Growth Trajectory 2006 – 07 (million tonnes) 2011 – 12 (million tonnes)

GDP @ 6.5% 39.5 - 40.7 57.8 - 59.9

The total steel consumption of finished steel has been estimated to touch 60 MT

in the year 2010-12 from the current level over 31 MT. Even after approximately

doubling the production capacity the per capita domestic consumption would

continue to be substantially below the world average of 145 Kg. There is good

prospect of domestic steel consumption growing at about 6 – 7% up to the year

2012. BSSL has drawn up a growth plan with the objective of increasing its

market share, including market penetration and maintaining its leading position in

Indian steel industry. One of the key objectives of BSSL is to be of a world-class

company and leader in Indian steel business by leveraging its key competencies.

This competency will enable BSSL to manufacture products at a lower cost and

more speedily than its competitors. Keeping all these in mind, BSSL has plan to

increase the production capacity of steel plant to 3.1 MT per annum steel

product and also to make technology up-gradation in different units in an

environment friendly way.

Since the present steel scenario is favorable to go for expanding the integrated

steel plant and Bhushan Steel & Strips Limited is in an advantageous position to

go for backward integration with a hot rolled plant upto a capacity of 3.1 million

tonnes per year. Presently HR coils are procured indigenously as well as

imported from foreign countries.




BSSL has initiated several steps as part of their backward integration programme

and this is one such step to establish 3.1 Mtpy integrated steel plant.

2.4 Location (Maps Showing General Location, Specific Location, Project Boundary, Project Site Layout) The Plant is located between latitude 20°46’41” to 20°49’20” N and longitudes

85°15’22” to 85°16’21” E at Meramandali block of Dhenkanal district of Orissa.

Land measuring about 1664 acres falling under villages Sibpur, Narendrapur,

Itapo, and Asanabani in district Dhenkanal in Orissa. The locator map showing

general topography and related feature is attached vide drawing no.

MEC/Q6BK/11/S2/01 sheet 1 of 1. The land is situated about 5 km from

Meramandali Railway Stations (on Angul – Cuttack broad gauze main railway

line). The National Highway no. 42 touches northern side of plant site. The plant

site is 18 km from Angul and 42 km from Dhenkanal. Nearest Railway station is

Meramandali on Eastcoast railway and nearest port is Paradeep, which is more

than 215 km away. The project layout is given in drg. No. MEC/11/14/Q6AT/DE/GN/50/001 sheet 1 of 1 REV.-5.

2.5 Size or Magnitude of Operation The size of the plant will be 3.1 Mtpy and plant operations shall confine to the

existing plant boundary and will not change the process route of operation as

given in the report.

2.6 Schedule for Approval & Implementation

Project planning The project envisages expanding existing project upto a 3.1 Mtpy Steel plant at

Meramandali, Orissa by M/s. Bhushan Steel & Strips Limited. The project will

involve the following main technological units:




Coal Washery (2.4 Mtpy)

Sinter Plant ( 1 x 177 m2)

DR Plants (14 x 170,000 tpy)

Blast Furnace ( 1 x 1681 m³)

SMS – I

Induction Furnace (12 x 15t)

Ladle Furnace (4 x 30t)

Billet Caster (2 x 2 strand)

SMS – II (Part)

Electric Arc Furnace (2 x 60t)


VD / VOD Unit (1 x 60t)

Conventional Slab Caster (1 x 1 stand)

SMS – II (Balance)

Electric Arc Furnace (2 x 180t)

Twin Shell CONARC Furnace 145 MVA


RH – OB Unit (1 x 180 t)

Conventional Slab Caster (1 x 1 strand)

Semi – continuous Hot Strip Mill

Pig Casting machine ( 2 x 2000 tpd)

Slag Granulation Plant

Power Plant (33 + 77 + 45MW)

Lime & Dolomite Plant

Oxygen Plant

In addition to the above main technological units, suitable supporting facilities

have also been envisaged like raw material handling facilities, compressed air




facilities, power distribution system, shop electrics and effluent and sewage

treatment plant, air conditioning & ventilation system, laboratories, etc.

The above project has been planned to be executed in 48 months from the

“Zero-Date”, which has been reckoned as “go ahead from MOE&F”.

2.7 Technology and Process Description

BSSL was granted NOC by MOE&F to set up 1.5 Mtpy plant at Meramandali

earlier in 2004-05. The main technological and auxiliary units for 1.5 Mtpy

integrated steel plant were as follows:

i) 3.2 Mtpy Coal Washery

ii) 8 x 170,000 tpy DR plant

iii) 1 x 100 m2 Sinter Plant

iv) 1 x 1250 m3 Blast Furnace

v) Pig Casting Machine

vi) 8x15t Induction Furnace(IF)

vii) 2 x 100 t+1x40 t Electric Arc Furnace

viii) 2 x 100 t+1x40 t Ladle Furnace

ix) 1 x 100 t RH-OB

x) 1.2 Mtpy Slab Caster

xi) 1.2 Mtpy Hot Strip Mill

xii) 0.3 Mtpy Billet Caster

xiii) 0.2 Mtpy Bar Mill

xiv) 1x300 tpd Oxygen Plant

xv) 2x300 t Lime Plant

xvi) 1 x 33 MW + 1 x 77 MW + 1 x 120 MW Power Plant (approx. 80 MW from

kilns hot gases and 30MW from AFBC boiler and 120 MW from CFBC

boiler)




xvii) Required services and auxiliary facilities

xviii) Matching Raw Materials Preparation Plant (RMPP)

The total plant schedule was expected to be completed by 2005 – 06.

Proposed Modification-Cum-Expansion of Plant

BSSL is now intends to augment their steel production capacity from 1.5 Mtpy to

3.1 Mtpy by suitable modification-cum-expansion in existing units proposed

earlier. These are as follows:

• One blast furnaces of capacity 1681 m3 instead of 1250 m3 earlier proposed

with cast house slag granulation facility,

• 2x2000tpd Pig casting machine

• One sinter plant of capacity 177 m2 instead of 100 m2 earlier proposed,

• Six additional DR kiln of 170000 tpy capacity

• The configuration also changed in SMS and casting facilities

• Three no Walking beam furnaces in the hot strip mill based on BF gas mixed

with LPG/Propane or mixed gas

• Two limited recovery coke oven battery of 0.45 Mtpy each to meet the coke

requirement of steel plant

• Lime and Dolo shaft to meet the flux requirement.

• 2.4 Mtpy coal washery instead of 3.2 Mtpy Coal Washery.

To supplement the auxiliary demands one 950 tpd Oxygen plant and

augmentation of raw material handling facilities is envisaged

The Plant Configuration at 3.1 Mtpy Stage

The ultimate plant facilities after the modification-cum-expansion shall be as

follows:




Table-2.1: The Plant Facilities at 3.1 Mtpy level Sl.

No. Description Units in 1.5 Mtpy

Stage(NOC Granted) The Plant Configuration at 3.1 Mtpy Stage

1. Coal Washery • 1x3.2 Mtpy • 1x2.4 Mtpy 2. Direct Reduction Iron

( DRI ) • 8 kilns x 170000tpy • 14 kilns x 170,000 tpy

3. Coke Oven Plant - • 2x0.45 Mtpy limited recovery type Coke Oven Batteries

4. Sinter Plant • 1x100 m2 • 1x177 m2 5. Blast Furnace • 1X1250M3 • 1 x 1681m3 6. Pig Casting Machine • 2x2000 tpd 7. Slag Granulation

Plant • 415500 tpy

8. Primary Steel making • 2 x 100 t+1x40 t EAF

• 8x15t Induction

Furnace (IF)

• 1 x 180 t CONARC • 2x60 t Electric Arc Furnace ( EAF) • 12x 15 t Induction Furnace ( IF )

9. Secondary refining • 2 x 100 t LF

• 1x40 t LF

• 1 x 100 t RH-OB

• 1 x 180t LF, • 2 x 60t LF and • 4x 30t LF, • 1x 60t VD/VOD unit, • 1 x 180 t RH-OB

10. Continuous Casting Plant

• 1.2 Mtpy Slab Caster • 0.3 Mtpy Billet Caster

• 2 x 1 strand slab caster and • 2 x 2 strand billet casters

11. Rolling Mill (HSM) • 1.2 Mtpy Hot Strip

Mill

• 0.2 Mtpy Bar Mill

• Conventional hot strip mill with 5-stand finishing train (2.514 Mtpy HR coils) and provision for 6th & 7th stand in future.

12. Lime & Dolo Plant • 2x300 t Lime Plant

• 1x500+1x100tpd lime plant • 1x500 tpd dolo plant

13. Power Plant • 1 x 33 +1x77+1x120 MW CFBC & WHRB based power plant

• 1 x 33+1x77 +1x45 MW WHRB based power plant

14. Oxygen Plant - • 1x950 tpd Oxygen Plant 15. Raw materials

Preparation Plant (RMPP)

• Matching the production facilities

• Matching the production facilities




Fig-2.1: Process Flow Diagram

Coal

Iron Ore

Coke Oven

COGCOG BFGBFGFuel GasFuel Gas

Boiler & PowerPlant

Sinter Plant

EAF

?

Continuous Slab/Billet

Casters

Hot Strip Mill

Re-heating Furnace

Hot Strip Mill

Re-heating Furnace

Blast Furnace

? ? ? ? ? G

BilletsSlab

CC BILLETS

DRI

HR COILS

COLD PIGS

PRODUCTION FACILITIES PLANNED IN 3.1 MTPA EXPANSION

SteamSteam

PowerPower

LF




The Material Flow Sheet corresponding to the ultimate stage of implementation

of the project is given in the Drg.No.MEC/Q671/11/18/01 sheet 1 of 1 and the

major facilities of the respective production units with their technical parameters

have been detailed in the following table.

Table-2.2: Major plant facilities and their capacities

Sl. No.

Plant facility Capacity

1 Coal washery 2.4Mt

2 Direct reduction plant 14 x 170,000 tpy

3 Iron ore crushing One No. double stage crushing circuit for

DR plant (4,862,000 tpy)

4 Sinter Plant 1 x 177m2

5 Blast furnace 1 x 1681 m3 useful volume

6 Pig casting machine 2 x 2000 t/d

7 Slag granulation plant 415,500 tpy

8 Primary steel making 1 x 180 t CONARC,

2 x 60 t EAF and 12 x 15t IF

9 Secondary refining 1 x 180t LF, 2 x 60t LF and 4 x 30t LF, 1x

60t VD/VOD unit, 1 x 180 t RH-OB

10 Lime and dolo plant (1 x 500 + 1 x 100) t/d lime and 1 x 500t/d

dole

11 Continuous casting 2 x 1 strand slab caster and 2 x 2 –

strand billet casters

12 Captive power plant (1 x 33 + 1 x 77 + 1 x 45) MW

13 Oxygen Plant 1 x 950 TPD

14 Hot Strip mill Conventional hot strip mill with 5-stand

finishing train (2.514 Mtpy HR coils) and




Sl. No.

Plant facility Capacity

provision for 6th & 7th stand in future.

15 Coke Oven Plant 2x0.450 Mtpy Limited recovery type coke

oven Batteries

Based on the envisaged product – mix, considered analyses of the required raw

materials and the facilities envisaged for the proposed project, a process – cum –

material flow has been worked out for the project.

Site and infrastructure The proposed site for integrated steel plant complex is located at Meramandali,

Dhenkanal district of Orissa, which is about 18 km from Angul, 42km from

Dhenkanal and about 100km north-west of Cuttack city. The selected land for

site measures 1623 acres falling under villages Sibpur, Narendrapur, Itapo and

Asanabani. It lies 125km from capital city, Bhubaneshwar. The South – Eastern

Railway’s line connecting Angul and Cuttack railway station and the National

Highway NH-42 are passing on the north of the plant site. The nearest railway

station is Meramandali, which is about 4km from the plant. The river Brahmani

flows from north-west to south east on the northern side of the plant at a distance

of about 6km.

Power The power requirement of the plant is about 410 MVA. It is envisaged that the

power for the main plant will be supplied by CPP running in parallel with grid over

a double circuit 220kv transmission line from Meramandali sub-station of

GRIDCO.




Water Water requirement of the plant is about 5400 m3/h. This requirement for the plant

will be met from the river Brahmani. River is at a distance of about 6km from the

plant site by road.

Raw Materials The annual requirements of various raw materials at 3.1 Mtpy level of the steel

plant and their indicative size specification, proposed sources, distance from

plant and mode of transport are given in Table-2.3.

Table-2.3: Estimated annual requirement of raw materials Sl. No.

Raw Material Size (mm)

Qty.(tpy) Source

1 Iron ore lump (BF grade) 8-30 489,300 Banspani/ Barbil

2 Iron ore fines (BF grade) 5-20 14,400 Banspani / Barbil

3 Iron ore Lump(DR grade) 0-80 5,141,200 Banspani / Barbil

4 Non-coking coal for injection (BF) <100 215,200 Port

5 Limestone (BF grade) 0-80 208,900 Satna/Maihar

6 Raw Dolomite (BF grade) 0-80 201,800 Baradwar

7 Purchased BF coke 25-80 639,200 Port

8 Purchased Coke breeze 25-80 131,200 Port

9 Quartzite 10-50 58,700 Local

10 Non-coking coal for DR 0-20 2,382,500 Patrapara, Coal block. “F” grade (Talcher Coal fields)

11 Limestone (SMS grade) 30-60 351,300 Port

12 Raw Dolomite(SMS grade) 30-60 227,300 Belha




Sl. No.

Raw Material Size (mm)

Qty.(tpy) Source

13 Purchased washed sized coal for

DR

<100 1,557,800 Patrapara, Coal

block. “F” grade

(Talcher Coal

fields)

14 Raw dolomite (DR grade) 1-4 74,000 Baradwar

It has been envisaged that raw material shall be received by Rail except

quartzite. Quartzite shall be received by Road. Accordingly 4 nos. wagon tipplers

with Side arm charges have been envisaged to handle full length of rake of 58

wagons. 4 nos. truck tipplers with hopper of 50 m3 capacity each is also

envisaged to unload the raw material which is received in truck from mines or

from in-house generation. Raw material received in sick wagons shall be

unloaded in track hopper. The holding capacity of track hopper shall be 3400t.

Coal Washery The proposed coal washery will form a part of the proposed material handling

plant (MH). The sized raw coal will be fed to the washery by raw coal conveyor of

the MH plant. Similarly clean coal and middlings will be carried away by

respective conveyors of the proposed MH plant.

In the coal washery plant, total clean coal requirement has been fixed 1,032,200

tpy on dry & net basis. The clean coal product shall be sized at (-) 20mm, 4-1,

20mm & 0-4mm.

The quality parameters of the clean coal will be as follows:

Ash content : 27.5%

Moisture content : 10%




For raw coal quality, following quality parameters has been assumed.

Ash Content : 39%

Moisture Content : ~ 9%

Thus total raw coal requirement has been worked out as 2,411,300 tpy catering

to the needs of DR kilns.

Direct reduction plant The direct reduction (DR) plant will comprise of fourteen rotary kilns of capacity

170,000 tpy each along with related accessories including waste heat power

generating units and related facilities. The production program of the direct

reduction plant, as envisaged is given below:

Product Production, tpy

Sponge iron (DRI) lump (3-18 mm) 1,785,000

Sponge iron fines (-3 mm) 595,000

Technological parameters of each DR kiln and cooler

Diameter of Kiln (ID), m 4.8

Length of kiln, m 80.0

Kiln speed, rpm 0.25 – 0.75

Diameter of cooler (ID), m 3.6

Length of cooler, m 50.0

Production, t/d/kiln (max) 500

Generation of DRI fines (-3mm), % 25

Kiln off gas volume (after ABC) 109,764 (max)

(Nm3/hr) 93,300 (avg)

Working days / year, No. 340




The typical quality of DRI would be as follows.

Degree of metallisation, % 90 + 2

Fe (t), % 92

Fe (m), % 83

FeO, % 9.5

SiO2, % 1.80

Al2O3 1.30

S, % 0.014

P, % 0.046

C,% 0.20 (max)

CaO Trace

MgO Trace

Sinter Plant In order to match the plan of construction of one 1681M2 volume Blast furnace of

Bhushan steel complex with an annual production capacity of 1,250,000 tons of

pig iron and as per the specified BF burden consisting of 75% iron ore and 25%

lump ore one Sinter machine with 177m2 of effective sinter area shall be set up to

produce 1.88 Mt of product sinter per annum (or maximum 1.96Mt of product

sinter per annum). The basic design and operating parameters as given in Table – 2.4

Table–2.4: Design and operating parameters

S.No Item Description Unit Value

1 No. of sinter machine x area No. x m2 1 x 177

2 Productivity (rated) T/m2/h 1.3

3 Annual sinter demand Mt/y 1.88 avg.

1.96 max.

4 Size of finished sinter Mm 5-50




S.No Item Description Unit Value

5 Annual working regime D/y 330

6 No. of working hours/ day H/d 24

7 Gaseous energy / consumption for

ignition/ton of BF sinter

Mj/t 100

8 Coke breeze consumption/ton of BF

sinter

Kg/t of

skip

70

11 Cooler type / bed height Mm Circular cooler

having 26m Dia /

1400mm

12 Temperature of cooled sinter °C Below 100

13 Dust content in exhaust gases at stack Mg/Nm3 Below 50

Coke Oven Battery Complex BSSL shall set up two-recovery type coke oven battery of 0.425 Mtpy capacities

each. The recovery type coke oven battery complex broadly consists of the

following units:

• Coal preparation Plant • Coke oven battery • Coke Handling plant • By-Product Plant • Effluent treatment Plant

The coal preparation plant has been envisaged to cater to daily requirement of

coke ovens. The imported coal will be received at port by ship and further

transportation of coal by rail to the plant site. The coal will be unloaded through

wagon tipplers and then stored in the open storage yard.




Each battery consisting of two blocks of 32 ovens each (64 ovens) has been

selected for this project. The major cold dimensions of the ovens will be as

follows:

Sl. No. Description Dimensions

1. Total Length of carbonization chamber 14080 mm

2. Effective length of carbonization chamber 13280 mm

3. Total height of carbonization chamber 4300 mm

4. Effective height of carbonization chamber 4100 mm

5. Average width 500 mm

6. Taper of carbonization chamber 20 mm

7. Central line distance of carbonization chamber 1200 mm

8. Effective volume of carbonization chamber 26.68 m3

9. Nos. of heating flues in heating wall 28

10. Central line distance of vertical flue of

combustion chamber

480 mm

The battery anchorage system will consist of bucks trays, tie rods, springs and

bracing and modern leak-proof oven casting equipment such as flash plates,

door frames, oven doors compatible to meet pollution control norms etc.

Gas off-takes: the system will comprise of ascension pipes, goosenecks,

isolation valves, gas collecting mains, necessary flushing liquor spraying. The

gas collecting mains will be provided on ram side only. Each oven will be

provided with stamp charging of cake.

Under firing system of ovens: the heating system for ovens will be so designed

that the battery can be heated with coke oven gas as well as blast furnaces gas.




The supply of heating gases will be provided through gas mains laid in the cellar

floor on the pusher side and coke side of the battery.

The following oven machines will be provided for the two batteries:

Sl. No. Description Quantity

1. Stamping and charging Car 2 sets

2. Pushing Car 2 sets

3. Dust guide car 2 sets

4. De-dust guide car 3 sets

5. Elec. Locomotive 2 sets

6. Quenching Car 2 sets

7. Stamping machine 2 groups

8. Hydraulic exchanger 2 sets

The coke guide car machine will be two spot operations. It will remove door,

clean the frame and also cleans the oven door. It will move to place the guide

cage at the oven, the door of which has been opened.

The coke-quenching car will be hauled by electric loco. The incandescent coke is

brought to a quenching station and sprayed with water for quenching, and after

quenching coke is discharged to coke wharf.

Quenching tower shall be of RCC construction with acid resistant brick lining and

arrangement for water spray system. Grit arresters along with vapour spray

system will be provided in quenching tower to contain quenching emissions.

Coke handling plant: coke-handling plant of 100 t/h capacity has been envisaged

to receive the run of oven coke from wharf through wharf conveyor. The coke will

be screened into the 3 fraction e.g. (-)10 mm, 10 mm – 25 mm and 25-80 mm.




By-Product Plant: the by product plant is designed to recover only essential by-

products like ammonia, crude tar. The plant will have a capacity to process

42000 Nm3/h of coke oven gas. The quantity of by-product will be as follows:

Sl. No. Description Units Quantity

1. Coke oven gas Nm3/h 42000

2. Ammonium Sulphate Tpy 9740

3. Crude Tar Tpy 40116

4. Sulphur Tpy 1626

The net calorific value of the coke oven gas is 4300 – 4500 Kcal/Nm3 Effluent Treatment Plant: The effluent treatment plant will be envisaged to treat

the effluent generated from coke oven battery and by-products plant (capacity 24

m3/h). The treatment plant is capable to treat phenolic water generated. Phenolic

water from ammonia column and other sources will be settled and freed from tar

and oil and treated for other toxicants to achieve the desired limit. The treated

liquor will be pumped to the quenching station where it will be used for quenching

of hot coke along with fresh water.

The surplus gas utilisation: The requisite quantity of coke oven gas will be

consumed by the battery itself for regular heating and balance quantity will be

supply to other users within the plant.

Dry Coke Quenching: As per directives of EAC, BSSL shall adopt dry coke

quenching within a period of 5 years from date of environmental clearance. Dry

coke cooling shall take the advantage of waste heat and generate power and

shall initiate for CDM benefits. The dry coke cooling technology is available

indigenously and could be utilized to avoid wet quenching. The detailed




technological features and plan shall be indicated to SPCB at the time of detailed

engineering.

Blast furnace Complex The blast furnace (BF) complex will comprised of one (1) BF of 1681 m3 useful

volume along with its auxiliaries. The BF is envisaged to operate with sized iron

ore, sinter, coke, coal dust, fluxes and additives. The BF will produce around

1.2944 Mtpy gross hot metal. The hot metal produced will be generally sent to

the steel Making Shop. Surplus hot metal will be poured in two double strand pig

casting machines. The liquid slag will be granulated at cast house slag

granulation unit. The BF top gas will be cleaned in dust catcher and gas cleaning

system and distributed for further consumption to the stoves, runner drying, pig

casting machines, sinter plant, etc.

Production Programme

S. No Product Annual quantity (tpy)

1 Gross Hot Metal 1,294,400

2 Net hot metal 1,268,500

3 Granulated slag (dry) 415,500

The major technological parameters of the Blast Furnace are given below:

Useful volume, m3 1681

Working volume, m3 1450

Productivity, t/d/m3

On useful volume

On working volume

2.2

2.55

Production, t/d 3700 (max)

Coke rate (dry), kg/thm 385




Coal dust injection, kg/thm 150

Oxygen enrichment, % 4

Slag rate, kg/thm 321

Slag basicity, CaO / SiO2 0.95

Top pressure, kg/cm2 (g) 1.5

Hot blast temperature, Deg. C 1200

Blast humidity, g/Nm3 60

Blast volume, Nm3 / thm 959

Gas generation, Nm3 / thm 1560

Steel making and continuous casting shop Two steel melting and casting shops have been envisaged namely SMS-I and

SMS-2. Under SMS-I, steel melting and casting shop has been designed to

produce about 1,313,100 tpy of liquid steel and cast the same into 600,000 tpy of

continuously cast billets and 670,600 tpy slabs.

Under SMS-2, steel melting and casting shop will produce 1,967,200 tpy of liquid

steel. The entire quantity of liquid steel will be cast to 1,908,200 tpy slabs.

SMS–1 SMS-I will consist of twelve (12) induction furnaces (IF) each of capacity 15t, four

(4) number of ladle furnace along with two (2) double strand billet caster. This

shop will have two (2) 60 t electric are furnace, two (2) 60 t ladle furnace, one (1)

60 t VD/VOD unit and one (1) single strand slab caster.

SMS-2 The SMS-2 will consist of one (1) twin shell CONARC of 180 t capacity, one 180 t

ladle furnace, one (1) RH-OB unit and one (1) single strand slab caster will be

installed to meet the annual production requirements.




Hot Strip Mill The mill will primarily comprise a slab charging table fed by slab charging cranes

located in the slab yard. Two 300 tph walking beam type slab reheating furnace

with slab charging and discharging equipment designed for cold as well as hot

charging of slabs, one 4-hi reversing roughing stand with attached edger, one

coil box, one hot crop shear, five 4-hi finishing stands, runout roller table

equipped with laminar cooling, two down coilers, coil handling facilities, coil

storage yards, necessary auxiliary facilities and roll shop equipment.

The mill will have an in-built capacity to produce about 2.5Mt of HR coils per

annum. Future provision for third reheating furnace, second roughing stand with

attached edger, 6th & 7th finishing stands and third down coiler has been

envisaged.

The broad technological parameters of the hot strip mill are given in Table–2.5.

Table-2.5: Technological parameters of hot strip mill

S. No Parameters Unit Value/feature

1 Capacity – HR coils tpy 2,514,300

2 Input material

A Type --- Continuously cast slabs

B Thickness mm 230

C Width mm 800 – 1680

D Length mm 10,300 max.

E Weight t ~31

3 Finished products

a Type HR Coils

b Strip thickness mm 1.6 – 20




S. No Parameters Unit Value/feature

c Width mm 800 – 1680

d Coil ID Mm 760

e Coil OD Mm 2,100 max.

f Coil weight t 30max.

Power Plant Production of sponge iron in DR kilns generates huge quantities of the flue gases

carrying considerable sensible heat. The surplus gas of the 1681 m3 blast

furnace has considerable heating value. These fuels if not used properly would

be simply wasted leading to inefficient use of energy as well as causing disposal

problems and to some extent pollution hazard in the plant premises. Surplus

blast furnace gas which is having a good calorific value can also be utilized for

power generation. Thus a captive power plant would be an ideally suited

proposition of effectively make use of these waste fuels. The quantities and heat

content of the waste fuels are enough to produce about 155 MW power which is

more than the requirement of the entire complex. Besides, the facility will also

cater to the requirement of steam driven turbo blowers and process. Thus the

CPP would not make the plant independent of external source of electric power

but would also result in energy conservation and environment improvement. A

composite power plant cum blowing station comprising the following has been

envisaged.

1x33+1x77+1x45 MW steam turbo-generator and auxiliaries.

14x48.5 tph waste heat recovery boilers (WHRBs) and auxiliaries,

1x80 t/h blast furnace gas fired boiler (BFG) and auxiliaries.

Steam turbine driven blowers – 2x60%,

Deaerators – 4 nos.




Lime and dolo plant The line and dolomite plant will comprise of 1No. vertical lime shaft kiln and 1 No.

dolomite shaft kiln of capacity 500 tpd each and 1 No. 100 tpd lime shaft kiln

which is being installed for SMS-1. The lime plant will have the following

production capacity as given below.

Sl. No. Item Qty. tpy.

1. Lime of size 15-55 for SMS 162,200

2. Calcined dolomite of size 15-55 for SMS 105,600

Technological parameters: Lime and Dolomite calcination unit

i) Nos. of Kiln - 3

ii) Kiln Capacity - 2 Nos. 500 tpd each and

1 No. 100 tpd.

iii) Kiln feed size, mm - 25-55

iv) Calcination temp. ºC - 950-1150

v) Specific consumption of - 850

fuel kcal/kg of burnt lime

and dolomite.

Oxygen Plant Oxygen will be required mainly for blowing into the EAF & CONARC for steel

melting and for enrichment of blast in the B. F. complex. Oxygen will also be

required for further removal of carbon in RH-OB, tap hole opening in blast

furnace, and also to meet cutting and general repair needs in the SMS / CCM,

Sinter Plant, Rolling mills and other units of the steel plant.




Argon will be required in the CCM for rinsing the steel in the ladle to homogenize

the bath temperature & chemical consumption and also for shrouding of tundish

during casting.

Nitrogen will be required in the blast furnace complex to meet cooling and

purging needs for the bell less top equipment, above burden probe, etc. and also

in the coal dust preparation and injection system. Nitrogen will also be required

to meet the testing & purging needs of LPG facilities and other units of the steel

plant.

To meet the above requirements of oxygen, nitrogen and argon, an oxygen plant

of capacity 950 t/ d will be provided with facilities for generation and compression

of gaseous products, storage of gaseous and liquid products, and distribution

system for products. Oxygen, nitrogen and argon will be produced by air

separation process based on low pressure cryogenic cycle and double column

rectification system.

Electrics The estimated power requirement of the proposed steel plant is as follows.

Maximum demand : 410 MVA

Annual energy consumption : -2000 M kWh

The power supply for the proposed plant will be made available by Orissa Power

Grid Co. Ltd., at 220 kV from Meramandali grid sub-station located near the plant

site. The power will be received through three circuits of 220 kV transmission

lines. Both the transmission towers will however be designed for double circuit

lines as a future provision.




It is proposed to install 77 MW and 33 MW captive power plants for in-plant

generation. The captive power plants will generate power at 11 kV. The 77 MW

CPP will by synchronized with the grid power supply at 220 kV at MRS through

100 MVA, 11/220 kV step up generator transformers. The 33 MW and 45 MW

CPP will be synchronized with the Grid power supply at 33 kV switchboard

located at Power Plant through 42 MVA and 60 MVA, 11/33 kV step up

generator transformers respectively. The 33 kV switchboards at PP will be

connected to the 33 kV switchboards at MRS through two Nos. tie line feeders.

Fuel oil and gas facilities Blast furnace (BF) gas will be used mainly as fuel in stoves, sinter plant and

power plant. In addition to the above consumers, BF gas will also be used for

cast house runner drying; LRS, PCK, and PCI, semi-clean BF gas will be used

for BF top pressure equalization etc. BF gas will be distributed to the consumers

through a system of piping network, operating at a pressure of 600-800mm WC

Mixed gas has been proposed to be utilized as fuel for the reheating furnace.

Light diesel oil (LDO) is proposed to be utilized as fuel for the initial firing and

flame stabilization in the boilers. In addition to boilers, LDO will also be required

for DR plant and SMS. The daily requirement of LDO is estimated at 120 kl.

Hence 2 Nos. of 450 kl capacity each LDO storage tanks will be required to be

provided for storage of 7 days requirement.

LPG/ propane storage facilities have been envisaged for about 6 days

requirement of the gas for different consumers of SMS (CONARC and EAF/IF)

and BF. The hourly average requirement of LPG/propane is 2.2 tph. Two Nos.

cylindrical storage vessels, each having a capacity to store 150 t of LPG/propane

have been planned.




The Fuel Balance of the Plant Hourly Fuel Consumption

(G cal) Sr. No.

Name of Shop / Unit Annual hours of operation

CV of gas kcal/Nm3

Total BF Gas LDO/LPG

A. GENERATION

1 Blast Furnace 8400 932 220 220 -

Total Generation 220 220

B. CONSUMPTION

1. BF stoves 8400 932 102.59 102.59

2. Pre-heater 8400 932 15.0 15.0

3. PCI 8400 932 9.32 9.32

4. Minor Consumers 8400 932 1.63 1.63

5. Top Pressure

Equalization

8400 932 16.76 16.76

6. Sinter Plant 7920 2000 11.18 11.18

7 Reheating Furnace for

HSM

8400 9800

kcal/kg

176.0 176.0

8. Lime Stone &

Dolomite Calcining

Plant

8400 9800

kcal/kg

46.0 46.0

Total Consumption 378.48 156.48 222.0

To meet the requirement for pulverized coal injection (PCI) system of the blast

furnace complex following shall be provided in the building. Two Nos of

centrifugal compressors each of 70 Nm³/min capacity discharging air at 14.5

kg/cm2 (g) pressure are envisaged. Out of these two compressors one will be

working and one will be kept as a stand by. One No of service air receiver of

60m³ for PCI is envisaged. This air receiver shall be provided outside the

compressed air station.




Water supply facilities The main source of raw water for the proposed steel plant will be river Brahmani,

which is about 6 km away from the plant site. It is proposed to construct an intake

structure on the river bank with necessary pumping and transportation facilities

up to the plant site. Water will be pumped from the intake pump house to the raw

water reservoir inside the plant through pipeline of approximate length 6 km. The

raw water reservoir shall have a storage capacity of 7 days’ requirement of the

plant.

The total requirement of fresh water from surface water source to meet process

make-up and drinking needs is estimated as 5400m³/h. Raw water, received at

the plant water reservoir, shall be treated through Clarifier/ Demineralisation

(DM) Plant / Softening plant before addition to the system as make – up. Water

will be further treated in a demineralised water plant and water softening plant to

meet the DM and Soft water demand of the plant.

The raw water and treated water shall be mainly used for the purpose of cooling,

steam generation and waste water for dust suppression in different production

units of the plant. Apart from this, small quantity of water shall also be used for

fire fighting, drinking and sanitary uses. Water balance for the plant is indicated in

the drawing DRG.NO. BSSL/0/ISP/7-1 Rev 0.

Manpower Planning In order to operate and maintain the plant facilities, including its technical general

administration needs, the estimated manpower requirement at the full

development stage of the integrated complex has been estimated to be 2827.

Category wise breakup of manpower




Sl. No. Category Requirement

1 Managerial 29

2 Executive 310

3 Skilled 938

4 Semi-skilled 735

5 Unskilled 775

6 Clerical 40

Total : 2827

2.8 Mitigation Measures to Meet Environmental Standards

Environmental management The steel plants are considered pollution causing units and to mitigate

environmental problems and meet the environmental norms prescribe by the

regulatory bodies process pollution control equipment are envisaged in the

design stage to comply the norms. The facilities planned for controlling the air

and water pollution are summarised in Table-2.6.

Table-2.6: Proposed facilities for control of air and water pollution Sl. No.

Shop/Unit Proposed Facilities

1 Coke oven and by product plant Scrubbers, tall chimney, BOD plant etc.

2 Sinter plant Electrostatic precipitators, etc.

3 Blast furnace plant GCP, SGP, Electrolyte precipitator etc.

4 Steel melting shop Fume Extraction System, gas coolers, chimney

etc.

5 Material handling system Bag filters, dust suppression systems, etc.

6 Refractory materials plant Bag filters etc

7 Power plant Electrostatic precipitators, chimney etc.

8. DRI units Electrostatic precipitators, chimney etc.




Apart from above there shall be effluent treatment facilities to treat the waste

water and recycle for lower quality of water at appropriate point.

2.9 Township BSSL proposes to develop a housing colony for 250 families, for the staff

members working in the plant. For this purpose, it is envisaged that four different

types of quarters would be constructed.

The land for the proposed housing colony is yet to be acquired by BSSL. The

nearest town, Angul is about 18 km by road from the plant site. Angul has

educational facilities, hospitals, markets and other social amenities. However,

some supporting facilities like first aid station, convenience shops and a

primary/nursery school have been envisaged in the proposed housing complex.

Sewage from the township shall be treated in a sewage treatment plant and the

treated water shall be used for greenbelt development.

2.10 Environmental Cost Considerations The total project cost has been estimated to be Rs. 63300.0 Million (Rupees

Sixty three thousands three hundred million). The capital cost of environmental

control measures is Rs. 3481.5 Million.

Bhushan Steel & Strips LimitedEIA/ EMP Study for Modification-cum-Expansion



BHUSHAN STEEL & STRIPS LTD., MERAMANDALI HOURLY FUEL GAS BALANCE

Hourly Fuel Supply/ Consumption

( Gcal / hr) (Million kcal / hr)

Sl No

Name of Shop/ Unit

Product

Annual Output/ Input

(x 1000T)

Annual Hours of

Operation

Sp. Yeild/ consumpti

on (Gcal/t)

Calorific Value of

GAS kcal/Nm3 Total BF

GAS C.O. GAS

BOF GAS

Annual Fuel OIL / LPG

GENERATION 1 Blast Furnace Hot Metal 1250 8400 1.430 900 212.80 212.80 0.00 0.00 2 Coke Oven & By-product Dry Coal 1146 8760 1.344 4200 175.82 0.00 175.82 0.00 Total Generation 388.62 212.80 175.82 0.00 CONSUMPTION 1 Blast Furnace Plant a) Stoves Hot Metal 1250 8400 0.576 900 85.71 85.71 0.00 0.00 b) Preheaters Hot Metal 1250 8400 0.182 900 27.08 27.08 0.00 0.00 c) PCI Hot Metal 1250 8400 0.121 900 18.01 18.01 0.00 0.00 d) Blast top pr.

equalisation Hot Metal 1250 8400 0.109 900 16.22 16.22 0.00 0.00

e) Minor consumers Hot Metal 1250 8400 0.021 900 3.14 3.14 0.00 0.00

2 Coke Oven Batteries Batteries on coke oven

gas * Dry Coal 1146 8760 0.666 4200 87.13 0.00 87.13 0.00

3 Sintering Plant a) S P Sinter 1880 7920 0.050 900 11.87 11.87 0.00 0.00 4 Steel Melting Shop a) SMS-I Liq. Steel 920 7680 9800 0.00 0.00 0.00 0.00 13,984 t LDO 25000 0.00 0.00 0.00 0.00 28,000 Nm3

LPG b) SMS-II Liq. Steel 4000 7680 9800 0.00 0.00 0.00 0.00 44,080 t LDO 25000 0.00 0.00 0.00 0.00 134400 Nm3

LPG c) CCM (SMS-I) Billet 970 7680 25000 0.00 0.00 0.00 0.00 408320 Nm3

LPG d) CCM (SMS-II) Slab 3940 7680 25000 0.00 0.00 0.00 0.00 1658500 Nm3

LPG 5 R M P

Bhushan Steel & Strips LimitedEIA/ EMP Study for Modification-cum-Expansion



Hourly Fuel Supply/ Consumption ( Gcal / hr)

(Million kcal / hr)

Sl No

Name of Shop/ Unit

Product

Annual Output/ Input

(x 1000T)

Annual Hours of

Operation

Sp. Yeild/ consumpti

on (Gcal/t)

Calorific Value of

GAS kcal/Nm3 Total BF

GAS C.O. GAS

BOF GAS

Annual Fuel OIL / LPG

Lime Plant Burnt Lime & dolo

124 7920 0.890 9500 0.00 0.00 0.00 0.00 11800 t LDO

Lime Plant Burnt Lime & dolo

272 7920 0.890 9800 0.00 0.00 0.00 0.00 24200 t LDO

Burnt Lime 33 7920 0.950 9800 0.00 0.00 0.00 0.00 3200 t LDO 6 Hot Strip Mill Reheating Furnace Slab(cold

charge) 1289 7200 0.400 2000 71.61 21.48 50.13 0.00

Slab(hot charge)

1289 7200 0.250 2000 44.76 13.43 31.33 0.00

7 DR Kiln DRI 10t LDO

8 Captive Power Plant 10t LDO 9 DG Set 10t HSD 10 Losses a) BF Gas - 3% 0.030 900 6.38 6.38 0.00 0.00 b) C.O.Gas - 1% 0.010 4200 1.76 0.00 1.76 0.00 TOTAL CONSUMPTION 373.67 203.33 170.34 0.00 SURPLUS (AVAILABLE) 14.95 9.47 5.48 0.00

BF gas generation : 2,36,400 Nm3/h @ 900 Kcal/Nm3 CO Gas generation : 46,450 Nm3/h @ 4200 Kcal/Nm3 Sinter Plant Consumption: 50,000 Kcal/t Sinter Production: 1880,000 t/y (avg) DC has guaranteed BF gas CV: 900 - 1000 Kcal/Nm3 50% slabs are hot charged at 600 °C * Battery under firing has been considered by coke oven gas

Annual production SMS is for both phase A & phase




3.0 PRESENT ENVIRONMENTAL STATUS

Information on the existing environmental status is essential for

assessing the likely environmental impacts of the proposed

modification-cum-expansion of existing project.

In order to get an idea about the existing state of the environment,

various environmental attributes such as meteorology, air quality,

water quality, soil quality, noise level, ecology and socio-economic

environment have been studied/ monitored.

Study Period It has been planned to carry out baseline environmental data generation for

air, water, noise and soil quality monitoring around the proposed plant site for

one full season covering three months of Summer (April-June’2006).

Study Area The present report covers baseline environmental data generated in the study

area (10 km radius all around the plant site).

3.1 Baseline Monitoring of Environmental Component

In order to get an idea about the existing state of the environment, various

environmental attributes such as meteorology, air quality, water quality, soil

quality, noise level, ecology and socio-economic environment are being

studied/monitored. The present report covers baseline environmental data

generated during April to June’2006 for meteorology, air quality, water quality,

noise levels and soil characteristics. Meteorological, air, water, noise and soil

monitoring stations are marked in Drg.No. MEC/Q6BK/11/S2/01 sheet 1 of 1.

Sampling and analysis has been carried out by Environmental Engineering

Laboratory of MECON, Ranchi which is having accreditation from regulatory

authority Central Pollution Control Board (CPCB) New Delhi.




3.2 Meteorology A meteorological station was set up at the roof top of MRS building within

the proposed plant premises. Meteorological data was generated during the

summer season monitoring period.

The following parameters were recorded at hourly intervals continuously

during monitoring period:

Wind speed

Wind Direction

Air Temperature

Relative Humidity

Cloud Cover

Rainfall was recorded on daily basis.

Table-3.1 gives wind frequency pattern of day-night (24 hours), day and night

respectively as monitored during the monitoring period.

Table-3.1: Summarized Meteorological Data for the Monitoring Period (Summer, 2006)

Wind speed m/s Temperature (°C) Relative humidity (%)

Rainfall (mm) Month

Max. Min. Mean Mean Max. Min. Highest Lowest Total 24hrs. highest

No. of rainy days

Cloud cover (Oktas mean)

April 2006 7.03 <0.44 1.29 28.4 48 19 73 17 - - - 2 May 2006 8.64 <0.44 1.59 34.7 46 20 92 20 - - - 2 June 2006 9.31 <0.44 0.85 32.8 45 18 96 23 4 - 4 2




Table-3.1: Wind Frequency Distribution at Meramandali during Summer Season’2006

A. 24 hours Overall

Velocity Ranges (m/s) Direction

0.44<V<=2 2<V<=3 3<V<=5 5<V<=6 V>6

Sum %

N

NNE

NE

ENE

E

ESE

SE

SSE

S

SSW

SW

WSW

W

WNW

NW

NNW

0.74

3.44

2.16

7.90

8.29

10.46

3.51

3.30

2.97

2.69

2.69

5.67

4.92

2.97

1.08

1.89

0.27

0.88

0.47

1.62

1.89

1.75

0.61

0.81

0.47

0.47

0.40

1.15

1.42

0.94

0.14

0.34

0.06

0.06

0.27

0.67

1.15

0.47

0.14

0.20

0.14

0.20

0.14

0.74

0.81

0.27

0.06

0.14

0.00

0.00

0.00

0.06

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.06

0.00

0.06

0.00

0.06

0.00

0.06

0.06

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

1.07

4.44

2.90

10.31

11.39

12.68

4.26

4.31

3.58

3.36

3.23

7.56

7.15

4.24

1.28

2.43

SUM % 64.68 13.63 5.52 0.18 0.18 84.19

CALM %(V< 0.44 m/s ) = 15.81

Figs-3.1: a the wind-rose diagrams at Meramandali for day-night

(combined) B. Day Time (0600 – 1800 Hrs)




Velocity Ranges (m/s) Direction

0.44<V<=2 2<V<=3 3<V<=5 5<V<=6 V>6

Sum %

N

NNE

NE

ENE

E

ESE

SE

SSE

S

SSW

SW

WSW

W

WNW

NW

NNW

0.81

3.77

2.29

7.80

5.90

8.89

2.80

3.20

3.36

2.29

3.77

7.68

7.00

3.23

1.62

2.69

0.14

0.54

0.27

1.10

1.48

1.48

0.67

0.67

0.40

0.27

0.40

1.88

2.29

1.10

0.14

0.40

0.14

0.14

0.14

0.54

0.94

0.40

0.14

0.00

0.14

0.40

0.27

1.10

1.10

0.40

0.14

0.14

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

1.09

4.45

2.70

9.44

8.32

10.77

3.61

3.87

3.90

2.96

4.44

10.66

10.39

4.73

1.90

3.23

SUM % 67.10 13.23 6.13 0.00 0.00 86.46

CALM %(V< 0.44 m/s ) = 13.54

Figs-3.1: b the wind-rose diagrams at Meramandali for day




C. Night time (1800 – 0600 Hrs.) Velocity Ranges (m/s)

Direction 0.44<V<=2 2<V<=3 3<V<=5 5<V<=6 V>6

Sum %

N

NNE

NE

ENE

E

ESE

SE

SSE

S

SSW

SW

WSW

W

WNW

NW

NNW

0.68

3.11

2.02

7.97

10.60

12.02

4.18

3.38

2.57

3.11

1.62

3.65

2.84

2.70

0.54

1.10

0.41

1.22

0.68

2.16

2.29

2.02

0.54

0.95

0.54

0.68

0.41

0.41

0.54

0.81

0.14

0.27

0.00

0.00

0.41

0.81

1.35

0.54

0.14

0.41

0.14

0.00

0.00

0.41

0.54

0.14

0.00

0.14

0.00

0.00

0.00

0.14

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.14

0.00

0.14

0.00

0.14

0.14

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

1.09

4.47

3.11

11.22

14.38

14.58

4.86

4.74

3.25

3.79

2.03

4.47

3.92

3.65

0.68

1.65

SUM % 62.09 14.07 5.03 0.28 0.42 81.89

CALM %(V< 0.44 m/s ) = 18.11

.

Figs-3.1: c the wind-rose diagrams at Meramandali for Night




From the above table predominant wind direction is found to be from North-

eastern to south eastern sector. During day time, East of South-East (ESE) is

the predominant wind direction (prevailing for about 10.77 % of the time),

followed by WSW (10.66 %) and W (10.39 %). Calm conditions prevailed for

13.54 % of the time. During night also the predominant wind direction is ESE

(14.58%), followed by E (14.38 %) and ENE (11.22%). Calm condition

prevailed for 18.11 % of the time. Overall (24 hours), the predominant wind

direction is also ESE (12.68 %), followed by E (11.39 %) and ENE (10.31 %).

Calm conditions prevailed for 15.81 % of the time.

Figs-3.1: a, b and c give the wind-rose diagrams at Meramandali separately

for day-night (combined), day and night time respectively, based on the

monitored data.




3.3 Air Environment To quantify the impact of the proposed power plant on the ambient air

quality, it is necessary at first to evaluate the existing ambient air

quality of the area. The existing ambient air quality, in terms of

Suspended Particulate Matter (SPM), Respirable Particulate Matter

(RPM), Sulphur-dioxide (SO2), Oxides of Nitrogen (NOx), Carbon

Monoxide (CO), Lead (Pb) and Dust Fall has been measured through

a planned field monitoring.

To assess the ambient air quality level, 5 (five) monitoring stations

were set up. Of these five stations, one was within the plant premises

(Core Zone), while rest were outside the lease up to a maximum

distance of 10.0 km from core zone limit (Buffer Zone). Table-3.3 gives

location of the ambient air quality monitoring stations.

Table-3.3: Ambient Air Quality (AAQ) Monitoring Stations

Sl. No.

Location Stn. Code Distance & Direction from center of lease

1. Motanga A1 4.75 km E

2. Galpoda A2 4.5 km SE

3. Nalatangra A3 4.5 km W

4. Nuahata A4 4.75 km NW

5. MRS building A5 Core Zone

Monitoring Schedule Samples of 24 hourly duration were taken for monitoring SPM, RPM, SO2

and NOx whereas for CO three one hourly sample was taken on each

monitoring day. Lead was also monitored in limited samples. Dust fall was

recorded as 30 days average at each AAQ monitoring station.




Methods of Sampling and Analysis The methods of sample collection, equipment used and analysis

procedure as followed are given in Table-3.4.

Table-3.4: Methodology of Sampling & Analysis and Equipment used Sl. No.

Parameters Instrument / Apparatus used

Method followed

Reference

1.

Suspended

Particulate Matter

(SPM)

Respirable Dust

Sampler (RDS/

HVS), Balance

Gravimetry

CPCB

Notification of

11.4.94

2.

Respirable

Particulate Matter

(RPM)

Respirable Dust

Sampler (RDS),

Balance

Gravimetry CPCB notification

of 11-4-94

3. Nitrogen Oxides

(NOx)

RDS/HVAS with

Impinger tubes,

spectrophotometer

Jacobs and

Hochheiser modified

(Na-arsenite) Method

CPCB notification

of 11-4-94

4. Sulphur di-Oxide

(SO2)

RDS/HVAS with

Impinger tubes,

spectrophotometer

Improved West &

Gaecke method

CPCB notification

of 11-4-94

5. Lead in SPM

RDS/HVAS, Atomic

Absorption

Spectrophotometer

(AAS)

Gravimetric followed

by AAS

CPCB notification

of 11-4-94

6. Carbon Monoxide CO Analyser NDIR Method CPCB notification

of 11-4-94.

Results and Discussions

The results of AAQ are given in Annexure-3.1. The results when

compared with National Ambient Air Quality Standards (NAAQS) of

Central Pollution Control Board (CPCB) for “Residential and Rural

Areas” show that the average values of ambient air quality parameters

are well within the stipulated limit.




Dust Fall

Dust fall rates were recorded as 30 days average during monitoring

periods at five (5) AAQ monitoring stations. The results are given in

Table-3.5.

Table-3.5: Measurement of Dust Fall Rate

Station Location Station No. Results (g/m2/day)

Motanga A1 0.39 Galpoda A2 0.33 Nalatangra A3 0.34 Nuahata A4 0.41 MRS building A5 0.45

In absence of Indian Norms, the results have been compared with the

German norm published in TA Luft, 1986 which is as follows:

98 percentile value : 0.65 g/m2/d

The above results indicate that the dust fall rates at all the stations are

well within the compared German standards.

3.4 Water Environment Water quality monitoring of the study area was carried out in order to

collect baseline data on existing water quality, which can be used to

predict the impacts due to the project on water regime. Grab samples

were collected from ten (10) locations comprising 7.0 ground water and

3.0 surface water samples which are listed in Table-3.6.




Table-3.6: List of Water sampling Stations

Sl. No. Location Stn.

Code Surface / Ground Water

1 Ground Water from Sibapur GW1 Ground water

2 Ground Water from Sibapur GW2 Ground water

3 Ground Water from Khaliberana GW3 Ground water

4 Ground Water from Motanga GW4 Ground water

5 Ground Water from Kochilimara GW5 Ground water

6 Ground Water from Galpoda GW6 Ground water

7 Ground Water from Ganthigriha GW7 Ground water

8 Ground Water from Narendrapur Gw8 Ground water

9 Lingra Nadi SW1 Surface Water

10 Kisinda Jhor before joining river Brahmani

SW2 Surface Water

11 River Brahmani, D/s of Lingra nadi SW3 Surface Water

Samples were analysed following standard methods of analysis.

The results of analysis of ground water are given in Annexure-3.2.

The results have been compared with the drinking Water Quality

standards specified in IS:10500. From the results it is obvious that

except Iron in GW3 all the ground water quality parameters meet the

prescribed norms.

The results of analysis of surface water are also given in Annexure-3.3.

The results have been compared with the Water Quality Criteria as per

Central Pollution Control Board. It can be seen that water from these

sources can be compared with class C and used for drinking after

conventional treatment and disinfection.




Water Quality Criteria as per Central Pollution Control Board

Parameters Class A Class B Class C Class D Class E pH 6.5–8.5 6.5–8.5 6.0-9.0 6.5–8.5 6.5–8.5 Dissolved oxygen (as O2), mg/l, min 6 5 4 4 - BOD, 3 days at 27° C, max 2 3 3 - - Total coliform organism, MPN/100 ml, max 50 500 5000 - - Free ammonia (as N), mg/l, max - - - 1.2 - Electrical conductivity, µmhos/cm, max - - - - 2250 Sodium absorption ratio, max. - - - - 26 Boron (as B), mg/l, max. - - - - 2

Class A: Drinking water source without conventional treatment but after disinfection Class B: Outdoor bathing (organized) Class C: Drinking water source after conventional treatment and after disinfection Class D: Propagation of Wild life and Fisheries Class E: Irrigation, Industrial Cooling, and Controlled Waste Disposal Below E: Not meeting A, B, C, D & E Criteria

3.5 Noise Levels In order to have an idea about the existing noise levels in the study area,

noise monitoring has been carried out at eight (8) locations, out of these 8

locations one location is in core zone and rest 7 are in buffer zone. All

these monitoring stations are listed in Table-3.7.

Table-3.7: Noise Monitoring Stations

Stn. No. Location Core Zone

/Buffer Zone Distance & Direction

(from Centre of proposed project)

N1 Narendrapur Buffer zone 2.2 km N N2 Shibapur outside lease area Buffer zone 1 km ENE N3 Motanga Buffer zone 4.75 km E N4 Kochilimara Buffer zone 2.25 km SE N5 Near MRS building Core zone - N6 Khaliberana Buffer zone 3.5 km NW N7 Ganthigriha Buffer zone 2.0 km W N8 Nalatangara Buffer zone 4.5 km W




Noise Monitoring Frequency At each ambient noise monitoring station, Leq. noise level has been recorded

at hourly intervals for 24 hours. Readings were taken by keeping the noise-

recording instrument ON for fifteen (15) minutes for each reading.

Results and Discussions The summarised monitoring results of noise level in ambient air given in

Table-3.8. The results have been compared with the standard specified in

Schedule III, Rule 3 of Environmental Protection Rules given in Table-3.9.

Table-3.8: Summarized Results of Noise Monitoring Results

Day (0600-2200 hr.) Night (2200-0600 hr.) Stn. No.

Location

Max. Min. Mean.* Max. Min. Mean.*

N1 Narendrapur (Near

Highway) 74.7 64.7 70.9 67.1 57.7 63.1

N2 Shibapur outside lease

area 54.3 44.3 50.8 44.4 39.2 41.5

N3 Motanga 48.3 44.2 46.8 45.8 40.0 42.5

N4 Kochilimara 56.8 45.8 54.3 48.5 40.7 43.8

N5 Near MRS building 68.8 58.3 66.1 62.8 58.1 59.8

N6 Khaliberana 47.6 42.7 46.2 43.5 39.7 41.3

N7 Ganthigriha 48.4 41.2 46.2 44.6 38.7 41.0

N8 Nalatangara 53.3 46.3 50.3 45.4 41.3 43.3

* Logarithmic Averages. All Values in dB (A).

Table-3.9: Ambient Air Quality norms in respect of Noise

(As Per Schedule III, Rule 3 of Environment Protection Rules)

Type of Area Day (0600 - 2200 hrs). Night (2200 – 0600 hrs.)

Industrial Area

Commercial Area

Residential Area

Silence Zone

75

65

55

50

70

55

45

40

All Values in dB (A)




At all the noise monitoring stations values of Leq. are well within their

respective norms.

3.6 Soil Characteristics To assess the quality of soil in and around the lease area, soil samples

were collected from five locations during summer season for physico-

chemical analysis. Soil sampling locations are mentioned in Table-3.10.

Table-3.10: List of Soil Sampling Locations

Sample No. Location Type of Land

S1 Motanga Agricultural

S2 Galpoda Agricultural

S3 Nuahata Agricultural

S4 Nalatangara Agricultural

S5 Shibpur Barren

The results of analysis are given in Tables 3.11, 3.12, 3.13, 3.14 & 3.15. Table-3.11: Physical Properties of Soil

Sample No. Colour Texture Water Holding Capacity (%)

S1 Brown Loam 56

S2 Light Brown Loam sand 41

S3 Light Brown Loamy sand 46

S4 Dark Brown Loam 49

S5 Dark Brown Loam 53

Table-3.12: Chemical Properties of Soil

Parameters S1 S2 S3 S4 S5

pH 6.5 6.8 6.3 6.6 7.3

Electrical Conductivity (µ mhos/cm) 150 99 326 125 67




Soil pH plays an important role in the availability of nutrients. Soil

microbial activity is also dependent on pH. In the study area the soil pH

is acidic to neutral (6.3 <pH< 7.3).

Electrical conductivity (EC) is a measure of the soluble salts and ionic

activity in the soil. In the collected soil samples the conductivity ranged

from 67 to 326 µ mhos/cm.

Table-3.13: Chemical Properties of Soil

Parameters S1 S2 S3 S4 S5 Available Nitrogen (kg/ha) 216 285 386 229 197 and Rating L M M L L Available Phosphorus (Kg/ha) 54 38 26 5 7

and Rating H H H L L Available Potassium (Kg/ha) 756 220 847 419 554

and Rating H M H H H

Organic carbon (%) 0.89 0.44 0.90 1.11 0.78 and Ratings H L H H H Organic matter % 1.53 0.75 1.56 1.92 1.35 Rating based on : Available Nitrogen <280 – Low; 280-560- Medium; >560 – High Available Phosphorus <10 - Low; 10 - 25 - Medium; >25 - High Available Potassium <120 - Low; 120 – 280-Medium; >280 - High. Organic carbon <0.50- Low; 0.5 - 0.75 -Medium; > 0.75 – High

Phosphorus and Nitrogen are limiting nutrients. In the tested soil

samples, availability of Nitrogen varies from low to medium while

Phosphorus is either low or high. Potasium and Organic carbon

content are in general high.




Table-3.14: Exchangeable Cations

Parameters S1 S2 S3 S4 S5

Calcium (meq/100gm) 17 5 46.9 8.9 31.2

% contribution to the Base Saturation 62.51 59.24 75.34 67.04 73.74

Magnesium (meq/100gm) 7.6 2.0 12.9 3.4 9.8

% contribution to the Base Saturation 27.96 23.70 20.56 25.28 23.16

Sodium (meq/100gm) 1.45 0.97 1.33 0.48 0.60 % contribution to the Base Saturation 5.34 11.49 2.14 3.58 1.42

Potassium (meq/100gm) 1.14 0.47 1.22 0.55 0.71 % contribution to the Base Saturation 4.19 5.57 1.96 4.10 1.68

The above results show that the tested soil samples have moderate

quantities of calcium and magnesium whereas levels of exchangeable

sodium and potassium were relatively low.

Table-3.15: Available Micronutrients in Soil

Parameters S1 S2 S3 S4 S5 Remarks

Copper 1.35 1.28 1.36 1.21 1.26 1.44

Zinc 3.2 2.45 2.26 2.54 2.18 2.82

Iron 13.5 12.4 12.7 12.9 12.8 12.4

Manganese 22.5 18.5 19.6 25.0 24.3 21.5

( Values in mg/ kg).

Soil micro-nutrients also play an important role in plant growth and

can act as limiting nutrients. Soil micro-nutrient analysis can be

employed as a diagnostic tool for predicting the possibility of

deficiency of a nutrient and the profitability of its application. For this,

the critical limits of micro nutrients are fixed. The critical limits of

copper, zinc and iron are 0.20-0.66 mg/kg, 0.50-0.65 mg/g and 4.5-

6.0 mg/kg respectively. From the above Table it can be seen that

concentration of copper in all the soil samples are beyond the limit.

Zinc and iron is also high in all the soil samples.




3.7 Biological Environment

The study area is sparsely populated. The biotic environment can be

described under following heads.

3.7.1 Project Site

The plant site is about 1664.50 acre of land. The project area is about

2 km wide and 4 km in length at max. The project site bounded by

village Narendrapur on North, Taldanga on west, Nuagaon on South,

Kochilimara on SE and Sibpur on East. The project area had already in

the possession of BSSL.

a. Land environment

The soil in the field is heavy, which swells on wetting and cracks on

drying. Irrigation facility is not upto the mark and thus only paddy is

grown during rainy season. Other crops, which are grown, are Khesari

and Moong.

b. Natural Vegetation

The project site mostly contains shrubs with tree spread scattered over

the area.

3.7.2 Study Area

The study area covers 7 km radius around the project site. The plant species

commonly found in the area is given in Table-3.16. The study area can

roughly be divided in two, the one with narrow valley and alluvial plains and

the other consisting of undulating tracts broken hills and mountains. The

former is best utilized for paddy and other agricultural crops. The study area

can be described as :




Table-3.16: Plants found in study area

Sl. No.

Botanical name Common name

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Pheonix dactylifera

Acacia arabica

Zyziphus mauritiana

Mangifera indica

Borassus flabellifer

Ficus bengalensis

Diaspyros melanoxylon

Azadirachta indica

Bambusa arundinacea

Butea frondosa

Albizzia lebbeck

Cassia florida

Artocarpus heterophylla

Madhuca indica

Annona squamosa

Ficus religiosa

Holarrhena antydysentrica

Anogeissus latifolia

Cassia fistula

Vitex negundo

Bombax ceiba

Polyalthia longifolia

Nerium odorum

Prunus amygdalus

Acacia auriculiflormis

Aegla marmelos

Saraca indica

Khajoor

Babool

Ber

Mango

Tad

Bargad

Kendu

Neem

Bans

Palasa

Siris

Chakunda

Kathal

Mahua

Sharifa

Peepal

Korai

Dhav

Sonnari

Sindwar

Semal

Ashok

Kaner

Badam

Auriculiformis

Bel

Ashoka




Sl. No.

Botanical name Common name

28.

29.

30.

31.

32.

33.

34.

35.

Shorea robusta

Terminalia tomentosa

Phyllanthus emblica

Terminalia belirica

Terminalia arjuna

Terminalia chebula

Syzigium jambolana

Dalbergia sissoo

Sal

Asan

Aonla

Bahera

Arjun

Harida

Jamu

Sisso

a. Forest Area

There is only one patch of forest, Jharbandh reserved forest, which is

in SE direction at 5.5 km from the project site. The forest is on hillocks

and is of mixed dry deciduous type, in highly degraded state. The tree

height varies from 2 to 5 m and trees are mostly like shrubs. The

common species are D. strictus, Cephalostachyum pergracile, H.

antidysentrica, A. indica, D. melanoxylon, F. bengalenisis, A. arabica,

A. latifolia, A. marmelos, A. squamosa, etc.

b. Agricultural land

The Irrigation facility is not proper in the study area, rainwater is the

main source of irrigation and thus paddy is the main crop grown in the

area. Other crops, which are grown, are Khesari, Groundnut, Moong,

Cajanus, Til, etc. where watering facility is available seasonal

vegetables are also grown.




c. Waste land

Wasteland in the study area is commonly seen in the area, is mostly

covered with species like Calotropis spp, Ipomea sp, Cassia tora,

Croton sp., Parthenium sp., Zizyphus sp., etc.

d. Grassland

Grassland in the study area is secondary in origin. The common

species found in the area are Dicanthium sp. Desmodium sp.,

Evolvulus sp, Cynodon dactylon, Cyperus sp., Imperata sp., etc.

e. Vegetation in and around human settlement

Near villages the vegetation pattern changes from rest of the area. The

common species grown near villages are Mangifera indica, Madhuca

indica, Sizygium sp., Artocarpus sp., Bambusa sp., Ficus spp.,

Azadirachta indica, Cassia siamea, Albezzia sp., Acacia auriculiflormis,

Nerium sp., Annona squmosa, Pheonix sp., Polyalthia sp., etc.

f. Avenue trees and Plantation

The roadside along NH 42 and other roads in the study area are

planted with trees in single to double rows. The common trees are

Acaccia auriculiformis, Azadirachta indica, Peltophorum, Syzigium sp.,

Mangifera indica, Bombax ceiba, Delonix regia, Cassia siamea, etc.

There are stretches of plantation done by CPP, NALCO, and other

industrial premises and residential areas, the common plants are,

cassia siamea, Leucaena leucocephala, Dalbergia sisso, Sarca indica,




Delonix regia, Azadirachta indica, Acacia auriculiformis, Mangifera

indica, Prunus amygdolus, Callistemon lanceolatus, etc.

g. Wild life and avifauna

There is only a small patch of Jharbandh forest falling into the study

area. Which is also in highly degraded state and do not support good

wild life? The common wild life found in the study area is given Table- 3.17. and Table-3.18 Table-3.17: List of Wild life species in the study area

Sl. No.

Common Name

Scientific Name Status Schedule of Wildlife Protection Act in Which Listed

1.

2.

3.

4.

5.

6.

7.

8.

Mongoose

Spotted deer

Wild boar

Monkey

Hare

Porcupine

Jackal

Squirrel

Herpestes edwardsi

Axis axis

Sus scrofa

Macaca mulatta

Lepus nigricollis

Hystrix indica

Canis aureus

Funambulus palmarum

-

-

-

-

-

-

-

-

IV

III

III

II

IV

IV

V

IV

Table-4.18: List of common birds found in the region

Common

Name Botanical Name Status Schedule of Wildlife

Protection Act in Which Listed

Greying goose

Comb duck

Blue rock

pigeon

Anser anser

Serkidiornis sp.

Columba livia

Francolinus

-

-

-

-

IV

IV

IV

IV




Common Name

Botanical Name Status Schedule of Wildlife Protection Act in Which

Listed

Black patridge

Red jungle fowl

Mynas

Parkeet

Bagula

francolinus

F. pondicerianus

Gallus gallus

Acridothere tristis

Psitiacula eupatria

-

-

-

-

IV

IV

IV

IV

h. Aquatic life

There are a number of ponds in the villages in the study area. On

visual observation these ponds seems to be oligo-trophic to meso-

trophic in nutrients status. The common rooted plants and hydrophytes

on the edges of these pons are Nelumbo sp., Potamogeton sp.,

Aponogeton sp.,Ipomea sp., Dichanthium sp., etc. The water in these

ponds are colourless to slight greenish in color.

There are three major rivers in the study area, Brahmni, Krishnajhor

and Nandirajhor. Out of these Nandirajhor River is the most polluted

due to the industrial effluent in the area. River Brahmni receives the

water of Nandirajhor.

The common fishes found in the area are Labio rohita, Catla catla,

Cirrhina mrigala, Calabasu sp., Cyprnus carpio, Grass carp, Silver

carp, Wallago attu, etc.

The Phytoplanktons in the rivers are basically dominated by

filamantous forms. The dominant ones are, Chaetophora sp.,

Cladophora sp., Pithephora sp., Oscillatoria so., Spirogyra sp.,

Cymbella sp., etc.




The Zooplanktons are basically dominated by Crustaceans and

Rotifers. The dominant ones are Crustaceans : Crustacean eggs,

Moinodaphina, Chydorus, Cyclops. Rptifers : Brachionus, Rotiferan,

etc. Others : Nematodes, Dipteran larvae, etc.

i. Animal husbandry

From the records of Veterinary hospitals it is found that there are

symptoms of fluorosis and high fluoride content in urine and blood

samples of few cattles in the study area. The fluorosis prone villages in

the study area and their distance direction are given in Table-3.19. The

reason for fluorosis in these villages may be attributed to high fluoride

content in ground water in few pockets. The reason for high fluoride

content in water is yet to be ascertained.

Table-3.19: Name of villages and their distance / direction from project site in which Cattle are affected with fluorosis

Sl. No.

Name of village Distance (km) / direction from project site

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Gotamara Banarapal Chaurhia Jhanjiribahal Garhasantil Amana Taltali Sanjapahara Bodibahal Garhasantri Nalatangara Bhagabatpur Narendrapur Nauhata Budapank Sanjaparha Ganthigarhia Santri

6.3;NW 5.6; NW

6.3; WNW 5.6; NW 6.3; W 5.6; W 6.8; W 4.1; W 2.8; W 3.1; W 4.0; W 3.4; W 3.1; W 4.4 NW

4.4; NNW 4.4; W 1.33; W 5.9; W

Chapter-3

Annexure-3.1

Summerised Ambient Air Quality results of Meramandli for Summer Season'2006 Results in µg/m3

Permissible AAQ standard SPM RPM SO2 NOx CO

Industrial 500 150 120 120 10000 Residential 200 100 80 80 4000

Monitoring Location Min. Max. Arth.

Mean Min. Max. Arth. Mean Min. Max Arth.

Mean Min. Max. Arth. Mean Min. Max. Arth.

Mean

Motanga 81 198 110 40 82 54 <10 17 - 15 39 29 875 1456 1111

Galpoda 70 133 93 37 66 47 <10 <10 - 14 43 24 823 1296 976

Nalatangra 81 208 119 41 97 59 <10 11 - 13 36 26 634 1168 924

Nuahata 76 162 103 40 87 53 <10 16 - 13 48 26 1796 3488 2485

MRS building 84 260 137 47 116 63 <10 16 - 15 38 22 1369 3859 2415

Chapter-3 Annexure-3.2

Results of Ground Water Analysis

Norms*

Requirement (desirable

limits)

Permissible limits in the absence of alternate source

Sibapur Village

(within lease area) GW1

Sibapur Village (outside lease

area)GW2

Khaliberana

GW3

Sl. No.

Parameters

Date of sampling 26.04.2006 26.04.2006 26.04.2006

Essential Characteristics

1 Colour, Hazen Units. 5 25 <5 <5 <5

2 Odour Unobjectionable - Unobjectionable Unobjectionable Unobjectionable

3 Taste Agreeable - Agreeable Agreeable Agreeable 4 Turbidity, NTU, Max. 5 10 <5 <5 <5 5 pH value 6.5 to 8.5 No Relaxation 7.1 7.2 7.6

6 Total Hardness (as CaCO3), mg/l, max

300 600 264 276 300

7 Iron (as Fe), mg/l, max. 0.3 1 0.26 0.15 0.02

8 Chloride (as Cl),mg/l, max. 250 1000 28 24 30

9 Fluoride (as F), mg/l, max. 1 1.5 1.23 1.34 0.68

Desirable characteristics

10 Total Dissolved Solids, mg/l, max. 500 2000 471 496 502

11 Calcium (as Ca), mg/l, max. 75 200 48 48 77

12 Magnesium (as Mg), mg/l, max. 30 100 35 38 26

13 Copper (as Cu), mg/l, max. 0.05 1.5 <0.01 <0.01 <0.01

14 Manganese (as Mn), mg/l, max. 0.1 0.3

15 Sulphate (as SO4), mg/l, max. 200 400 44 43 34

16 Nitrate (as NO3), mg/l, max. 45 100 0.73 0.76 26

17 Phenolic compounds(as C6H5OH), mg/l, max.

0.001 0.002 <0.001 <0.001 <0.001

18 Mercury, (as Hg), mg/l, max. 0.001 No relaxation <0.0005 <0.0005 <0.0005

19 Cadmium (as Cd), mg/l, max. 0.01 No relaxation <0.005 <0.005 <0.005

20 Selenium (as Se ), mg/l, max. 0.01 No relaxation <0.005 <0.005 <0.005

Norms*


limits)


Sibapur Village

(within lease area) GW1

Sibapur Village (outside lease

area)GW2

Khaliberana

GW3

Sl. No.

Parameters

Date of sampling 26.04.2006 26.04.2006 26.04.2006

21 Arsenic ( as As), mg/l, max. 0.05 No relaxation <0.03 <0.03 <0.03

22 Cyanide (as CN), mg/l, max. 0.05 No relaxation <0.01 <0.01 <0.01

23 Lead (as Pb), mg/l, max. 0.05 No relaxation <0.05 <0.05 <0.05

24 Zinc (as Zn ), mg/l, max. 5 15 ND ND ND

25 Anionic Detergents (as MBAS), mg/l, max.

0.2 1 <0.1 <0.1 <0.1

26 Chromium (as Cr6+), mg/l, Max. 0.05 No relaxation <0.01 0.05 <0.01

27 Mineral oil mg/l, Max. 0.01 0.03 <0.1 <0.1 <0.1

28 Alkalinity ( as CaCO3), mg/l 200 600 242 268 260

29 Aluminium (as Al ), mg/l 0.03 0.2 <0.01 <0.01 <0.01

30 Boron (as B), mg/l, max. 1 5 <0.01 <0.01 <0.01

* Drinking Water Specification, IS : 10500 (1991) & Amendment no.1, January’1993

Norms*


limits)


Motanga GW4

Kochilimara GW5

Galpoda GW6

Sl. No.

Parameters

Date of sampling 26.04.2006 26.04.2006 26.04.2006 Essential Characteristics

1 Colour, Hazen Units. 5 25 <5 <5 <5

2 Odour Unobjectionable - Unobjectionabl

e Unobjectionabl

e Unobjectiona

ble 3 Taste Agreeable - Agreeable Agreeable Agreeable 4 Turbidity, NTU, Max. 5 10 <5 <5 <5 5 pH value 6.5 to 8.5 No Relaxation 6.8 7.5 6.6

6 Total Hardness (as CaCO3), mg/l, max 300 600 416 404 284

7 Iron (as Fe), mg/l, max. 0.3 1 0.46 1.1 0.54

8 Chloride (as Cl),mg/l, max. 250 1000 97 66 54

9 Fluoride (as F), mg/l, max. 1 1.5 1.32 1.04 0.78


Norms*


limits)


Motanga GW4

Kochilimara GW5

Galpoda GW6

Sl. No.

Parameters

Date of sampling 26.04.2006 26.04.2006 26.04.2006

10 Total Dissolved Solids, mg/l, max. 500 2000 762 625 556

11 Calcium (as Ca), mg/l, max. 75 200 67 35 82

12 Magnesium (as Mg), mg/l, max. 30 100 60 77 19

13 Copper (as Cu), mg/l, max. 0.05 1.5 <0.01 <0.01 <0.01


15 Sulphate (as SO4), mg/l, max. 200 400 56 24 36

16 Nitrate (as NO3), mg/l, max. 45 100 0.59 6 4

17 Phenolic compounds (as C6H5OH), mg/l, max. 0.001 0.002 <0.001 <0.001 <0.001

18 Mercury, (as Hg), mg/l, max. 0.001 No relaxation <0.0005 <0.0005 <0.0005

19 Cadmium (as Cd), mg/l, max. 0.01 No relaxation <0.005 <0.005 <0.005

20 Selenium (as Se ), mg/l, max. 0.01 No relaxation <0.005 <0.005 <0.005

21 Arsenic ( as As), mg/l, max. 0.05 No relaxation <0.03 <0.03 <0.03

22 Cyanide (as CN), mg/l, max. 0.05 No relaxation <0.01 <0.01 <0.01

23 Lead (as Pb), mg/l, max. 0.05 No relaxation <0.05 <0.05 <0.05

24 Zinc (as Zn ), mg/l, max. 5 15

25 Anionic Detergents (as MBAS), mg/l, max. 0.2 1 <0.1 <0.1 <0.1

26 Chromium (as Cr6+), mg/l, Max. 0.05 No relaxation <0.01 <0.01 <0.01

27 Mineral oil mg/l, Max. 0.01 0.03 <0.1 <0.1 <0.1

28 Alkalinity ( as CaCO3), mg/l 200 600 380 350 272

29 Aluminium (as Al ), mg/l 0.03 0.2 <0.01 <0.01 <0.01 30 Boron (as B), mg/l, max. 1 5 <0.01 <0.01 <0.01


Norms*


limits)


Ganthigriha GW7

Narendrapur GW8

Sl. No.

Parameters

Date of sampling 26.04.2006 26.04.2006 Essential Characteristics 1 Colour, Hazen Units. 5 25 <5 <5

2 Odour Unobjectionable - Unobjectionable Unobjectionable

3 Taste Agreeable - Agreeable Agreeable 4 Turbidity, NTU, Max. 5 10 <5 <5 5 pH value 6.5 to 8.5 No Relaxation 7.4 7.3

6 Total Hardness (as CaCO3), mg/l, max 300 600 576 328

7 Iron (as Fe), mg/l, max. 0.3 1 0.06 0.28

8 Chloride (as Cl),mg/l, max. 250 1000 103 34

9 Fluoride (as F), mg/l, max. 1 1.5 1.2 1.29


10 Total Dissolved Solids, mg/l, max. 500 2000 992 589

11 Calcium (as Ca), mg/l, max. 75 200 61 79

12 Magnesium (as Mg), mg/l, max. 30 100 103 32

13 Copper (as Cu), mg/l, max. 0.05 1.5 <0.01 <0.01


15 Sulphate (as SO4), mg/l, max. 200 400 80 47

16 Nitrate (as NO3), mg/l, max. 45 100 6 9

17 Phenolic compounds (as C6H5OH), mg/l, max. 0.001 0.002 <0.001 <0.001

18 Mercury, (as Hg), mg/l, max. 0.001 No relaxation <0.0005 <0.0005

19 Cadmium (as Cd), mg/l, max. 0.01 No relaxation <0.005 <0.005

20 Selenium (as Se ), mg/l, max. 0.01 No relaxation <0.005 <0.005

21 Arsenic ( as As), mg/l, max. 0.05 No relaxation <0.03 <0.03

22 Cyanide (as CN), mg/l, max. 0.05 No relaxation <0.01 <0.01

23 Lead (as Pb), mg/l, max. 0.05 No relaxation <0.05 <0.05

24 Zinc (as Zn ), mg/l, max. 5 15

Norms*


limits)


Ganthigriha GW7

Narendrapur GW8

Sl. No.

Parameters

Date of sampling 26.04.2006 26.04.2006

25 Anionic Detergents (as MBAS), mg/l, max. 0.2 1 <0.1 <0.1

26 Chromium (as Cr6+), mg/l, Max. 0.05 No relaxation 0.09 <0.01

27 Mineral oil mg/l, Max. 0.01 0.03 <0.1 <0.1

28 Alkalinity ( as CaCO3), mg/l 200 600 526 316

29 Aluminium (as Al ), mg/l 0.03 0.2 <0.01 <0.01 30 Boron (as B), mg/l, max. 1 5 <0.01 <0.01


Chapter-3

Annexure-3.3 Results of Surface Water Analysis

Sl. No.

Parameters River Lingra SW1

Kisinda Jhor before joining Rver Brahmani

SW2

River Brahmani d/s of Lingra river

SW3 Date of Sampling 26.04.2006 26.04.2006 26.04.2006

1. Colour, Hazen units, Max. <5 <5 <5

2. Turbidity, NTU, Max. <5 <5 <5 3. pH Value 8.1 7.9 7.7

4. Dissolved Oxygen (as O2), mg/l 5.8 5.6 6.1

5. BOD, 3 days at 27° C, mg/l 2 1 2

6. Total Hardness (as CaCO3), mg/l, Max. 80 100 124

7. Iron (as Fe), mg/l, Max. 0.25 0.59 0.28 8. Chloride (as Cl), mg/l, Max. 22 44 24

9. Fluoride (as F) mg/L, Max. 1.12 2.21 1.0

10. Dissolved Solids mg/l, Max. 178 304 254

11. Calcium (as Ca), mg/l, Max. 18 32 24

12. Magnesium (as Mg), mg/L, Max. 9 5 16

13. Copper (Cu), mg/l, Max. <0.01 <0.01 <0.01

14. Sulphate (as SO4), mg/l, Max. 7 48 14

15. Nitrate (as NO3), mg/l, Max. 0.57 1.22 1.15

16. Phenolic Compounds (as C6 H5OH), mg/l Max. <0.001 <0.001 <0.001

17. Mercury (as Hg), mg/l, Max. <0.0005 <0.0005 <0.0005

18. Cadmium (as Cd), mg/l, Max. <0.005 <0.005 <0.005

19. Selenium (as Se), mg/l, Max. <0.005 <0.005 <0.005

Sl. No.

Parameters River Lingra SW1

Kisinda Jhor before joining Rver Brahmani

SW2

River Brahmani d/s of Lingra river

SW3 Date of Sampling 26.04.2006 26.04.2006 26.04.2006

20. Arsenic (as As), mg/l, Max. <0.03 <0.03 <0.03

21. Cyanide (as CN), mg/l, Max. <0.01 <0.01 <0.01

22. Lead (as Pb), mg/l, Max. <0.05 <0.05 <0.05

23. Anionic detergent (as MBAS) mg/l, Max. <0.1 <0.1 <0.1

24. Chromium (as Cr6+), mg/l, Max. <0.01 <0.01 <0.01

25. Mineral oil mg/l, Max. <0.1 <0.1 <0.1

26. Alkalinity (as CaCO3) mg/l, Max. 72 88 118

27. Aluminium (as A1) mg/l, Max. 0.01 0.01 0.02

28. Coliform organisms, MPN/100ml 600 400 900

29. Sodium Absorption Ratio 0.78 2.03 0.84




4.0 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 General

The first step in environmental impact assessment is to list all the potentially

significant environmental impacts. These are then examined critically and the major

impacts (both negative and positive) are analyzed in detail for the EIA.

The existing plant had been planned out considering low specific consumption of

raw materials and energy and minimum impact on the environment. In order to

ensure comprehensiveness, the various aspects considered in listing of impact

during modification-cum-expansion of the plant are:

• Investigation of project components.

• Investigation of project phases.

• Investigation of Impact generating activities.

• Investigation of types of impacts.

There are various techniques available for listing of impact. These include

checklists, matrices, networks and cause effect diagrams etc. The objective of

undertaking EIA of the project under consideration at the selected site is to identify

the probable impacts on the pre-project, or the present environmental setting of the

project site surroundings. This gives a first-hand assessment of the degree of

impacts caused by the project activities from construction stage to operational stage.

From the assessment, it can be judged to what extent the potential impacts are

likely to occur and if so to what level it can be minimized by implementing suggested

environmental management plan (EMP) from the design stage itself.




4.2 Listing Matrix

The possible environmental attributes that may be affected by industrial activities

are:

• Air

• Water

• Noise

• Soil / land

• Ecology

• Infrastructure

• Socio-economics.

The various activities which could have significant impact during modification-

cum-expansion of existing plant have been classified under following groups.

• Existing Operations.

• Future Activities

4.3 Evaluation of the Steel Making Process

The basic chemistry of steel making is to reduce oxides of iron ore with a

carbonaceous reductant such as coke and coal to produce hot metal. This hot metal

contains about 4 to 6 per cent of carbon, which needs to be oxidized by reacting with

oxygen to produce crude liquid steel. The entire process chemistry works at an

elevated temperature.

There are two process routes that dominate the global steel production, although

variations and combinations of two exist. These are the ‘integrated’ one based on

BF-BOF/LD route and electric arc furnace (EAF) route. The BOF route to steel

making is based on the production of iron in BF and later conversion to steel in the

BOF converters. In case of EAF, the source of iron is predominantly scrap/DRI with




the electrical energy being used in the conversion process. Although, the EAF route

to large volume steel production is uneconomical in Indian conditions due to high

costs of electrical power, still BSSL has chosen this route due to substantial power

generation from waste heat available from hot waste gases from process.

Existing plant site is generally plain with minor undulation. The existing plant is well

connected to state high way and nearby railway station Meramandali. Hence only

connecting line from plant to Meramandali station is required as infrastructure.

Therefore, construction for infrastructure does not require and hence does not affect

the environment in any way.

Construction

The major construction will involve excavation and fabrication work for facilities,

which are addition to existing BSSL plant. This will involve excavation, construction,

erection of equipment, engagement of labour force, laying and routing of pipelines,

commissioning and testing activities etc. Air, water, noise and soil / land are likely to

be affected by the above activities. . It will have marginal impacts on air, water, and

noise quality. Socio-economic pattern may be marginally improved due to

generation of temporary employment. However, these impacts will be for a short

duration only. Marginal impact is anticipated on Aesthetics, Land use and Socio

Economic pattern.

Operation

The existing plant is partially operational and producing 650000 tpy sponge iron

products. When the plant is fully operational the generation of fugitive and process

dust, heat and noise may have negative impact on health and safety but due to

proper management its impact shall be marginalized. While the employment

generated by the project for the operation is having positive socio-economic impact.




The proposed additional major production facilities of the modernization-cum-

expansion program as described in Chapter 2 are (i) augmenting Sintering, (ii) coke

making additional (iii) augmenting BFs, and (iv) Steel making in EAFs v) additional

DRI kilns etc . The supporting production units and facilities are Secondary Refining

Facilities, Pig-Casting, Slag Granulation, Continuous Casting, Billet Caster, Hot Strip

Mill, Oxygen Plant, Lime Plant, Coal Dust Injection System in BF, etc.

Each of the main such production process has got different pollution potential as

may be seen from the Table 4.1.The predominant environmental pollution would be

the air pollution due emissions of dusts and gases and water pollution due to Hot

Strip mill effluents containing toxic substance like oil.

In addition to air and water pollution, there would be generation of solid wastes such

as DRI fines, char, dust from GCP, BF slag, EAF slag, mill scales and washery

rejects and middling etc, major part of which are recycled to the process or used by

others and part may require dumping/storage on the ground for future use.

The environmental impacts of the above additional activities are given in the

following Table 4.1.

Table 4.1: Sources and types of environmental impacts

Section /Units

Feed & Fuels Operation Pollutants Recipient Form of pollution

I. Construction Stage Dusts Noise

Air Air pollution

Slurry water Open drain Water pollution

Construction materials -

Construction debris Land Land pollution II. Operational Stage Raw Material Handling

All types of solid raw materials

Mechanical handling, sizing and conveying

Dusts Air Air pollution

Coking Coal, by-product fuel gas as fuel

Coal carbonization Heat, Dust SO2, NOX VOCs

Air Air pollution




Section /Units

Feed & Fuels Operation Pollutants Recipient Form of pollution

Phenolic Effluent

Plant Drain Water pollution

Heat, Dusts, SO2 , NOX

Air Air pollution Sinter Plant Iron ore fines, Limestone fines, LD slag etc as feed and coke and flue gas as fuel

Sintering at an elevated temperature

Noise Air Work-zone pollution

Heat, Dusts, SO2, NOX

Air Air pollution

Noise Work-zone air

Work-zone pollution

Blast Furnace

Coke, Lump Iron Ore, Sinter, Fluxes and by-product fuel gas

Hot metal making

Particulate dusts laden water


Dust, SO2 Air Air pollution Noise Work-zone

air Air pollution DRI Coal, Lump iron ore,

Fluxes Sponge iron making

Blow down water water Water pollution Heat , Dusts Air Air pollution Steel melt

shop (SMS) Hot Metal, Fluxes, Ferro alloys

Steel making, refining and continuous casting of slabs

Particulate dusts laden water


Heat, SO2, NOx Air Air pollution Noise Work-zone

air Noise pollution

Hot Strip Mill (HSM)

Steel Slabs and by-products fuel gas as fuel

Hot rolling of Slabs

Oil and particulates laden mill effluent


Lime/Dolo calcining

Limestone and by-product fuel gas

Calcinations Heat, SO2, NOx Air Air pollution

Heat, SO2, NOx

Air Air pollution

Noise Work-zone air

Noise pollution

Captive Power Plant and Blower House

By-product fuel gas as fuel

Steam raising and power generation

Waste-water of DM Plant containing acids/ alkalis


4.4 Identification of Impacts

An attempt has been made to identify and list all possible aspects, which could

generate significant impact due to various phases of the modification-cum-

expansion on different environmental attributes. Some of these impacts are

insignificant and don't warrant further analysis. Thus objective is to identify and list

only the significant impacts, which shall require detailed analysis to the extent of

decision-making purposes. The major construction activities will be of short duration

and will have very few lasting impacts. The operation will have the potential of major

impacts, which has been analyzed in detail. Based on the impacts identified, most

affected environmental attributes have been considered for detailed evaluation.




4.5 Prediction of Impacts:

In the screening of impact the environmental attributes that may be affected

due to the proposed modification-cum-expansion of existing steel plant have

been identified. Impact prediction is a way of foretelling the environmental

consequences of the significant aspects of the proposed modification-cum-

expansion of plant. Impacts on various environmental attributes during

construction as well as operation have been discussed. The impact

assessment will focus on the proposed modification-cum-expansion and will broadly

cover the following:

Estimation of physical effects for all phases including construction and

operation. Estimation by type and quantity of expected contaminants i.e.

residues, and emissions (air, water, noise, solid wastes) resulting from the

operation of the proposed expansion and modification of existing unit.

Assessment of the positive and negative impacts on land use, future

development, cultural / historic resources, peoples, demographics,

infrastructure, employment, income, education etc.

Indirect impacts which may arise from proposed modification-cum-expansion of

plant.

However, the anticipated environmental impacts of the proposed modification-cum-

expansion are discussed below under the category (a) Impacts during construction

and (b) Impacts during operation.




4.6 Prediction of Impacts During Construction

4.6.1 Land use

BSSL will not acquire any new land for proposed modification-cum-expansion. Most

of the units of the proposed expansion will be either higher capacity unit or

modification of the existing unit cleared during 1.5 Mtpy stage. Accordingly the

construction activity will be limited within the existing BSSL plant premises and in the

already built up area. Thus no large-scale excavation, soil erosion, loss of topsoil is

expected. The BSSL plant site is already a fairly well developed area with all sorts of

infrastructure already available. It is therefore most unexpected that influx of

construction labour is going to change present land use pattern. Further this land

use change during construction is only temporary and will persist during construction

phase only.

4.6.2 Impacts on Ambient Air Quality

The existing plant is already partially in operation and its

modification/expansion will have limited construction work i.e. limited to

specific modification in existing units as well as additional units to be put into

the place. During the limited construction phase, civil work is being carried out

to put the units in its place. The construction work leads to a generation of

fugitive dust. However the fugitive dust is not expected to spread too far. In

addition, water spraying is being undertaken to suppress dust being spread.

Due to limited construction activities, the impacts on ambient air quality will

not be permanent and will cease once the modification construction is

completed after that generation of fugitive dust will reduce drastically.




4.6.3 Impacts on Noise Levels

The present noise level is due to construction and operation of existing plant.

The production units are being chosen by criteria of environmental friendly

technology and shall generate less noise level. Noise levels during this limited

construction are likely to increase initially due to increased movement of

trucks and other diesel powered material handling equipment. This is

unavoidable and limited during day time only. Therefore, movement of trucks

and machinery will be regulated to reduce the impacts of increased noise.

The construction phase will be limited to short period and temporary, the

impacts on ambient noise levels will be insignificant and ceases once the

construction is completed.

4.6.4 Impacts on Water Environment

The water required for construction purpose will be met by extending the

existing water network of the existing plant. However, during construction, a

large volume of debris, mud etc will be generated, which during the rainy

season, can contaminate the storm water run-offs with large amounts of

suspended solids. Efforts will be made to reduce the suspended solids

content of storm water run-offs by routing the storm water drains through

catch pits. Moreover storm water run-offs will occur only during the monsoon

season which lasts for about 2-3 months in the study area. Moreover these

impacts will be temporary lasting only for the duration of the modification-

cum-expansion construction period.

It has already been indicated that the proposed expansion will be limited within an

existing plant. The plant is already having all infrastructure facilities including water

supply. The water requirement during the construction phase will be low and can be

met through the already existing water supply facilities. Thus no ground water is




expected to be extracted. Therefore, it is most unlikely that construction phase will

bring any significant modification in the ground water regime of the area. Therefore,

the construction phase of the proposed expansion will have insignificant impact on

the ground water.

4.6.5 Impacts on Ecology

The modification cum expansion of existing BSSL plant will remain within the

existing boundary of Steel plant and no new area will be acquired for

expansion. The area involved in modification-cum-expansion shall be very

small and hence the impacts on the study area as a whole will be

insignificant. Impact on ecology will be insignificant.

4.6.6 Socio-Economic Impacts

During the modification-cum-expansion limited construction work shall be

carried out in civil as well as machinery handling. The construction phase of

the project involves large deployment of manpower, both direct and indirect.

This involves employment of temporary labour, which is being engaged to

perform these tasks. This will have positive employment effect, both direct

and indirect. This will affect the economy of the study area in positive

direction as the employment shall generate income which gets routed in local

economy.

4.7 Prediction of Impacts During Operation

Generally operation of any production plant emits pollutants. Iron and Steel

industries are also no exception to that. Once the modification-cum-expansion of

existing steel plant to 3.1 Mtpy completed and total plant get operational, there

expected slight increase or marginal impacts on ambient air quality, noise levels,

water quantity and quality, ecology and positive socio-economic environment.

Environmental releases may be in the form of:




a) Emission to air

b) Waste water discharges

c) Solid waste disposal

d) Noise level etc.

These emissions, discharges and disposal may release different pollutants, which

may affect air, water, land and ecological environment directly. However, all these

are mainly primary impact. In addition to these primary impacts any industrial project

or expansion of a project has some overall impact on its surrounding socio-

economic environment through the existence of social and economic linkages

between the project and society, which are actually secondary impact. Under this

clause, all these primary and secondary impacts due to this proposed expansion are

being discussed and wherever required, impacts have also been quantified.

Accordingly under subsequent clauses impacts on air environment, water

environment, soil, noise, land use, and socio-economic environment due to the

proposed expansion are being elaborated.

4.7.1 Impacts on Ambient Air Quality

The principal impacts on ambient air quality due to operation of the fully operational

3.1 Mtpy plant will be due to emissions from the stacks of the various units and

emissions of fugitive dust from the iron ore and coal handling areas.

The prediction of Ground level concentrations (GLC) of pollutants emitted from the

stacks has been carried out using ISCST-3 Air Quality simulation model released by

USEPA. This model is basically a Gaussian dispersion model, which considers

multiple sources. The model accepts hourly meteorological data records, to

define the conditions of plume rise for each source and receptor combination

for each hour of input meteorological data sequentially and calculates short




term averages upto 24 hours.

The impact has been predicted over a 10 km X 10 km area with centre of the

sinter plant stack as the centre. To obtain greater resolution, the receptors

are defined with respect to 16 radial wind directions (N to NNW) and radial

distance from centre. GLC have been calculated at every 500 m grid point to

have better results.

The emissions have been computed based on the following:

a) Particulate matter (SPM) has been calculated considering emission rate of 50

mg/Nm3

b) Sulphur content of the coal has been assumed to be 0.5% as per CPCB

guidelines

c) NOx emissions from Plant have been estimated based on the assumption 75

mg/Nm3 in flue gas and SO2 emission is based on 40 % in gas phase and 60 %

in solid waste as per guideline of technology supplier Lurgi.

Details of the proposed stacks and estimated emissions are given in Table- 4.2.

Table-4.2: Stack Emission Data of 3.1 Mt Steel Plant

Stack Co-

ordinate

(Plant Centre at

10,10)

Emission Rate

(g/sec)

Sl.

no.

Description of Stack

x-co-

ord.

y-co-

ord.

Stack

Height

(m)

Stack

Dia (m)

Flow

Rate

(Nm3/hr)

Exit

velocity

(m/sec)

Temp

°C

SPM SO2 NOx

Pollution

Control

equipme

nt

envisage

d

Sinter Plant Complex (1x177 m2)

1. SINTER PLANT –(MAIN STACK) 10000 10000 100 5.0 1020000 20.48 150 14.2 4.25 5.67 ESP

2. SINTER PLANT –Cooler ESP

stack

10128 9850 60 3.5 412950 12.52 40 5.7 ESP

3. SINTER PLANT -de-dusting 10172 10022 35 2.5 223460 13.28 40 3.1 ESP

Coke Oven Complex (2x65 Oven 4.3 ht)25:75 ratio CO gas to BF gas Stamp Charge




Stack Co-

ordinate

(Plant Centre at

10,10)

Emission Rate

(g/sec)

Sl.

no.


x-co-

ord.

y-co-

ord.

Stack

Height

(m)

Stack

Dia (m)

Flow

Rate

(Nm3/hr)

Exit

velocity

(m/sec)

Temp

°C

SPM SO2 NOx

Pollution

Control

equipme

nt

envisage

d

4. Coke Oven Plant-1 11289 10172 120 4.5 105600 3.05 220 0.7 4.40 5.87

5. Coke Oven Plant-1 11322 10183 120 4.5 105600 3.05 220 0.7 4.40 5.87

Blast Furnace Complex (1x1681 m3) bag filter design norm 50 mg/Nm3

6. BF STOVE STACK(3 stove) 10589 9978 70 3.386 160250 7.02 150 1.1 2.23 2.67

7. BF Cast House-de-dusting 10672 9783 45 4.2 816000 17.18 40 11.3 3.4 - Bag Filter

8. BF Stock House-de-dusting 10539 10089 45 3.1 440000 17.01 40 6.1 - - Bag Filter

DRI Process Stacks after Waste heat Recovery Boilers(14x170000 tpy) ESP design norm 50 mg/nm3

9. DRI PROCESS STACK-1 8733 9439 76 2.17 120000 12.79 150 2.7 20.2 ESP














DRI Kilns - De-dusting stacks (ESP design norm 50 mg/Nm3)

23. DRI KILN-1 & 2-in plant de-

dusting -ESP

8736 9750 45 2.7 300000 15.77 50 4.2 - - ESP




Stack Co-

ordinate

(Plant Centre at

10,10)

Emission Rate

(g/sec)

Sl.

no.


x-co-

ord.

y-co-

ord.

Stack

Height

(m)

Stack

Dia (m)

Flow

Rate

(Nm3/hr)

Exit

velocity

(m/sec)

Temp

°C

SPM SO2 NOx

Pollution

Control

equipme

nt

envisage

d


dusting -ESP

8850 9778 45 2.7 300000 15.77 50 4.2 - - ESP

25. DRI KILN-5& 6-in plant de-

dusting -ESP

8911 9778 45 2.7 300000 15.77 50 4.2 - - ESP


dusting -ESP

9005 9805 45 2.7 300000 15.77 50 4.2 - - ESP


dusting -ESP

9161 9867 45 2.7 300000 15.77 50 4.2 - - ESP


dusting –ESP

9294 9856 45 2.7 300000 15.77 50 4.2 - - ESP


dusting -ESP

9400 9883 45 2.7 300000 15.77 50 4.2 - - ESP

SMS Complex

30. SMS-1 EAF+LF FUME

EXTRACTION-I

9444 9456 36.5 3.0 300000 15.15 110 4.2 Bag Filter

31. SMS-1 EAF+LF FUME

EXTRACTION -II

9766 9528 36.5 3.0 300000 15.15 110 4.2 Bag Filter

32. IF+LF FUME EXTRACTION -I 9578 9289 29.5 1.75 150000 22.26 110 2.1 Bag Filter

33. IF+LF FUME EXTRACTION -II 9783 9339 29.5 1.75 150000 22.26 110 2.1 Bag Filter

34. SMS-II EAF+LF FUME

EXTRACTION-I

10417 9522 65.0 5.82 1600000 21.47 110 13.3 Bag Filter

35. SMS-II EAF+LF FUME

EXTRACTION -II

10439 9478 65.0 5.82 1600000 21.47 110 13.3 Bag Filter

HOT STRIP Mill

36. RE-HEATING STACK-1 10933 9372 70 4.5 132700 6.24 530 0.9 1.8 7.37

37. RE-HEATING STACK-2 10961 9378 70 4.5 132700 6.24 530 0.9 1.8 7.37

38. RE-HEATING STACK-3 10978 9383 70 4.5 132700 6.24 530 0.9 1.8 7.37

Raw Material Preparation Plant (Bag Design 50 mg/Nm3)

39. LIME PLANT 1(100tpd Shaft) 9567 9839 40 0.75 17000 13.38 100 0.2 - - Bag Filter

40. LIME PLANT 2(500tpd shaft) 10389 9744 40 1.5 65000 12.79 100 0.9 - - Bag Filter

41. DOLO PLANT-1(500 tpd shaft) 10350 9972 40 1.5 65000 12.79 100 0.9 - - Bag Filter

Captive Power Plant(fuel Clean BF gas 5mg/Nm3)

42. BFG gas fired Boiler of CPP 10639 10056 55 2.0 140000 17.98 160 1.0 - -

* Out of 14 DRI kiln maximum 10 kiln will operate at a time




The meteorological data of the day on which the maximum GLC occurred is shown

as Table-4.3. Stability has been computed by Turner’s method and mixing height

has been obtained from literature and nearby IMD station. The predicted GLC

values have been provided at Table-4.4.

Table 4.3: Meteorological inputs (Summer 2006)

Time (hours)

Wind Direction

Wind speed (m/s)

Temp. (°K)

Stability Mixing height (m)

01.00 315.0 1.39 302 6 50 02.00 315.0 1.67 301 6 50 03.00 202.5 1.1 301 6 50 04.00 292.5 0.83 302 6 50 05.00 315.0 0.83 302 5 50 06.00 247.5 0.83 302 4 100 07.00 292.5 1.67 302 3 200 08.00 315.0 0.56 303 2 200 09.00 292.5 0.83 305 2 500 10.00 315.0 0.56 307 2 600 11.00 315.0 0.56 308 2 750 12.00 315.0 0.83 310 2 950 13.00 315.0 0.83 311 1 1100 14.00 315.0 0.83 313 1 1200 15.00 292.5 0.83 313 1 1400 16.00 337.5 1.67 312 2 1200 17.00 315.0 1.1 311 3 1000 18.00 315.0 1.67 310 4 800 19.00 315.0 1.1 308 6 700 20.00 315.5 1.1 302 6 500 21.00 292.5 1.1 302 6 250 22.00 292.5 0.83 302 6 200 23.00 315.0 0.83 302 6 150 24.00 202.5 1.1 302 6 100

NOTES: STABILITY CLASS 1=A, 2=B, 3=C, 4=D, 5=E AND 6=F.




Table-4.4: Predicted value of GLCs

Max. 24 h. Avg. (µg/m3) of Pollutants Rank SPM SO2 NOx

1 30.5 (7500;11000) 49.8 (8000;10500) 3.1 (9000; 11000) 2 29.6 (7500;11000) 49.0 (7000; 11500) 3.1 (8500; 11500) 3 29.2 (8000;11000) 47.3 (6500; 12000) 3.1 (9500; 11000) 4 29.0 (8000;10500) 46.6 (7000; 11500) 3.0 (9000; 11500) 5 28.8 (7500;11000) 46.5 (7500; 11000) 2.9 (9000; 12500) 6 28.7 (8000;10500) 44.8 (6000; 12500) 2.9 (8500; 12500) 7 28.6 (7500; 11000) 44.6 (6500; 12000) 2.9 (8500; 13000) 8 28.6 (7000; 11500) 43.9 (7500; 11000) 2.9 (8000; 13000) 9 28.2 (8000; 11000) 42.5 (5500; 13000) 2.8 (9000; 11500)

10 27.9 (8000; 10500) 42.3 (7500; 11000) 2.8 (9000; 12000)

The predicted maximum contribution of GLC for all stacks is indicated in above table

at different co-ordinate, which is 30.5 ug/m3 for SPM, 49.8 ug/m3 for SO2 and 3.1

ug/m3 for NOx respectively. The nearest AAQ monitoring station where maximum

GLC values have occurred is Nuahata village in Northwest direction. The monitored

background mean value for AAQ of Nuahata is 103 ug/m3 for SPM, <10.0 ug/m3

for SO2 and 26.0 ug/m3 NOxx for summer season respectively. The AAQ station

Nuahata village is on Northwest side of the plant at a distance of 4.75 km. The

predicted contributions of different pollutants from the proposed steel plant when

added with the monitored existing background levels of Nuahata village indicate that

the maximum concentrations will be 133.5 ug/m3, 59.8 ug/m3 and 29.9 ug/m3 for

SPM, SO2 and NOx respectively. The isopleths of SPM, SO2 and NOx are enclosed

as Fig 4.2, a,b,c respectively. The concentration is well within the norms of rural &

residential area norms. However, the area after establishment of 3.1 MT steel plant

will be a industrial area and applicable industrial area norms are 500 ug/m3 for SPM,

120ug/m3 for SO2, and 120 ug/m3 for NOx. The computed GLC values are based

on assumption that only ten DR kiln will be operating at a time out of 14 DRI kiln

proposed as per technologist. Since, the values are much less then the norms for

rural and residential areas, therefore no significant impacts are expected from the




steel plant provided steel plant authority incorporates pollution control measures

indicated in the report and implemented holistically. From the results it is observed

that impact in operation of its rated capacity of 3.1 Mtpy will be well within the norms

of ambient air quality.

In order to improve the work zone air quality inside the plant premises, the following

measures will be taken to prevent escape of dusty air and harmful gases from plant.

All the fugitive emissions where de-dusting suction hoods cannot be provided due to

physical constraints shall be provided with dry fog dust suppression system/water

sprinklers.

Habitation centers such as Angul and Denkanal are about 17 and 21 km away from

plant respectively and the levels of air pollutants expected are much less. Hence no

significant impact can be expected.




0 2000 4000 6000 8000 10000 12000 14000 16000 18000

DISTANCE (m)

ISOPLETHS OF SPM

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

DIS

TA

NC

E (

m)

MAX. GLC - 30.5 ug/m3( (7500,11000)

PLANT CENTRE - (10000, 10000)

Fig-4.2a: ISOPLETH OF SPM




0 2000 4000 6000 8000 10000 12000 14000 16000 18000

DISTANCE (m)

ISOPLETHS OF SO2

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

DIS

TA

NC

E (

m)

PLANT CENTRE - (10000, 10000)

MAX. GLC - 49.8 ug/m3( (8000,10500)

Fig-4.2b: ISOPLETH OF SO2




0 2000 4000 6000 8000 10000 12000 14000 16000 18000

DISTANCE (m)

ISOPLETHS OF NOx

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

DIS

TAN

CE

(m)

PLANT CENTRE - (10000, 10000)

MAX. GLC - 3.16 ug/m3( (9000,11000)

Fig-4.2c: ISOPLETH OF NOx




4.7.2 Impacts on Water Environment

Impacts on Water Resources The source of water for the proposed steel plant will be the Brahmani River.

The BSSL plant authority has permission for the drawal of 100 cusecs of

water, from Brahmani River for use in steel plant (permission letter enclosed

as Annexure at the end of this chapter). The actual requirements of integrated

steel plant will be 5400 m3/h (1.5 m3/s). Drawl of 129600m3/day water from

Brahmani river will not affect the availability of water for others, as the lean

season flow rate in the Brahmani River is 1450 cusecs (1,48,105 m3/h).

The steel plant does not extract any ground water nor will do so in future.

Thus operation of the steel plant will not affect ground water availability in the

study area.

Impacts on Water Quality As the plant water system is designed based on maximum re circulation

system and effective discharge from plant to outside will be insignificant. The

effluents likely to be generated from the proposed plant are:

• Underflow from Raw Water Clariflocculator

• Backwash Waste from Filtration Plant

• DM Plant Regeneration Waste

• Run-off water from Raw Material Storage Yards

• Waste Water from Slab Caster & Billet Caster

• Waste Water from Hot Strip Mill

• Cooling tower blow-down of various shop

• Plant Sewage & Canteen Effluents




• BOD plant effluent in coke oven complex

Sludge from Raw Water Clariflocculator and Backwash from Filtration Plant

will be led to a sludge pond for removing suspended solids. The overflow

from the sludge pond will be used for dust suppression and irrigation of green

cover. The sludge from the sludge pond will be dried and dumped in low lying

area.

In the coke oven complex, phenolic effluent shall be generated. The quantity

of effluent shall be estimated to be 40 m3/h. The effluent will be treated in

BOD plant ETP. The treated liquor shall be recycled to the quenching station,

to be used for quenching of hot coke.

Water from the BF GCP will be sent to a clarifier / thickener. The overflow

from the thickener will be reused in the Pig Casting Machine.

Run-off water from the raw material storage yard will be routed through

garland drains to catch pits to settle out suspended solids. The clear water

will be discharged into natural drainage channels.

Acidic/ Alkaline effluents will be generated at the DM Water Plant. These

effluents will be properly neutralized in neutralization pit before recycling back

for dust suppression.

Effluents from the slab caster and HSM complex are likely to contain

suspended solids and oil & grease. These effluents will be routed to settling

pits fitted with oil & grease trap. The clarified water will be reused in the plant.

Cooling Tower Blow-down and Boiler Blow-down will be utilized for slag




granulation in BF complex and dust suppression in the raw material handling

area. Blow down from the Oxygen Plant will be used in the Pig Casting

Machine. Blow-down from the Fume Extraction Units will be utilized in the

Slab Caster.

Sewage from the plant canteen will be treated in septic tanks and soak

pits.

All storm water drains from the raw materials and solid waste handling areas

will be routed through catch pits of sufficient volume to settle out suspended

solids present in the storm water run-offs.

The lists of water pollution control systems envisaged are summarized in

Table-4.5.

Table-4.5: List of Water Pollution Control Systems

Source Pollutants Control System Raw material handling yard

Suspended Solids Catch Pits

Raw Water Treatment Plant

Suspended Solids Clarifier, Thickener, Sludge Pond

BF Gas Cleaning Plant Suspended Solids Clarifier, Thickener, Sludge Pond

Phenolic effluent Phenols, Ammonia, etc

BOD Plant

DM Water Plant pH Neutralizing Pit Slab Caster and Hot Strip Mills

Suspended Solids, Oil & Grease

Settling Tanks fitted with Oil & Grease Trap

Cooling Tower and Boiler Blow-down

Temperature, Dissolved Solids

Reused in the plant for dust suppression and slag granulation

Canteens, Toilets BOD, Suspended Solids

Septic Tanks, Soak Pits

Thus integrated steel plant will recycle water to the maximum extent possible.

However, in abnormal condition occasionally small quantities of waste water




have to be discharged to prevent build up of excess dissolved solids in

circulating water. During the monsoon requirement of water for dust

suppression and green belt irrigation will be drastically reduced. Hence

excess water from the sludge pond will have to be discharged. This waste

water will mostly contain salts of Calcium and Magnesium and suspended

solids already present in the raw water. Moreover, the waste water quality will

be well within the stipulated norms.

4.7.3 Generation of Solid Waste

The major solid wastes expected to be generated from the various facilities of

integrated steel plant are as follows:

Table-4.3: Quantity of Solid Waste Generated in the 3.1Mtpy Steel Plant

Sr.

No.

Solid Waste Nature of Solid Waste Quantity

(tpy)

Probable Re-use

DRI SECTION:

1. DRI fines Iron fines:33%

coal fines in the form of

solids as fixed C: 9%

Ash:58%

714000 100% will be utilize within plant in

sinter making and steel making

2. Char Ash:60%

C:35%

H2O : 3.5%

VM:1.5%

749700 100% will be sold to BEL who is

setting up CFBC based Power

Plant within plant boundary.

3. Transfer point dust

from ESP

Solid dust 324655 100% will be utilized within plant in

sinter making

4. Kiln Accretion and

miscellaneous

waste

- 42273 Dumped in low lying area and may

be used in clay making for various

purpose in steel plant

COKE OVEN COMPLEX

Coke Breeze 127000 Will be reused in sinter making




Sr.

No.


(tpy)

Probable Re-use

within steel plant

SINTER PLANT

Sinter dust solid 11607 Will be reused in plant

BLAST FURNACE

5. Dust from GCP Fe:50%

CaO:20%

SiO2:2%

Al2O3:3%

50430 Will be reused in sinter making

6. Granulated Slag MgO:8%

Al2O3:22%

401000 Granulated and 100% sold to

cement plant

7. Usable in-plant

scrap

47619 Will be recycled in SMS.

SMS SECTION:

6. Slag CaO:40-60%

SiO2:12-18%

MgO:4-7%

Fe2O3:5-7%

445032 will be used in the land fill, Boulder

soling of plant roads and may be

partly used in sinter making

.

7. Dust FeO:70%

MgO:9%

CaO:6%

22888 To be reused in the sinter plant

8. Scales Fe:>90% 15894 100% reused in sinter making

9. Usable Scrap 82000 100% Reused in steel making

HSM (Mill)

9. Return Scrap 38700 100% Reused in steel making

10. Scales Fe:>90% 24600 100% reused in sinter making

ORE CRUSHING

13. Iron Ore fines 1458600 100% reused in sinter plant

COAL WASHERY:

14. Middling from coal

washery

Ash : 45%

Carbon : 24%

O2:2.9%

1118000 100% sold to Bhushan Energy

Limited who is setting CFBC based

power plant within steel plant




Sr.

No.


(tpy)

Probable Re-use

H2:1.6%

S:0.5%

boundary

Solid waste shall be in the form of following:

• Fines collected from de-dusting system,

• Scales & scraps

• Slag from BF & EAF

Scales and skulls shall be generated as solid waste from integrated steel plant of

BSSL. These Scales and skulls are of ferrous nature and shall be recyclable. There

will be generation of scrap, which will be recycled in the plant itself in the Induction

furnace.

Slag from Blast furnace will be granulated and sold to the cement plants for slag

cement. Scrap from SMS and other areas will be recycled in the proposed steel

plant to the extent possible. Scale and debris from HSM will be recycled to the

maximum extent possible in the plant itself.

Management of SMS slag

The estimated slag generation from SMS operation shall be 445,032 tpy. The 50%

SMS slag will be used in land fill at low-lying areas and will be given for road making

purpose along with internal reuse. The remaining 50% shall be used in BF & inter

Mix as flux.

Management of Char & Washery Reject

The char is generated from DR kiln operation. The quantity and its disposal is

indicated in the table 5.2. The 100% char shall be sold to Bhushan Energy Limited




(BEL) for utilization in CFBC boilers. The coal washery shall generate 1,118,000 tpy

rejects and middling. These rejects shall be sold 100% to BEL for its use in CFBC

boilers to generate 300 MW power.

4.7.4 Impacts on Noise Levels

During normal operations of the plant ambient noise levels will increase

significantly only close to the turbines/compressor but this will be confined

only within plant boundary. However noise levels will increase greatly during

bleeding-off of excess steam. But such incidents are rare and will last only for

few minutes at a time only. The noise level within the plant boundary is

occupational noise levels and confined within shops. The level will be further

minimized when the noise reaches the plant boundary and the nearest

residential areas beyond the plant boundary, as elaborate green belt

development is envisaged for all along the boundary for attenuation of noise

and fugitive emission.

All the equipment in the steel plant will be designed/operated in such away

that the noise level shall not exceed 85 dB (A) as per the requirement of

OSHA Standard (Occupational Safety and Health Association). However, if

during operation, the noise level exceeds the OSHA norms then the

protective measures given in Environmental Management Plan will be

followed.

In addition to it, green belt development around the shops is to be done to minimise

propagation of noise to nearby areas.

4.7.5 Impacts on Ecology

The thresh-hold limit for continuous exposure of SO2 on plants is about 50 ug/m3

and that for NOx is 100 ug/m3 (Env. Engg., Chapter 7 by H. S. Pavy, D. R. Rowe,

G.T. Chobanoglous. Mc.Graw-Hill Book Co.1986). The level of air pollutants due to




operation of the present project will be much below the above said level for most of

the time, thus it is expected that the natural vegetation in the area will not be

affected. Although SO2 level will exceed the threshold norms in case all ten DRI

kilns are operating it is most unlikely that the excess level of SO2 will persist for a

sufficiently long duration for the plants to suffer any significant damage. So far as

agriculture crops are concerned, as they will remain in the field for three to six

months only, the impact on the same is also not anticipated.

As green belt will be provided all around the plant and effects on ambient air quality

and noise levels will be negligible beyond 4-5 km from the project site hence no

impact on flora and fauna are anticipated of the project.



© 2007 MECON Limited. All rights reserved 5-1

5.0 ENVIRONMENTAL MANAGEMENT PLAN

5.1 Introduction

It has been observed in the chapter 4.0 that due to modification-cum-expansion

of integrated steel plant, there will be minor impact during construction and

operation of plant. The adverse impacts can be minimized, if suggested pollution

control measures are undertaken and implemented. To mitigate the

environmental problem, a comprehensive Environmental Management Plan

(EMP) has been formulated in this context. The EMP has been worked out based

on present environmental conditions and anticipated environmental impact

appraisal. The EMP has been made for formulation, implementation and

monitoring of environmental protection measures during and after commissioning

of the project taking into consideration the following:

• Mitigation of Adverse impacts

• Occupational safety and Health

• Training facilities

5.2 Mitigation of Adverse Impacts

5.2.1 Air Pollution Management

In the integrated steel plant the sources of air pollution will be:

• Burning of fuel (coal) in DRI, Sinter plant, Blast Furnace and coke ovens

• Air pollution in the form of fumes due to melting of iron scrap and sponge iron

in Electric Arc furnaces etc

• Fugitive dust due to handling of coal and iron ore and other raw materials etc




The major emission due to coal/coke burning in DRI, Sinter plant, Blast furnace,

coke ovens will be Particulate Matter (PM). The hot gases from DRI and BF are

taken to waste heat recovery boiler to utilize the waste heat content of gases

after which these gases are discharge to atmosphere after cleaning in ESP to

reduce the emissions of SPM from the stacks. The ESPs will have an efficiency

of 99.8%. ESP will be designed with 50-mg/Nm3 dust emission. This will limit the

emission of SPM from each flue to maximum 50 mg/Nm3. as per design norms.

The lime/dolomite in the raw material feed mix in DRI/ fluidized combustion boiler

reduce the concentration of sulphur in the waste gases, which will lead to less

emissions of SO2 in the air. Moreover the stack will be of 76 to 120 m tall to

ensure sufficient dispersion (i.e. dilution) of the pollutants. In the proposed steel

plant the sources of air pollution and their mitigation measures are described

below:

Raw material handling area: The material handling section would be provided

with dust suppression (DS) by water sprinkling at the stockyard and multiple dust

extraction (DE) systems for the dust generation points at the screen, conveyor

transfer points and gas sealing devices to arrest the dust emissions to the

atmosphere. The DE system will consist of bag filter units complete with ducts,

extraction fans and stack of appropriate height.

DR Kiln

The exhaust gas from the rotary kilns would be cleaned by dry gas cleaning

system. The waste gas would be passed through a series of pollution control

equipment, which are as follows:

i) Dust settling chamber to settle coarse dust particulate.




ii) Post combustion chamber to burn out the CO in the flue gas.

iii) Waste heat recovery boiler to utilize waste heat for generation of steam.

iv) Electrostatic precipitator to reduce the dust particulate load to 50 mg/m3 and

the clean gas would be let to the atmosphere through a tall stack.

The fugitive dust emission and transfer point dust in DRI section shall be sucked

and cleaned in the ESP to the level of 50 mg/Nm3 and then discharge to

atmosphere.

Sinter Plant

The main pollutants in the sinter plant are dust emissions and the flue gas

emissions. It is proposed to use electrostatic precipitators to arrest the dust

before discharging it to atmosphere through tall chimney. ESP will be provided

for all de-dusting stack.

Coke Oven

The coke oven shall be provided with modern leak-proof oven doors and

door frame compatible to meet the pollution norm for PLD & PLO. The gas

off take system shall have ascension pipe gooseneck, isolation valves, gas

collection main and spray system to prevent any leakage from system.

Quenching emission is controlled by water spraying system in quenching

station.

Coke oven gas is cleaned and limited by-product is recovered and clean

gas is supplied to various users including coke oven batteries for heating.




Blast Furnace

Dust laden air will be sucked from different dust generating points by means of

suction hood, ducts and exhausted in the atmosphere after cleaning/collecting

dust in the dust collection equipment using bag filters.

For the blast furnace gas, it is proposed to use dry cyclone and wet scrubbing of

gas. Settling of particulate matter will be accomplished in water clarifiers and dust

settling chambers.

Lime calcining plant

The dust coming out from the lime kiln would be collected through bag filters and

the cleaned gas would be led into atmosphere through a tall stack. The dust

from the non point source would also be collected by DE hoods and the dust

laden gas would be cleaned by bag filters.

Electric arc furnace

The emissions from melting and refining would account to about 90 percent of

total EAF emissions. The remaining 10 per cent of emissions are generated

during charging and tapping. The primary emissions from the EAF would be

taken through a duct on the furnace roof to bag-filters.

The secondary emissions during charging and taping would be collected by a

canopy hood over the EAF and taken in the same manner to the bag-filter. Both

the emissions will be discharged into the atmosphere through a stack of suitable

height.




Induction Furnace

The primary emissions from the IF would be collected by canopy hood over the

furnace roof and taken in to bag-filters. The emissions will be discharged into the

atmosphere after bringing down the SPM level below 50 mg/Nm3.

Ladle Furnace

The dust laden hot fumes coming out from the ladle furnace would be collected

with fume extraction devices and cooled in a similar manner and let into the

same bag-filter after passing through a mixing chamber. Exhaust gas coming out

of the bag-filter is a clean one, which is let into the atmosphere through the stack.

Slab Casting & Hot Rolling

The water required for cooling of slabs would give rise to hot fumes containing

mostly water vapour. This would be collected by suitable fume extraction system

and taken through a condenser to separate out the steam condensate and the

spent gas let out through a roof top stack into the atmosphere. The waste water

coming out from the slab caster unit and hot rolling mill would be treated in a

scale pit where the coarse sized iron scales and the oil would get separated

followed by clarifier separation of fine particulates. The treated water would be

recycled after cooling. The hot gases from the soaking pit would be let out

through tall chimneys.

To reduce fugitive dust emission due to handling of iron ore, coal, dust extraction

and dust suppression systems will be installed at appropriate locations. The

Crusher House will be provided dry type dust extraction system with bag filters.

The dust extraction systems will consist of suction hoods, fans and bag filter units




with all accessories Plain water type dust suppression system will be provided at

the all around the coal/ raw material stockpiles and coal washery. The dust

suppression systems will consist of water sprinkling systems.

In order to prevent the spread of fugitive dust, green belt of adequate width will be developed all around the plant boundary and other locations described later. The sources of air pollution and the control methodologies are summarized in Table-5.1.

Table-5.1: Sources of Air Pollutants and Control Methods Source Pollutants Control Method Raw Material Handling Yard

Fugitive Dust Dust Suppression System, Green Belt

DRI process gas Dust,SO2 ESP, Lime & Dolomite Blast Furnace Stock House

Dust Bag Filter

Blast Furnace Stove SO2, NOx Burner Design, Stack of adequate height

Blast Furnace Dust in Top Gas Gas Cleaning Plant Lime Plant Dust, SO2, NOx Bag Filter, Stack of adequate

height Steel Melting Shop Dust Bag Filter Ferro-Alloys Plant Dust Bag Filter Reheating Furnace NOx Burner Design, Stack of

adequate height Coke ovens SO2, NOx Stack of adequate height,

gas cleaning in by-product recovery unit

Sinter plant Dust,SO2 & NOx ESP and stack of adequate height

Following are the list of pollution control equipment provided in the plant.

Table-5.2: LIST OF AIR POLLUTION CONTROL EQUIPMENT




Name of the unit Pollution control system

Sinter Plant Complex 1. Sinter Plant-Main Stack ESP 2. Sinter Plant – Cooler Stack ESP 3. Sinter Plant – De-dusting Stack ESP

Coke Oven Complex 4. Coke Oven Plant Stack1 - 5. Coke Oven Plant Stack2 - Blast Furnace Complex

6. Bf Stove Stack Tall Stack 7. Bf-Dry Gas Cleaning Bag House 8. Bf-Stock House Bag Filter 9. Bf-Cast House Dry Fog Dust Suppression System DRI Process Stacks after Waste heat Recovery Boilers

10. DRI Process Stack -I ESP 11. DRI Process Stack -II ESP 12. DRI Process Stack -III ESP 13. DRI Process Stack -IV ESP 14. DRI Process Stack -V ESP 15. DRI Process Stack -VI ESP 16. DRI Process Stack -VII ESP 17. DRI Process Stack -VIII ESP 18. DRI Process Stack -IX ESP 19. DRI Process Stack -X ESP 20. DRI Process Stack –XI ESP 21. DRI Process Stack –XII ESP 22. DRI Process Stack –XIII ESP 23. DRI Process Stack -XIV ESP

DRI Kilns - De-dusting stacks 24. DRI KILN-1 & 2-in plant de-dusting ESP 25. DRI KILN-3 & 4-in plant de-dusting ESP 26. DRI KILN-5& 6-in plant de-dusting ESP 27. DRI KILN-7& 8-in plant de-dusting ESP 28. DRI KILN-9 & 10-in plant de-dusting ESP 29. DRI KILN-11& 12-in plant de-dusting ESP 30. DRI KILN-13& 14-in plant de-dusting ESP

SMS Complex 31. SMS-1 EAF+LF Fume Extraction-I Bag Filter

32. SMS-1 EAF+LF Fume Extraction -II Bag Filter 33. IF+LF Fume Extraction -I Bag Filter




34. IF+LF Fume Extraction -II Bag Filter 35. SMS-II EAF+LF Fume Extraction-I Bag Filter 36. SMS-II EAF+LF Fume Extraction -II Bag Filter

Hot Strip Mill 37. RE-HEATING STACK-1 38. RE-HEATING STACK-2 39 RE-HEATING STACK-3

Captive Power Plant 40. BFG gas fired Boiler of CPP

Lime & Dolo Plant 41. LIME PLANT – KILN1 Bag Filter 42. LIME PLANT – KILN2 Bag Filter 43. DOLO PLANT – KILN5 Bag Filter

Raw Material Preparation Plant 44. RMP CRUSHER Bag Filter

5.2.2 Wastewater Management

The prevention and control of water pollution aim at conserving make-up water

by recycling the wastewater after treatment. During the operation of the plant,

three major categories of wastewater, viz. blow down water from the cooling

tower, ash slurry water and sanitary waste water streams would be generated.

Wastewaters are expected to be generated from different facilities of the

proposed plant. Water Balance Diagram is given in Drg No BSSL/0/ISP/7-

1 sheet 1 of 1. Efforts are made to reuse most of the water in the plant

itself.

The wastewater likely to be generated from the integrated steel plant is:

Underflow from Raw Water Clariflocculator

Backwash Waste from Filtration Plant

DM Plant Regeneration Waste




Run-off water from Raw Material Storage Yards

Waste water from gas cleaning system in BF

Phenolic effluent in Coke oven complex

Waste Water from Hot Strip Mill

Cooling Tower Blow-down

Boiler Blow-down

Sewage & Canteen Effluents

Sludge from Raw Water Clariflocculator and Backwash from Filtration

Plant will be led to a thickener for removing suspended solids. The

overflow from the thickener will be reused in the plant water system. The

sludge from the thickener will be dried and dumped. During the monsoon

season, this treated effluent along with run-off will be discharged to nearby

natural drainage system. Since this treated effluent will contain only solids

present in the raw water drawn from Brahmani River, the discharge of this

treated effluent will not affect the quality of Brahmani River by any

appreciable degree.

Water from coal washery will be treated in thickener. Overflow from thickener

(clarified water) will be reused in the plant. The coal washery shall maintain

close circuit operation.

Water from the BF GCP will be sent to a clarifier / thickener. The overflow

from the thickener will be re-circulated. The underflow from the thickener

will be sent to a press filter and recovered cake will be recycled in sinter

plant.




Acidic and Alkaline effluents will be generated at the DM Water Plant.

These effluents will be properly neutralized and reused in the plant through

ash pond.

Effluents from the slab caster and hot strip mill complex are likely to

contain suspended solids and oil & grease. These effluents will be routed

to settling pits fitted with oil & grease trap. The clarified water will be

reused in the plant.

Cooling Tower Blow-down from various recirculation systems will be

cascaded for reuse in other qualitatively compatible systems as shown in

enclosed water balance drawing.

Thus, proposed plant will recycle water to the maximum extent possible.

However in abnormal cases periodically small quantities (50 m3/h max) of

effluents if and when required to be discharge to prevent build up of

excess dissolved solids into natural drainage channels through

stabilization in pond and will be well within the stipulated norms of quality.

Efforts will be made to harvest rainwater in the plant. Run-off water from

the office areas, shop roofs will be collected and stored for future use.

oil sewer will collect water from areas where there are possibilities of

contamination by oil (transformer yard, fuel & lubricating oil storage areas, and

workshop) and the drains from such areas will be routed through an oil-water

separator. The collected oil shall be sold to re-refiner approved by SPCB.

All storm water drains from the raw materials and solid waste handling

areas will be routed through garland drains into catch pits of sufficient




volume to settle out suspended solids present in the storm water run-offs.

The clear water will be discharged into natural drainage channels. This

type of effluent is anticipated only in monsoon season.

The sewage from the Plant, Township and Canteen waste water will be treated in

sewage Treatment Plant. The treated sewage will be diverted for irrigation of

green cover.

5.2.3 Solid Waste Management/Disposal

The principal solid waste produced by any steel plant is slag, scrap, scale and

dust. The dust from dust catcher of DRI unit, dust from SMS section will be

recycled to the extent possible in the plant itself or sold to outside parties.

SMS slag from EAF will be used in land fill at low-lying areas. Slag from Blast

furnace will be granulated and sold to the cement plants for slag cement. Scrap

from SMS and other areas will be recycled in the steel plant to the extent

possible. Scale and debris from HSM will be recycled to the maximum extent

possible in the plant itself. The solid waste generated and their probable uses are

indicated in the Table-5.2.

Table-5.2: Quantity of Solid Waste Generated in the 3.1Mtpy Steel Plant

Sr. No.

Solid Waste Nature of Solid Waste Quantity (tpy)

Disposal methodology

DRI SECTION: 1. DRI fines Iron fines:33%

coal fines in the form of solids as fixed C: 9% Ash:58%

714000 100% will be utilize within plant in sinter making & steel making

2. Char Ash:60% C:35% H2O : 3.5% VM:1.5%

749700 100% will be sold to BEL who is setting up CFBC based Power Plant within plant boundary.

3. Transfer point dust from ESP

Solid dust 324655 100% will be utilized within plant in sinter making




Sr. No.

Solid Waste Nature of Solid Waste Quantity (tpy)

Disposal methodology

4. Kiln Accretion and miscellaneous waste

- 42273 Dumped in low lying area and may be used in clay making for various purposes in steel plant

COKE OVEN COMPLEX

5. Coke Breeze 127000 Will be reused in sinter making within steel plant

SINTER PLANT

6. Sinter dust solid 11607 Will be recycled in sinter plant

BLAST FURNACE

7. Dust from GCP Fe:50% CaO:20% SiO2:2% Al2O3:3%

50430 Will be reused in sinter making

8. Granulated Slag MgO:8% Al2O3:22%

401000 Granulated and 100% sold to cement plant

9. Usable in plant scrap

47619 Will be recycled in SMS.

SMS SECTION:

10. Slag CaO:40-60% SiO2:12-18% MgO:4-7% Fe2O3:5-7%

445032 will be used in the land fill, Boulder soling of plant roads and may be used partly in sinter making .

11. Dust FeO:70% MgO:9% CaO:6%

22888 To be reused to the sinter plant

12. Scales Fe:>90% 15894 100% reused in sinter plant

13. Usable Scrap 82000 100% Reused in steel making HSM (Mill)

14. Return Scrap 38700 100% Reused in steel making 15. Scales Fe:>90% 24600 100% reused in sinter making

ORE CRUSHING 16. Iron Ore fines 1458600 100% reused in sinter plant

COAL WASHERY: 17. Middling from coal

washery Ash : 45% Carbon : 24% O2:2.9% H2:1.6% S:0.5%

1118000 100% sold to Bhushan Energy Limited who is setting CFBC based power plant within steel plant boundary




The iron ore fines and BF GCP Sludge will be recycled in sinter plant.

Since the proposed plant envisages such a facility, the iron ore fines will

be used for sintering. The GCP Sludge will be recycled in sinter plant.

Sludge from water treatment plant and dust recovered from dust extraction

systems will be dumped in sludge pond. The slag from the Blast Furnace

will be granulated and sold to cement manufacturers. The SMS slag will be

sold to parties engaged in building roads.

Other solid wastes, which will be generated in the proposed steel plant,

include waste refractories, scrap, scales, waste lubricants etc. Waste

refractories will be sold as road building material or dumped in landfills. All

the scrap will be recycled fully. Waste lubricants will be sold to

reprocessing units. Scales will be recycled. The used batteries shall be

returned back to the manufacturer in lieu of the new batteries of equivalent

numbers.

Hazardous wastes from by product plant will be reused and balance will be

disposed / sold as per Hazardous waste rules of Indian government.

5.2.4 Noise Level Management

In integrated steel plant crusher area, furnace area, the power generating sets,

fans and pumps will be the major sources of noise.

Noise generation levels will be considered while selecting equipment. Equipment

should not generate noise more than 85 dB (A) at 1m distance. Wherever

required noisy equipment will be placed on vibration isolators or housed in a

separate enclosure or surrounded by baffles covered with noise absorbing

material. As the operator would be stationed in the control room, there is




minimum chance of exposure to high noise levels. However Personnel working in

high noise zones will be issued with personal noise protection equipment (e.g.

ear muffs, ear plugs) and their duty hours will be regulated to control noise

exposure levels. In addition green belt will be developed all around the plant

boundary and around various shops and offices to prevent the spread of

noise produced inside the plant.

5.2.5 Green Belt Development Plan

Green belt is an important sink for air pollutants. Trees also absorb noise and by

enhancing the green cover, improve the ecology and aesthetics and affect the

local micrometeorology. Trees also have major long-term impacts on soil quality

and the ground water table. By using suitable plant species, green belts can be

developed in strategic zones to provide protection from emitted pollutants and

noise.

Plant species suitable for green belts should not only must be able to

flourish in the area but must also have rapid growth rate, evergreen habit,

large crown volume and small / pendulous leaves with smooth surfaces.

All these traits are difficult to get in a single species. Therefore a

combination of these is sought while selecting trees for green belt. The

green belt should be planted close to the source or to the area to be

protected to optimize the attenuation within physical limitations.

In the proposed plant, green belt will be developed in vacant areas,

around office buildings, around stores, along the side of roads, along the

plant’s boundaries and around the waste dump area. Plant species suitable

for green belts should not only be able to flourish in the area but must also have

rapid growth rate, evergreen habit, large crown volume and small / pendulous

leaves with smooth surfaces. All these traits are difficult to get in a single




species. Therefore a combination of these is sought while selecting trees for

green belt. The green belt should be planted close to the source or to the area to

be protected to optimize the attenuation within physical limitations. A total of

approximately 33% area will be developed as green belt or green cover. Green

belt will also be planted in township. The widths of the belt will 50 m to 100 m as

per the space availability all along the boundary. Whereas, around waste dumps

site an area of about 100 acre will be under green belt with a width ranging from

30 m to 50 m as per the availability of space. A total of about 1200 - 1500 per ha

plants will be planted. The species for green belt development will be

selected in consultation with the State Forest Department. The following

species are suitable for planting in the area as recommended by Central

Pollution Control Board in their publication “Guidelines for Developing

Greenbelts” (PROBES/75/1999-2000):

A very elaborate green belt development plan has been drawn for the proposed

plant. The areas, which need special attention regarding green belt development

in the industrial area, are:

- Along Plant Boundary

- Along Road Side

- Around Various Shops

- Around Office and Other Buildings

- Stretch of Open Land

- In and Around Township




Selection of Species

The species for plantation have been selected on the basis of soil quality, place

of plantation, chances of survival, commercial value (timber value, ornamental

value, etc.), etc. It is to be noted that only indigenous species will be planted.

Exotic species such as Eucalyptus and Australian Acacia will not be planted. The

species will be selected in consultation with State Soil Conservation Department.

Mixed plantations will be done keeping optimum spacing between the saplings.

Along Plant Boundary

The row of plants facing plant should be smaller species and those facing outside

should be taller species. The species suggested for plantation is:

Small Species

Kaneer (Nerium sp.)

Prosopis (Prosopis juliflora)

Bougainvellea (Bougainvillea spp.)

Ber (Zizyphus spp.)

Gulmohar (Delonix regia)

Duranta (Duranta sp.)

Kamayani (Murriya exocitica)

Bilayati Babool (Prosopis juliffera)

Babool (Acacia arabica)

Tall Species

Amaltas (Cassia fistula)

Siris (Albizzia lebbeck)

Neem (Azadirachta indica)




Druping Ashok (Polyalthia longifoila)

Mango (Mangifera indica)

Peepal (Ficus religiosa)

Arjun (Terminalia arjuna)

Jackfruit (Artocarpus heterophylla)

Palash (Butea spp)

Cassia (Cassia siamea)

Bottle brush (Callistemon lanceolatus)

Road Side Plantation

Avenue plantation should include the following species:


Gulmohar (Delonix regia

imli (Tamarindus indica)






Bargad (Ficus bengalisis)



Around Various Shops

As there will be limited space (in height) due to various over head pipelines, thus

small and medium sized species are suggested and they should be planted




depending on the vertical height and lateral space available for the plant growth.

The species selected will be from among the following:

Small Species

Ber (Zyziphus sp.)

Sharifa (Annona squamosa)

Prosopis (Prosopis sp.)

Cassia (Cassia auriculata)

Duranta (Duranta sp.)

Kamayani (Murrya exotica)

Medium Size Species

Kaner (Nerium sp.)


Subabool (Leucaena leucocephala)

Cassia (Cassia alata)

Babool (Acacia arabica)

Around Office and Other Buildings

Plantation will be done around various shops, stores and other buildings, along

the side of connecting roads. Species suggested for plantation are as follows

which are mostly ornamental plants:

Cassia (Cassia javanica)








Lagerestromea (Lagerestromea flosregennae)

Peltophorum (Peltophorum feruginium)

Gulmohar (Delonix regia)


Stretch Of Open land

In the proposed plant, green belt will be developed in vacant areas. Species

suggested for such areas are:


Pakur (Ficus racemosa)


Imli (Tamarindus indica)

Peltophorum (Peltophorum feruginium)






Bargad (Ficus bengalisis)



Mixed plantation will be done to take care of different heights and rates of growth.




In and Around Township

In the proposed township plantation will be done in following areas:

- Along the township boundary

- Along the roads

- Stretch of open land

For the above areas the plants to be planted will be from among the list given

above for respective areas in the plant premises.

Phase Wise Green Belt Development Plan

Green belt will be developed in a phase wise manner right from the construction

phase of the proposed plant. In the first phase (in the first and second year of

construction) along with the start of the construction activity the plant boundary,

the township boundary, around the proposed waste dumps, and the major roads

will be planted. In the second phase (in the third year of construction) the office

building area will be planted. In the third phase (in the fourth year of construction)

when all the construction activity is complete plantation will be taken up in the

plant area, in stretch of open land, along other roads and in the township will be

taken up.

The trees may be watered using the effluent from the sewage treatment plant.

They will be manured using sludge from the sewage treatment plant. In addition

kitchen waste from the town-ship and plant canteen can be used as manure

either after composting or by directly burring the manure at the base of the

plants.




Kitchen waste from plant canteen can be used as manure either after composting

or by directly burying the manure at the base of the plants.

5.3 Rainwater Harvesting

BSSL is planning to have a system of rainwater harvesting at plant in

Meramandali. Rainwater harvesting is primarily dependent on various site

characteristics such as soil properly, catchments characteristics; rainfall

characteristic, and ground water table etc.

There are artificial as well as natural rainwater harvesting system. The

recharging system can be implemented for

i) Individual units

ii) Centralized collection system

Scheme I: Collection of rainwater harvesting from individual building units and

construction of filter beds at individual building unit. Rainwater falling on other

open area is to be collected, through constructed drainage system and discharge

system and discharge to surface out-fall (by passed for rainwater harvesting)

Scheme II: Construction of rainwater filter bed at centralized place where water

from individual unit as well as storm water from open area shall be diverted

The rainwater carries suspended solids as washed out from open area. A filter

bed filters the particles thus prevent them from reaching / contaminating ground

water.




The first layer of filter bed shall be coarse sand the second layer shall be pebbles

and third layer shall be gravel. The filtrate thus collected from the bottom of filter

bed shall be piped to recharge bed.

5.4 House Keeping

Proper house keeping is an essential part of sound environmental management.

It will be rigorously seen that there is no accumulation of wastes, especially

combustible wastes (e.g. Oily rags, oil sludge, wood from packing boxes, etc.)

inside the plant area. In summer dry grasses & vegetation growing inside the

plant area will be cut and removed. All fire fighting equipment and warning

devices will be kept in perfect working conditions.

It will be seen that all personnel are aware of the implications of environmental

pollution and simple practices to avoid pollution.

5.5 Occupational Safety and Health

Maintenance of occupational safety and health is very closely related to

productivity, good employer employee relationships and good relationships

among all on board personnel.

The main factors of occupational health in steel plant are dust, heat and noise.

Following measures will be undertaken in the installation for occupational safety

and health of workers.

Inspection and maintenance of pollution control systems will be undertaken

only after checking that the equipment has been properly shut down or with

permission of authorised officer.

Immediate removal of waste accumulated in working areas.




Insulation of hot surfaces.

All safety measures will be strictly implemented. Fire fighting equipment will

be tested regularly to ensure their full serviceability. Contingency plans drawn

up to deal with accidents will be rehearsed by all personnel.

Training of employees for use of safety appliances and first aid.

Regular medical check up of personnel will be carried out.

5.6 Pollution Monitoring

The proposed plant’s Environmental laboratory may be equipped to monitor

meteorology, air quality, noise, water quality, emissions from stacks and solid

wastes. External laboratories may be contracted to carry out the required

monitoring work. The frequency of sampling will be as per Central and State

Pollution Control Board guidelines. Continuous on line monitoring facilities will be

provided for each major stack. An Environment Management department will be

constituted to operate and maintain all pollution control systems, organise

necessary environmental monitoring and maintain records & details of

monitoring.

5.7 Training Facilities

To achieve the objective of pollution control it is essential not only to provide

latest pollution control and monitoring systems but also provide trained

manpower to operate and maintain such systems. So the Environmental

Management department personnel will be provided with additional specialized

training to operate and maintain the equipment to be deployed on the installation.

All personnel will be trained to deal with pollution emergencies also.




5.8 Community Development Plan

BSSL is committed to community development around the steel plant. It

has an ambitious plan to adopt 10 villages for community development. A

substantial amount has been allocated for the following activities for the

social up-liftment of surrounding villages.

• An school for children of surrounding villages upto XIIth standard

• A 50 bedded community hospital for the population in surrounding

villages

• Provision of drinking water facilities in surrounding villages

• BSSL will facilitate the technical training institute such as ITI in

collaboration with state authority.

• Provision for training of women folks (sewing, stitching etc) of

surrounding villages for their economic up-liftment.

5.9 Charter on Corporate Responsibility for Environmental Protection (CREP):

Integrated Iron & Steel Industry 1. Coke Oven Plants To meet the parameters PLD (% leaking doors), PLL (%leaking lids), PLO (%

leaking off take), of the notified standards under EPA within three years (by

December 2005). Industry will submit time bound action plan and PERT Chart

along with the Bank Guarantee for the implementation of the same.

To rebuild at least 40% of the coke oven batteries* in next 10 years (by December 2012). The coke oven plant is expected to be implemented in 2008-09 with all latest technology and shall meet all government guidelines given in CREP.




2. Steel Melting Shop

Fugitive emissions - To reduce 30% by March 2004 and 100% by March 2008

(including installation of secondary de-dusting facilities).

The primary fume extraction system and secondary dedusting facilties will be

installed.

3. Blast Furnace

Direct inject of reducing agents —— by June 2013.

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

reducing agents will be provided.

4. Solid Waste / Hazardous Waste Management

Utilization of Steel Melting Shop (SMS) / Blast Furnace (BF) Slag as per the

following schedule:

By 2004 - 70%,

By 2006 – 80% and

By 2007 – 100%.

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

and ballast for railway track. BF slag will be granulated and it will be sold to

nearby cement plant and the schedule given in format will be followed.




Hazardous Wastes

Charge of tar sludge / ETP sludge to Coke Oven by June 2003.

Inventorization of the Hazardous Waste as per Hazardous Waste (M&H) Rules,

1989 as amended in 2000 and implementation of the Rules by Dec. 2003.

(tar sludge, acid sludge, waste lubricating oil and type fuel falls in the category of

Hazardous Waste)

Inventorisation of the hazardous waste will be done in line with the notification.

5. Water Conservation / Water Pollution

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

flat products by December 2005.

The water conservation as per the directives of CREP, when the plant gets

stabilised and below 8 m3/t for flat products.

To operate the CO-BP effluent treatment plant efficiently to achieve the notified

effluent discharge standards. - by July 2003

The Phenolic effluent shall be treated in BOD plant and treated effluent shall be

used for coke quenching after suitable Addison of makeup water.

6. Installation of Continuous stack monitoring system & its calibration in major

stacks and setting up of the online ambient air quality monitoring stations by June

2005.




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

provided. 5 nos. of permanent AAQ monitoring stations around plant is also

envisaged.

7. To operate the existing pollution control equipment efficiently and to keep

proper record of run hours, failure time and efficiency with immediate effect.

Compliance report in this regard is submitted to CPCB / SPCB every three

months.

Agreed

8. To implement the recommendations of Life Cycle Assessment (LCA) study

sponsored by MoEF by December 2003.

The issue shall be examined & shall be to be done as per the Government

directives

9. The industry will initiate the steps to adopt the following clean

technologies/measures to improve the performance of industry towards

production, energy and environment.

- Energy recovery of top Blast Furnace (BF) gas.

We are committed to adapt best available technology

- Use of Tar-free runner linings.




Best available indigenous material will be used.

- De-dusting of Cast House at tap holes, runners, skimmers ladle and charging

points.

Agreed

- Suppression of fugitive emissions using nitrogen gas or other inert gas.

His will be done as per the best available technology

- To study the possibility of slag and fly ash transportation back to the abandoned

mines, to fill up the cavities through empty railway wagons while they return

back to the mines and its implementation.

It is already envisaged in the project

- Processing of the waste containing flux & ferrous wastes through waste

recycling plant.

Committed to adapt best available technology.

- To implement rainwater harvesting.

We have planned for rain water harvesting.

- Reduction of Green House Gases by:




• Reduction in power consumption

Reduction of power consumption will be done by regular energy auditing.

• Use of by-products gases for power generation

It is included in the project and we are using the kiln outlet gases for power

generation

• Promotion of Energy Optimisation Technology including energy audit

This plant will be one of the best example for promotion of energy optimisation

technology.

- To set targets for Resource Conservation such as Raw material, energy and

water consumption to match International Standards.

All effort will be made to match international standards

- Up-gradation in the monitoring and analysis facilities for air and water

pollutants. Also to impart elaborate training to the manpower so that realistic

data is obtained in the environmental monitoring laboratories.

We have already planned for best equipped laboratory for analysis of air, water

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

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

independent Environmental Management Cell.




- To Improve overall house keeping.

Agreed

10. Sponge Iron Plants

Inventorisation of sponge iron plants to be completed by SPCBs/CPCB by June

2003 and units will be asked to install proper air pollution control equipment by

December 2003 to control primary and secondary emissions.

* As per rebuilding schedule submitted to CPCB/MoEF.

Proper air pollution control equipment shall be employed




6.0 EMP IMPLEMENTATION AND MONITORING

Various measures have been suggested in the environmental management

plan for mitigation of impacts. These have to be implemented according to

the suggestions and monitored regularly to prevent any lapse.

A large part of the sampling and measurement activity is concerned with long

term monitoring aimed at providing an early warning of any undesirable

changes or trends in the natural environment that could be associated with

the plant’s operation. A separate department has already been to look after

all environmental related matters of the plant.

Quarterly environmental audits will be carried out for expansion plant to

check for compliance with standards. This is being carried out by external

experts.

Third party environmental audits will be carried out once very year.

BSSL has already taken ISO:14001 EMS certification in many of its plant and

will implement Environmental Management System (EMS) in Meramandali

also.

The unit is taking all necessary steps to implement the measures suggested

by Central Pollution Control Board (CPCB) in the Charter on Corporate

Responsibility for Environmental Protection (CREP) for Integrated Iron and

Steel Industry.




6.1 Laboratory Facilities

It is imperative to BSSL to have a well-equipped environmental control

laboratory inside the plant premises. The Environmental control laboratory

shall apply for recognition as per EP Act 1986 and notified in Government of

India Gazette. The laboratory shall be running continuously 24 hours in three-

shift operation and carrying out all monitoring as specified in their Consent

condition.

All the personnel deployed in the laboratory have been given training by

external experts so to carry out necessary environmental monitoring as well

analysis. The equipment will be made available for carrying out

environmental monitoring shall be as follows:

Table 6.1: List of Monitoring / Analytical Equipments required with

Environmental Lab of Meramandali Steel Plant

Sl.

No.

Item Description / make/ model Quantity

1. High Volume Sampler Vayubodhan APM-4-0 4 2. Respirable Dust Sampler Vayubodhan APM-451 4 3. Stack Monitoring Kit Env. Engg. Nagpur SMK-70 1 4. HVS Flow Calibrator Andersons samplers S-53 1 5. PM-10 HVS Ecotech Pvt. Ltd. 2 6. Dry Gas Meter Env. Engineers Inc. A-1 3 7. Analytical Balance The Balance Works (P) Ltd. 1 8. Digital Balance Sartorious L-22005 1 9. Anemometer Dynalab 1 10. Digital Balance Sartorious R-200 D 1 11. Personal Sampler Gillian HFS-113 A 1 12. Nephelo Turbidity meter HACH / 16800 2 13. DR-2000 Spectrophoto Meter HACH / 44800 2 14. COD Reactor HACH / 45600 2 15. Portable Dissolved Oxygen

Meter Toshniwal Process Inc. Ltd. OXI-191 2

16. PDV-2000 Digital Voltameter Chemetronics Austria PDV-2000 1




Sl.

No.

Item Description / make/ model Quantity

17. Selective Iron Meter Orion Reaserch Inc. AE-940 1 18. Selective Iron Meter Orion Reaserch Inc. AE-960 1 19. Composite Sampler Sigma / 702 2 20. Visible Spectro Meter Nikal Associates Genway UK/6100 1 21. BOD Analyser HACH/2173-B 1 22. BOD Incubator Newtronic 10 GRS 1 23. Ultrasonic Flow Meter Polysonics 18408 MST-P 4 24. Vaccum Pump Charles Austerm Pumps Ltd. Capes-

L3C 1

25. Vaccum Pump Charles Austerm Pumps Ltd. Capes-L2C

1

26. Muffle Furnace Okay 1 27. Drying Oven Scientists Own Concern – 360 2 28. Ultrasonic Cleaner Lucas Dawe B 3200 E4 1 29. Adjustable Digital Pipettes HACH (Eriuliben) 1 30. Spectrophotometer Toshniwal (BOM) Inst. Pvt. Ltd. 1 31. Digital Multimeter Philips Scientific – 8050 A 1 32. D.O Meter ORION 810 1 33. Hot Plate 1 34. Muffle Furnace Super Heating India 1 35. Electronic Balance Anamed Co AA-2200 1 36. Digital Conductivity meter Unitech U-31 C 1 37. Sound Level Meter with

calibrator & Octave Pilter Set Bruael & Kjear – 2230 1

38. CEL-275 SLM Lucas CEL-275 1 39. CEL-177 Precision Acoustic

Calibrator Lucas CEL 1

40. CEL-296 Octave Y-3 Octave filter

1

41. CEL-238 Secondary Processor with Printer

Lucas CEL 1

42. UHER 4200 Report Monitor UHER – 4200 1 43. Electronic Balance ORTELING 1 44. On-line ambient air monitoring

station 2

45. On-line stack monitoring of major stack

15

6.2 Meteorology

A meteorological station will be set up at a suitable location within the plant

premises. The following parameters will be recorded regularly:




Wind speed and direction

Rainfall

Temperature and humidity

Evaporation rate

6.3 Primary & Secondary Emissions Monitoring & Air Quality

Ambient air quality shall be monitored regularly in accordance with CPCB /

Orissa State Pollution Control Board (OSPCB) guidelines. Work zone air

quality shall also be monitored as per directives of OSPCB to assess the

levels of particulate matter, NOx and SO2.

Efforts will be made to install continuous Ambient Air Quality monitoring

systems in accordance with the CREP. All major stacks will be provided with

on-line monitoring system. The emissions from all the stacks shall be

monitored once a month using the manually operated stack emissions

monitoring equipment. However the frequency of monitoring may be

increased if required in accordance with the stipulations of OSPCB or other

statutory authorities.

6.3.1 Stack Emission Monitoring*

Shop Nos. of Stacks Monitoring Frequency

per month

1. Sinter Plants 3 3

2. Coke Ovens 2 2

3. Blast Furnaces 3 3

4. Refractory Material Plant 3 3




Shop Nos. of Stacks Monitoring Frequency

per month

5. Steel Melting Shop 6 6

6. Hot Strip Mill 3 3

7. DRI Units 17 17

* Parameters = TPM, SO2, NOX

6.3.2 Ambient Air Quality Monitoring*

Description Nos. of Stn Monitoring Frequency

1. AAQ Monitoring 5 Once per Week

* Parameters = SPM, SO2, NOX

6.3.3 Water Quality Monitoring*

Description Nos. of Locations Monitoring Frequency

1. Outlets 2 Once a Week

* Parameters = pH, SS, Phenol, Cyanide, COD, BOD, DO, NH3-N, Temp. O & G

6.3.4 Noise Monitoring

Description Nos. of Locations Monitoring Frequency

1 Ambient Noise 10 Once in 3 months

The suggestions given in the EMP shall be implemented by the EMD by following an

implementation schedule.




• Along with the performance and guarantee test of main plant equipment,

performance and guarantee test of pollution control equipment will be made

before taking over the expansion plant. EMD shall also be a party in preliminary

and final acceptance tests.

• A detailed maintenance schedule shall be drawn for all pollution control systems.

The maintenance shall be done strictly as per schedule and guidelines furnished

by plant manufacturer.

• Ground level concentration in ambient air, stack emission and work zone

monitoring results shall be discussed in the EMD and any variance from norms

shall be reported to the Executive Director for immediate study and rectification

action

6.4 Drainage System

The effectiveness of the drainage system depends on proper cleaning of all

drainage pipes/channels. Regular checking is being done to see that none of

the drains are clogged due to accumulation of sludge/sediments. The clogged

drains are cleaned as soon as possible, preferably the same day. The catch-

pits linked to the storm water drainage system from the raw material handling

areas are regularly checked and cleaned to ensure their effectiveness. This

checking and cleaning is rigorous during the monsoon season, especially if

heavy rains are forecast.

6.5 Water Quality

Effluents from outfall, Sewage treatment plant from Township and Plant are




monitored and tested in Environmental Control Laboratory at least once a

month as per CPCB guidelines / directives. However the frequency of

monitoring may be increased if required in accordance with the stipulations of

OSPCB or other statutory authorities. In addition to above BSSL shall also

carrying out monitoring of certain parameter in some of the plant

equipment/area as a quality measures for measurement of pollutants going to

outfall

6.6 Noise Pollution

The EMD shall monitor and keep the record of noise levels and take necessary

organisational actions like rotation of workmen, availability and use of personal

protective devices, damage to enclosures or insulation layers over enclosures and

piping.

6.7 Green Belt Development

As discussed in EMP chapter BSSL shall plant trees in almost all possible locations

and continuously encourage others to plant trees in their garden, locality etc.

However following plan shall also be made for future program

o Annual plans for tree plantation with specific number of trees to be planted shall

be made. The fulfillment of the plan shall be monitored by the EMD every six

months.

o A plan for post plantation care will be reviewed in every monthly meeting. Any

abnormal death rate of planted trees shall be investigated.




o Watering of the plants, manuring, weeding, hoeing will be carried out for

minimum 3 years

6.8 House Keeping

The EMD shall be keeping a very close monitoring of house keeping activities and

organising regular meetings of joint forum at the shop level (monthly), zonal level –

(once in two months) and apex level ( quarterly). The CED (Civil Engineering

Department) shall take care for the house keeping of shops.

6.9 Occupational Health

Routine medical examination of personnel shall be carried out as a

systematic programme at plant.

6.10 Interaction with State Pollution Control Board (SPCB)

EMD shall be in regular touch with OSPCB and send them quarterly progress report

on EMP. Any new regulations considered by State/Central Pollution Control Board

for the Industry are been taken care of.




7.0 DISASTER MANAGEMENT PLAN

An Emergency Plan has been formulated to take care of any disaster in the

existing integrated steel plant and surrounding areas and is detailed as under:

In order to prevent occurrence of any disaster, the plant will be provided with

various safety and disaster control facilities. Normally, in the steel plant, no major disaster affecting nearby population areas are foreseen. However, accidents inside the plant affecting workplace in vicinity cannot be ruled out. Work-force inside the plant shall be exposed to various high pressure

system pipelines and vessels, acids and chemicals, fuel such as coal and

furnace oil and other process equipment which, if not properly operated and

maintained, can cause serious accidents affecting life and property in the vicinity

of accident site. In addition to these, numerous material handling systems, heavy

road transport, high-tension electric lines, level crossings, overhead cranes and

various other handling and transport systems always have chances of accidents.

Definition of Disaster

A situation will be called a `Disaster' if it entails any one or more of the following

factors:

i) Risks of loss of human lives - ten or more in one single situation.

ii) Loss of property as a consequence of the incident is over Rs.1 crore

and/or bears a potential to the above.

iii) A situation which goes beyond the control of the available resource of the

plant.

iv) A situation apparently may not have much loss but its long-term severity

can affect loss of life, production and property.




The types of possible disaster are given below:

Type of disasters

i) Disaster due to emergencies on account of:

- Fire

- Explosion

- Oil spillage

- Spillage of toxic chemicals

- Electrocution

ii) Disaster due to natural calamity on account of:

- Flood

- Earth quake / cyclone / Storm / Cloud burst / lightning

iii) Disaster due to external factors on account of:

- Food poisoning / water poisoning

- Sabotage

Objectives

Objectives of disaster control/management plan for existing Steel Plant are:

i) To identify type of major disasters which may occur in the plant?

ii) To collect data on type of disasters which has happened already in other

steel plants?




iii) An action plan to handle disaster.

Identification of Hazardous Process/Area

1. Furnaces area - Explosion

2. Fuel Oil tanks - fire & spillage

3. Turbine Hall – Explosion

4. Boiler Explosion

Electrical premises

1. Electrical Rooms - Fire & Electrocution

2. Transformer area - Fire & Electrocution

3. Cable Tunnel - Fire & Electrocution

Other premises

Storage facilities for coal and fuel oil -Fire/spillage

Level of Accident

If there is any disaster in any part of the plant /work place due to any reason the

area which may be affected can be classified in the following four classes.

1. Level I - Operator level

2. Level II - Local/community level

3. Level III - Regional/ national level

4. Level IV - International level




There is only level I and II class of accidents can be considered for the steel plant.

Level I

Under this level, disasters may happen due to fire, explosion, oil spillage and

spontaneous ignition of inflammable materials.

This level has probability of occurrence affecting persons inside the plant. The

various shops, which have been mentioned as potential hazard areas, will be

affected during this level of accident.

Level II

In case of sabotage/complete failure of all automatic control/warning systems for

example in fuel oil storage area the oil kept in tanks and covered by tank bund

may leak out. However, the probability of this is very low due to adequate

security and training of persons of the plant operating such system.

Disaster Preventive Measures

If any disaster takes place it is not easy to control if contingency plans are not

available. For effective control of disaster adequate manpower, technical

know-how, alertness and internal help are necessary. It always betters to take

preventive measures to avoid any disaster. In proposed plant following

prevention measures will be taken to prevent disaster.




Plant layout: i) Design, manufacture and construction of all plant and machinery’s and

buildings will be as per national and international codes as applicable in

specific cases and laid down by statutory authorities.

ii) Provision of adequate access ways for the movement of equipment and

personnel are kept.

iii) Minimum two numbers of gates for escape during disaster shall be

provided.

iv) Siting of fuel oil storage shall be in protected fenced area inside tank

bend.

v) Water spraying in coal storage area.

Fire Fighting The existing plant is having a well-equipped fire-fighting group for the existing

steel plant with 5 Officers, 25 Workers trained in this field. Following fire-fighting

equipment shall be in place when the plant fully commissioned:

- Fire Tender 2 No.

- Jeep 4 Nos

- Portable Extinguishers Lot

- Foam generator Lot

- Static tanks Lot

List of Fire Extinguishers Required at Different Locations

Name of site Type

Kiln Area

CO2 Foam type

Dry Chemical type




Name of site Type

IF & EAF Area

Caster Area

Turbo generator Area

Cable galleries

High voltage pannel

Various control rooms

Various MCC rooms

Various pump houses

Fuel Tank Area

Guest Houses & offices

CO2 Foam type

Dry Chemical type

CO2 Foam type

Dry Chemical type

CO2 Foam type

Dry Chemical type

CO2 Foam type

Dry Chemical type

CO2 Foam type

Dry Chemical type

CO2 Foam type

Dry Chemical type

CO2 Foam type

Dry Chemical type

CO2 Foam type

Dry Chemical type

CO2 Foam type

Dry Chemical type

Sand Baskets

Dry Chemical powder type




Name of site Type

Godowns

Crusher House

Foam type

CO2 Foam type

Dry Chemical type

However before installing fire station & safety equipment, an experienced fire

officer would be appointed who carry out an in-depth study and shall decide

about the selection of equipment.

Safety

The existing steel plant when fully commissioned will have a safety department

manned by experienced engineers and staff whose main job will be to bring

about safety consciousness amongst the work force in the plant. The safety

department will conduct regular safety awareness courses by organizing

seminars and training of the personnel among the various working levels.

Safety awareness will also be created by the various posters highlighting the safe

working practices in different shops, hazards in working area, public places and

roads etc. Safety engineers of the plant will conduct regular checks and mock

exercises on the safe working of their department and report will be given to

departmental head for corrective measures to improve the safety conditions.

Training

A department of training will also be set up to train officers. They will arrange

training on safety accident prevention, first aid, hazard control, house keeping




and environmental management. Special emphasis with mock drills in disaster

control will also be planned.

Communication

During the proposed modification-cum-expansion of steel plant there will be an

up-to-date communication facilities with telecommunication and wireless,

walkie-talkies, telecommunication and loud speakers in each shop, office and

gate to warm workers in case of an accident.

Organization to combat contingency

The contingency plan is prepared from the experiences of accidents that have

occurred in various other Steel plants. The contingency plan being a dynamic

plan will need periodical reviews and modifications with new experiences. Even

with all precautionary measures taken to avoid disaster, disaster may occur. To

tackle situations during and after disaster, a well-defined contingency plan is a

must. A Disaster Control Room (DCR) will be set up having links with all plant

control rooms. An officer will be manning the DCR. On getting information about

any accident, the officer will verify from the affected plant control room and inform

the Disaster Controller (DC) and/or other co-ordinators immediately.

The responsible officers of Disaster Control Group will assemble in the DCR and

formulate control procedures as per the contingency plans. The functions of the

various officers of the Disaster Control Group will be as follows:




Functions of Disaster controller

- To declare "Disaster Emergency" after consulting the Sr. officer available and

inform Fire Station Control Room to sound the sirens accordingly and arrange

to convey the message in public address system

- To report to DCR immediately.

- To receive messages from the communication center.

- To take decisions in consultation with the Commanding Officers of different

services and convey them to the disaster point.

- To be responsible for planning and provisions of assistance from township

and from local authorities.

- To keep higher authorities informed about the situation.

- The decision of the Disaster Controller on any matter to meet the objective of

disaster control plan will be final.

Functions of Officer In-charge:

Disaster Controller will nominate an officer whose functions will be as follows:

- To be responsible for the operation of DCR and for the dispatch of messages.

- To decide on the priority of dispatch of messages.




- To keep liaison with all activities and give up to date and accurate

appreciation of the situation.

- To be responsible for the efficient organization of the Disaster Control Room.

Functions of Commanding Officers of various services:

The Commanding Officers of various services are designated Coordinator

(services), Coordinator (Operation) and Coordinator (external services). The

following are their functions:

- To report to the Control Post immediately on hearing "Disaster Siren".

- To keep Disaster Controller posted with the up-to-date information regarding

manpower and material available concerning their respective services.

- To advise Disaster Controller on all matters arising out of disaster.

- To assist Disaster Controller for provision of material and man power

concerning his service.

- To convey message to his service teams through communication centre after

consulting Disaster Controller.

- To consult between themselves on matters related to more than one service

and to decide on the action to be taken.




Casualty services

The Commanding Officer of Casualty Services will be medical officer.

Functions

- First aid service by first aid parties on the spot.

- Ambulance service for transport of casualties from the spot to township

hospital and from township hospital to outside, if required.

Procedure for treatment

On getting a signal from the Disaster Control Room or information on telephone

or hearing siren, the Sub-Commanding Officer of the Casualty service will report

to hospital and doctor on call duty and first aid personnel will report to Disaster

Control Room. The Ambulance with the driver will report to Disaster Control

Room. First aid parties will render first aid to casualties at the place of

occurrence and those requiring further treatment would be transported to the

nearest hospital by ambulance.

In case of extra help from outside or within CMO would contact Co-ordinator

(Planning) for help in areas such as:

- Extra medical helps from neighboring hospital or main hospital.

- Evacuating the casualties.

- Essential assistance in first aid.




First Aid

It is necessary to give first aid to the persons injured in disaster. There will be two

first aid posts to meet the workload, one post will be near the Disaster Control

Room and the other post will be in the township hospital. At each post 3 first aid

parties shall be kept in rotating shifts of 8 hours.

Equipment

Each member of the first aid will be provided with the following personnel

equipment.

Helmet - 1 no.

Water bottle - 1 no.

Torch - 1 no.

First aid box - 1 no.

Rescue and repair services

The responsibility of effective working of Rescue and Repair Services are with

Co-ordinator (Services) and Sub-Commanding Officers as follows:

Rescue services

- To extricate persons from the debris of collapsed building and save human

lives.

- To hand over the dead bodies and injured persons to first aid parties.




- To take immediate steps as may be necessary for the temporary support or

demolition of buildings and structures, the collapse of which is likely to

endanger life or obstruct traffic.

- To cut of supplies of water, steam & gas, electricity to damaged buildings /

structures.

Each rescue party will be provided with the following equipment:

1. Gas mask respirator

2. Fire proximity suits

3. Resuscitators

4. Petromax lamp, Torches

5. Axes/hand saw

6. Fire entry suits

7. Fire blankets

8. Ropes

9. Ladders

10. Rubber glove (Tested up to 25,000 voltage)

11. Blankets

12. Rubber shoes or Industrial shoes.

Repair services

- To take up quick repairs of the damaged machinery.

- To take up repair of damaged building roads and culverts.

- To maintain essential public utility services viz. water, electricity and sewage

system.




Fire fighting services

Fire officer will be the Commanding Officer of Fire Fighting Services. Additional

strength for fire fighting which is beyond the control of fire station will come from

security and maintenance personnel and if required form outside fire stations.

Functions

- To co-ordinate fire fighting activities

- To enforce all regulations for prevention of fire.

- To request neighboring industries and District Authority for rendering services

of their fire fighting crew under mutual aid schemes, if necessary.

Traffic control

The free movement of the fire vehicles and ambulance at the scene of

fire/emergency is very important and therefore, the security personnel on duty

must ensure that all the roads at the scene of fire/emergency are kept clear and

free from obstruction. Persons arriving by motor transport at the scene of

fire/emergency must not park their vehicles within 100 meters of fire, near fire

hydrants, at road junction and at access roads. The ignition key should be left in

the vehicles.

Training services Functions

- To arrange training of volunteers/employees nominated by Commanding

Officers of various services.

- To arrange refresher training courses once in a year.




- To arrange mock drills, twice in a year.

- To make a list of employees trained in various specialized disasters so that

they can be easily contacted to handle a particular type of disaster. The

person concerned will immediately report to Disaster Control Room.

Faculty

Faculty will be consisted of commanding officers/sub-commanding officers and/or

their nominated officers.

Depot and Transport services

Functions:

- Dispatch of vehicle to the place of incident as per orders from the DCR.

- To get back the vehicle as soon as the work is completed.

- General administration of the depot including repair and maintenance of

vehicle.

- Storage maintenance and inspection of equipment.

- Maintenance of discipline and moral.

- Ensuring adherence to the depot duties.

- Welfare of personnel in the depot.

Vehicle repair

The Sub-Commanding Officer and his staff will promptly attend to all major

repairs of the essential vehicles under his supervision.




For carrying out minor repairs, vehicle repair party will be detained at the depot.

The party will be provided with a vehicle for quick movement.

Commanding Officer will evolve a system such that he is apprised of the

conditions of the vehicles scheduled at 1500 hrs. daily during peace time. This is

required so that the vehicles are available at a short notice.

Fuel

The Commanding Officer will contact Coordinator external services for

arrangement of fuel for vehicles during fuel crisis and stop supplying fuel to

vehicles other than those, which are in use for disaster control.

Supply services

A senior person will head supply service from stores department.

Functions:

- To be responsible for planning, organizing and procuring necessary

equipment/materials.

- To be responsible for storage of equipment/materials at accessible location

and for quick distribution on demand.

- To obtain the requirement of equipment / materials from Commanding

Officers of various services for their respective services.

- To co-ordinate with Commanding Officer of Depot and Transport Services for

transports required for distribution of equipment / materials in consultation

with DCR.




Salvage service

The salvage services will be under the charge of Committee. This committee will

be formed taking one person from stores and one from production.

Functions:

- To salvage properties from debris

- To take care of such properties

- To return the properties to respective shop in-charges.

- To co-ordinate patrolling with the help of, police and security personnel for the

safeguard of valuable properties till the same are removed to a safe place.

Welfare services

Management of proposed Steel plant will nominate one person from

administration side and he will be the Commanding Officer of welfare services.

Vacant buildings, schools complex and club will be used for housing those

rendered homeless. Emergency camps will be set up only in exceptional cases

on playing ground. For this purpose necessary material will be brought from

nearby market.

Functions:

- To provide shelters to affected persons.

- To arrange enough stock of essential commodities through co-operative

society.




- To arrange cooking of food in canteen supply to place where people are given

shelters in township. For plant people, food will be supplied within battery

area by mobile vans.

- If canteen is affected by disaster, the food will be cooked at school complex

and will be served as indicated above.

- To arrange clothing and medicines to affected persons. Doctor(s) will assist

for giving medicines.

To arrange drinking water, if supply is disrupted, with the help of District

Authorities.

Mobile canteen

One mobile canteen in a motor van/truck will be made available in the plant area.

The mobile van will be stationed in Depot.

Co-operative Society

There will be one cooperative society in township, which will be dealing in

essential commodities. The District authorities during any emergency will further

supplement the resources of this society.

Security services

Chief Security officer will be Commanding Officer, Security Services.

Functions:

- Security services will be primarily responsible for the security of the plant.




- Commandant in consultation with co-ordinator (external service) will keep a

close liaison with local police and district authorities.

- To control the vehicular traffic inside the plant.

- To help local police in patrolling the area of plant and outside the battery area,

necessary.

- To assist Fire fighting services in fighting fires.

- To assist in transporting injured persons.

- To assist local police in patrolling in township and work out adequate

arrangement for protection of property.

One jeep and one motor cycle will always be kept as reserve to cope up with

emergency demand and for immediate mobility of security personnel.

Crash shut down of Units

Section head will be the Commanding Officer for Crash Shut down of the units,

which are affected and may further aggravate disaster.

Function

To shut down the unit(s) affected and which may cause further disaster.

Public Relation Service

The Officer-in-Charge of Public Relation Services will look after this job.

Functions

- To consult DC before communication, if required with outside agencies.




- PRO will be the official spokesman for the steel plant with outside agencies.

- PRO will arrange for photography and filming of the whole disaster as

photography and filming of such incidents are of immense value for the

purpose of investigation, training and education.

.

Contingency Plan

The following contingency plan shall be followed:

Fire and Explosion

- Plant fire fighting is activated.

- Disaster Controller along with Commanding Officers takes overall charge of

the situation.

- DC will assess the situation for possible after effects of the fire in the plant

and the surrounding areas likely to get affected.

- DC will inform local authorities to send fire tenders, if necessary.

- DC will inform the people of likely affected areas through communication

system to leave the area and move to other areas earmarked, if necessary.

- DC will inform co-ordinator, external services to inform the District authorities

of the disaster and request them for help.

- To evacuate people from the affected areas outside the plant.




- To control the traffic and law and order.

- To arrange medical aid for the affected people.

- DC will arrange inspection of affected areas to get first hand knowledge of

damages occurred.

Alarm System

On receiving the message of `Disaster' from Disaster Controller, fire station

control room attendant will sound SIREN WAILING TYPE FOR 5 MINUTES. DC

will arrange to broadcast disaster message through Public Address System.

On receiving the message of "Emergency Over" from DC the fire station control

room attendant will give All Clear Signal by Sounding Siren straight for two

minutes. The features of the alarm system will be explained to one and all to

avoid panic or misunderstanding during disaster.

Actions to be taken on hearing the warning signal

On receiving the message of "Disaster" the following actions will be taken.

- All the co-ordinators will report to the Disaster Control Room even if not

contacted by the Cell :

- The Commanding Officers and Sub-Commanding Officers will report to the

place of accident.




- The Process Unit persons will remain ready in their respective units for crash

shut down on the instruction from the co-ordinator.

- The persons from other sections will report to their respective officer.

- The concerned section (Civil, Engineering Services, Mechanical, Project etc.)

will take immediate action to remove contractors personnel outside the plant

gate.

- The residents of the township will remain alert.

Disaster due to natural calamity and external factors

Most of the measures & processes shall be same as given under in-house

disaster except that the disaster controller will contact the state / district

authorities for necessary instructions to co-ordinate with them.

Chemicals/Oil spillage

The possibility of large chemical/oil spillage in the final effluent discharged in

reservoir is remote. However, DC will arrange to inform the following:

- State Pollution Control Board

- District authorities and request them to arrange patrolling of the area along

with security personnel.

- District authorities, to warn people in the affected area against fire/hazard that

may occur and against the adverse effect of using water for any purpose.




- Disaster Controller along with Commanding Officers takes overall charge of

the situation.

- DC will inform the people of likely affected areas through communication

system to leave the area and move to other safe areas earmarked.

- DC will inform co-ordinator, external services to inform the District authorities

of the disaster and request them for help.

- To evacuate people from the affected areas outside the plant. -To control the

traffic and law and order.

- To arrange medical aid for the affected people.

- DC will arrange inspection of affected areas to get first hand knowledge of

damages occurred.

Cloud burst/lightning

Cloud burst/lightning may lead to a situation, which could be minor to major

emergency. In such emergency, actions indicated under fire and explosion will be

initiated.

Food poisoning

In case of food poisoning in plant canteen the following actions will be taken:

- DC will inform the medical officer of steel plant health center for immediate

first aid.




- DC will contact District Authorities and seek their help, if necessary.

- Security Personnel and employees will help in evacuating the affected people

to various hospitals.




8.0 SOCIO-ECONOMIC IMPACT ASSESSMENT

8.1 General

Present Scenario

Socio-economic development is closely linked with the growth of industrialization. This

necessitates the development of various types of industries as the economy passes

through different stages of development. A project is a cash flow which in fact puts a

break in investment flow of a region. Such investment may be widespread impact on

the socio-economy of the area surrounding it, through multiplier and linkage effects.

At the same time possibility of some adverse impact can not be ruled out. Therefore, a

thorough socio-economic impact assessment is required for any such project /

investment. Bhusan Steel & Strips Limited has proposed to modify and expand the

existing steel plant near Angul, Orissa. The project involves substantial investment to

which the local people have strong adherence due to some obvious impact on their

socio-economic conditions. Accordingly, it is necessary to carry out a detailed socio-

economic impact assessment of the project. On this backdrop, the present study is

directed towards the following objectives:

Objective

• To assess the impact of the project on agricultural situation;

• To examine the impact of the project on pattern of demand;

• To assess the in impact of the project on consumption pattern;

• To examine the employment and income effects of the project;

• To explore the possibility of local industrialization as an offshoot of the project;

• To examine the effect of the project on education status of the people in the study




area; and

• To judge peoples' perception regarding the project.

8.2 The Study Area & Analytical Framework

In the present investigation, the study area is considered as the circle with 7 km with

centre at the project site. Major portion of the study area falls under the Dhenkanal

district while the smaller part is in Angul district. Table-8.1 depicts a synoptic view of

the basic statistics of the study area. The population of the area is around 23293 with

a density of 151 persons per square km.

Table-8.1: Estimated Population and Occupational Pattern of the Study Area

(Nos)

Item

up to 0.5 kms 0.5 - 3 kms 3 - 7 kms Total

1. Population

Total Including

Male

Female

SC

ST

94

49

46

16

11

3713

1912

1801

624

434

19486

10035

9451

3274

2280

23293

11996

11297

3913

2725

2. Households 17 675 3543 4235

3. Literate 49 1913 10041 12003

4. Occupational pattern

a) Main workers 35 1366 7171 8572

i) Cultivators 13 505 2650 3168

ii) Agricultural labourers 12 486 2553 3051

iii) Workers in household

industry

2 59 312 373




Item

up to 0.5 kms 0.5 - 3 kms 3 - 7 kms Total

iv) Other workers 8 316 1656 1980

b) Marginal workers 5 204 1072 1281

Total working population (4) 40 1570 8242 9853

Land use pattern of the area is given in Table-8.2. It is observed that forest cover is

quite high on around 15.4% of the land in the study area. Net Sown area constitutes

about 39% of the area. Among other categories misc. trees, permanent pastures,

barren, fallow are worth mentioning.

Table-8.2: Land use of the study area

Sl. No. Type of land Study area % of total

1 Forest land 23.7 15.4

2 Misc. trees 7.7 5.0

3 Permanent pastures 5.2 3.4

4 Culturable waste 4.5 2.9

5 Land put to non agriculture use 8.6 5.6

6 Barren 5.9 3.8

7 Current fallow 2.6 1.7

8 Other fallow 3.4 2.2

9 Net Sown Area 60.7 39.4

10 Others 31.8 20.6

Total 154.0 100.0




8.3 Analytical Framework

Sampling

The study area is divided in to three strata --- (i) within 0.5 km radius circle centering

the project site, (ii) area between 0. 5km radius circle and 3 km radius circle and (iii)

area between 3 km radius circle and 7kms radius circle. A sample of 40 respondents

is selected using two-stage stratified random sampling technique. In the first stage

villages are selected and in the second stage, the respondents are selected at random

from the selected villages.

Respondents have been interviewed with the structured questionnaire specially

designed for this study keeping in view the objectives. Major constituents of the

questionnaire are as follows:

1. Cropping pattern

2. Crop productivity

3. Cost of cultivation

4. Net return from crops

5. Household budget

6. Consumption pattern

7. Peoples' perception about the project etc.

Methodology

The major methods used as tools of analysis in this study are as given below:

1. Regression: Simple linear regression of the following type in considered




Yi = a + b Xi + Ui (Where, U is the stochastic error term having its usual properties)

The model is fitted to data applying Ordinary Least Square (OLS) to obtain

estimated demand and consumption functions.

2. Fitted regression models is used to work out

i) Elasticity of demand with respect to disposable income (e) in case of

demand functions :

e = (dy / dx) . (y/x)

ii) Marginal propensity to consume (MPC) from consumption function :

MPC = dC / Dy

3. Frequency distribution of peoples' perception, educational status, land holding

etc

8.3.1 Agriculture Situation

Agriculture is a major source from which people of the area derive their income.

However, the climatic condition and the quality of soil of the area are not suitable for

developed agriculture. Table-8.3 represents the cropping pattern in the study area.

From the table it is evident that paddy is the main crop produced. Paddy is grown on

about 67% the Gross Cropped Area (GCA). Other than paddy, maize is grown on

1.4% of the area.




Table-8.3: Cropping Pattern & Cropping Intensity

Sl No Crop Area covered in GCA (%)

1 Paddy (Kharif) 66.8

2 Maize 1.4

2 Others 31.8

TOTAL 100.0

Table-8.4 depicts productivity of crops. The productivity figure for paddy is found to be

quite low and much below state average. Productivity of maize is 0.1 qtl/ac.

Table-8.4: Crop Productivity

Sl. No. Crop Productivity (Qtl./ac.)

1 Paddy 9.5

2 Maize 0.1

Table-8.5 presents average investment in agriculture, net return and cropping

intensity. It is observed that agriculture is still profitable in this area as net return from

agriculture is positive (Rs 3230 per acre). The cropping intensity is quite low (128.5%).

This indicates backwardness of agriculture. Scanty rainfall, scarcity of irrigation water

and low quality soil permitted them to produce only a few crops

Table-8.5: Cost of Cultivation, Net Return And Cropping Intensity

Sl No Item Quantity

1 Investment in agriculture (Rs/acre) 1145

2 Net return (Rs/acre) 3230

3 Cropping intensity (%) 128.5




8.3.2 Consumption Behaviour

Table-8.6 presents the source-wise distribution of average family consumption. It is

observed that the major portion of consumption (65.8%) goes to meet the need for

food items while clothing constitute 14.0% and medical expenses 3.9% of the total

consumption.

Table-8.6: Source-Wise Distribution of Family Consumption

Total Food Education Clothing Medical Others Total

Average family consumption

(Rs/yr)

21643 878 5250 2629 7357 37257

Percentage Distribution 58.1 2.4 14.1 5.7 19.7 100.0

8.4 Anticipated Socio-Economic Impacts

The survey reveals that the respondents spend major portion of their disposable

income on food items. However, there has been a growing tendency among the

respondents, of higher expenditure allocation on non-food items although their

basket of consumption has only few items other than food. To go to the details of

their pattern of demand, income elasticity of demand is calculated by fitting demand

functions. Table-8.7 presents the results of the regression analysis conducted for

fitting the demand functions. It is observed that all the demand functions give

uniformly good fits to the data because R2 in all the cases is found to be quite high.

Moreover, as indicated by t-test, the relevant parameter of the demand functions is

found to be statistically significant at 1% level. The income elasticity of demand as

measured from the fitted functions are 0.83 and 0.86 for food and non-food items

respectively. The inelastic demand for food and non-food items indicates their strong

necessity of these items. The higher magnitude of elasticity in case of non-food

items is indicating their tendency to shift the demand in favour of non-food items as

their income increases.




Table-8.7: Demand Functions For Food And Non-Food Items

Regression parameters Form of the fit Item

ln a b R2

Dij = a * Ybj * U

(Where,

Dij = Demand for the ith item by

jth respondent.

Yj= Disposable income of the jth

respondent

Food

Non-

food

0.336

0.371

0.834

(17.05)*

0.857

(21.3)*

0.9604

0.9743

Figures in ( ) indicate t - values * Significant at 1% level.

Hence, the impact of the project on the pattern of demand can be reasonably

predicted as a shift from food to non-food items i.e., a consumer behaviour which

may closely follow the Engel law. This is not a bad indication provided considerable

income is earned by them; otherwise, if the shift is a substitution of necessary food

requirements then it is not desirable in true socio-economic sense.

8.4.1 Agriculture Situation

Overall assessment of the agricultural situation of the area reveals that agriculture is

still quite backward in this area. Constraints of such backwardness as reported by the

farmers are scanty rainfall, lack of irrigation water, unproductive soil and the major one

is lack of credit. Majority of the farmers opined that unproductive land is the most

important among these constraints. Keeping this in mind, it can be concluded that

even if some irrigation facilities are provided/extended in this region, agriculture will

still continue to be traditional.

Given the persistent nature of backwardness of agriculture, it can reasonably be

argued that the project is not going to cause significant damage to it. Hence, the

project will not have much of adverse impact on the existing agricultural situation of




this area. Instead, the industrial project is likely to provide the farmers with

supplementary income, which appears to be essential for raising the standard of living

of the people of the study area.

8.4.2 Consumption Behaviour

To investigate the consumption behaviour of the respondents in detail, Marginal

Propensity to Consume (MPC) is calculated by fitting the consumption function. The

results of the regression analysis performed for fitting the consumption function are

presented in Table-8.8. It is observed that the function gave uniformly good fit to

data because R2 is high and parameters are also found to be statistically significant

at 1% level. The MPC worked out on the basis of the fitted consumption function is

0.642.

Table-8.8: Fitted Consumption Function

Regression parameters Form of the fit

a b R2

Cj = a + b Yj + Uj

Where,

Cj = Consumption of the jth respondent

Y = Gross income of the jth respondent

5039.7 0.642

(22.5)*

0.977

Figures in ( ) indicate t-values * Significant at 1% level

Effort is taken here to work out the multiplier effect of investment on the people of

the study area. The calculations are done using the following model:

Let us consider that the consumption behaviour of the respondents closely follow the

following type of consumption function:




C = a + bY (1)

We know that, in equilibrium

Y = C + I (2)

Where, Y = Gross income, C = Consumption and

I = Investment

Putting (1) in (2) one gets,

Y = a + bY + I

=> Y = ( 1 / (1-b) * [ a +I ] (3)

Where, 1 / (1-b) is the multiplier .

Assuming that consumption behaviour of the people in the study area closely follow

this fitted consumption function, one can easily see that existing size of the multiplier

is 2.8. Hence, investment on this project and the consequent generation of

additional income will have strong multiplier effect in raising average consumption.

The proposed project is going to have positive income effect and consequently, the

multiplier effect is expected to lead to an overall increase in average consumption of

the people of the study area. Therefore, one can conclude that the impact of the

project on consumption behaviour of the local people is likely to be satisfactory and

positive.

8.4.3 Employment and Income effect

Direct employment

During the construction period, the project is going to create substantial employment

and income. A large portion of these is likely to trickle down to the local people.

Besides this, some persons from the study area may get employment on permanent

basis for actual operation of the plant in the form of skilled or semi-skilled, or




unskilled labour. Thus, substantial amount of employment and income are expected

to be generated for the local people. Hence, it can be ascertained that the project is

going to have significant employment and income effects.

Indirect employment

In the case of indirect employment also, the effect is quite strong and widespread.

Besides direct employment, the project is expected to generate substantial indirect

employment in other sectors. So far indirect employment is concerned, the effect is

very strong and widespread specifically, in ancillary industries, service and transport

sectors. In view of the above, it can be justifiably concluded that the present project

has tremendous positive employment and income effects.

Overall assessment of the employment and income effects indicates that the project

has strong positive direct as well as indirect impact on employment and income

generation.

8.4.4 Educational status

The existing educational status of members of the sampled households is depicted

in Table-8.9. The table revealed that about 55% of total members in the sample are

illiterate. This figure includes the non-school going children also. About 13% of the

members have education at primary level. Middle school level educated people

constitute around 14%. Persons with high school and intermediate level education

are observed to be around 9%. The study area has some highly educated persons

(i.e., Graduate, PG and technical).

As reported by the respondents during field survey, their interest towards education

has been increasing due to hope of getting employment which may come up

especially in the non-agricultural sectors in this region, as an indirect impact of this




project. The general awareness towards the importance of education is expected to

increase as a result of the new project and hence, it can be said that the project has

a strong positive impact on the level of education of the people of the study area.

Table-8.9: Educational Status of the people of the Study Area

Sl. No Level of education No (% in total)

1. Illiterate* 169 (54.9)

2. Primary 39 (12.7)

3. Middle school level 42 (13.6)

4. High schooling and intermediate 30 (9.7)

5. Graduation 17 (5.5)

6 P G 5 (1.6)

6 Technical 4 (1.9)

Total 308 (100.0)

* Includes non-school going children

8.4.5 Peoples' perception

Peoples' perception regarding a project is as important as the impact of the project.

So, it is worthwhile to examine what people perceive about the project. To fulfil this

objective, an opinion poll was conducted. The results of the poll are analysed and

furnished in Table-8.10 It is observed that 85.0% of them have identified the direct

and indirect employment opportunity due to the project. Opportunities of business

development is pointed out by about 32.5% of the respondents. 15 % of them have

identified industrialisation in the area as an advantage. Along with the growth of

industrialisation the entire area will be more urbanised. 10% of the respondents feel

increase in urbanizatin of the area.




On disadvantages, about 55% of the respondents have cited pollution as the major

factor. Around 45% of the respondents seem worried about adverse impact of the

project on health of people. The problem related to scarcity of water and displacement

of people are pointed out by around 27.0% and 23.0% of the respondents

respectively.

Table-8.10: Peoples' Perception

Perception Respondents

ADVANTAGES

1 Employment 34 (85.0)

2 Business development 13 (32.5)

3 Industrialisation 6 (15.0)

4 Urbanisation 5 (12.5)

5 Development of the area 6 (15.0)

DISADVANTAGES

1 Pollution 22 (55.0)

2 Health damage 18 (45.0)

3 Scarcity of water 11 (27.5)

4 Displacement 9 (22.5)

[ Figures in ( ) indicate % in total no. of respondents. Individuals have spelt

out more than one advantages / disadvantage ]




8.5 Conclusion

On the basis of the overall results of the present impact assessment the following

conclusions are drawn:

i) The project is not going to cause any damage to the existing agricultural

situation. Instead, it is likely to provide the farmers with supplementary income

which, in turn, may be invested back on agriculture.

ii) The project is going to have positive impact on pattern of demand which can

be reasonably predicted as a shift from food to non-food items i.e., a

consumer behaviour which may closely follow the Engel law. This is not a

bad indication provided considerable income is earned by them; otherwise, if

the shift is a substitution of necessary food requirements then it is not

desirable in true socio-economic sense.

iii) The project has strong positive impact on average consumption standard of

people and also has intensive multiplier effect.

iv) The project has good impact on employment and income generation, both

direct as well as indirect. This will lead to diversification of skills.

vi) The project has strong positive impact on the level of education of the people

of the study area.

vii) Peoples’ perception on the project is positive. Respondents expressed

spontaneous support for the project as they foresee relatively more

advantages for the people of the study area.




9.0 ORGANISATION AND MANPOWER

Bhushan Steel & Strips Limited (BSSL) shall have Environmental Management

Division (EMD) at plant level as well as at corporate level for interaction with

statutory bodies and managing environmental issues at plant level. Executive

Director (works) of plant operation is the head of the plant level pollution control cell

with Environmental Engineer, Chemist, etc. The plant level EMD will be provided

with well-equipped laboratory for carrying out analysis of the samples of the water,

air etc. Plant EMD will carry out the monitoring of the stack emission, noise level,

analysis of the water etc. and keep the regional / local statutory body informed about

the status of pollution control with intimation to the Corporate office EMD. BSSL will

arrange professional training for personnel of EMD at plant level. The proper training

shall be provided in area of monitoring and continuous analysis of the pollutants,

legal requirement and environmental management system.

9.1 Organisational Set Up

Environmental monitoring and reporting has been designed to provide a close

watch on the surrounding natural environment and provide early warnings of

any adverse changes that may be related to some dimension of the plant’s

operations.

Organisation motto

The importance of environmental control has been recognised by BSSL and it has

taken necessary steps to identify and control pollution in the plant, respond to

impacts on its own captive population and also in the peripheral areas.




A. The above objective has been intended to be achieved through the following:

i) Improvement in the quality of raw materials.

ii) Best available technology for manufacturing operations in steel plant,

iii) Using automation & Computer control to have improvement on technology and

on working condition,

iv) Pollution Monitoring and Control,

v) Occupational health set up including regular medical monitoring of employees,

vi) A well developed safety management organisation,

vii) Preparation of Emergency/Disaster Control plan and a properly trained group to

meet the emergency situations,

viii) Green belt development inside the plant and township.

ix) Development of awareness in employees and public including student

population towards environmental preservation,

x) R & D activities in regard to specific pollution problems.

B. The following strategies are being employed to meet the above objectives:

a) All new units coming under expansion would be environmentally audited to

meet the pollution control standards.

b) As environmental management is also associated with optimum energy

utilisation & water conservation, all steps are taken to optimise the conservation

of energy and consumption of water.

c) The pollution control systems are operated and maintained as per technological

norms.

An Environmental Management Division (EMD) will co-ordinate with other

departments like Safety Management, Project Engineering, and Community

Development under Chief Town Administrator, Water Supply Department etc. and




also do the liaison work with external agencies like State & Central Pollution Control

Boards and Corporate Office.

A senior officer of the rank of Deputy General Manager (DGM), shall be the

head of the EMD. In his day to day work, he shall be assisted by

Environmental Engineers, Chemists and Laboratory Assistants. The DGM

(EMD) reports to the General Manager (EMD), who in turn reports to the

Executive Director (Works). A tentative Organisation Chart of the EMD is

given as Fig. 9.1.

9.2 Man Power

EMD is manned by adequate staff. Services of retired forest officials may be

taken for effective implementation of plantation schemes. For development

and maintenance of jobs like drainage, settling tanks etc. assistance from the

projects civil engineering department shall be taken.

9.3 Training Facilities

For the proposed project, additional training facilities will be developed for

environmental control. Specialized courses at various Research/ Educational

institutes will be organized. Training will cover the following fields:

• Awareness regarding Pollution Control and Environmental protection.

• Operation and maintenance of pollution control equipment.

• Afforestation / plantation and post care of plants.

• Field monitoring, maintenance and calibration of pollution monitoring

instruments.

• Chemical analysis of various environmental parameters at laboratory.




• Repair of pollution monitoring instruments.

• Knowledge of norms, regulations and procedures.

• Occupational health and safety.

• Risk assessment and Disaster Management Plan.

Executive Director

(Works)

General Manager (Environmental Management Division)

Dy. General Manager EMD(1)

Lab Chemist (05 Nos.)

Lab Assistant (03 Nos.)

Field Assistant (AAQ Monitoring Staff)

(05 Nos.) Ash Dump Area

(06 Nos.)




10.0 ENVIRONMENTAL COST & PROJECT BENEFITS

10.1 Environmental Cost Component

The project cost has been estimated to be Rs. 63300 Million (Rupees Sixty three

thousands three hundred million). The capital cost of environmental mitigation

measures is estimated to be Rs. 3481.5 Million, which includes:

Cost Of Air Pollution Control Systems : Rs. 1393.0 million

Cost of Water Pollution Control : Rs. 0870.0 million

Cost of Solid Waste Management System : Rs. 1045.0 million

(Including cost of dust storage with bund)

Green belt development : Rs. 0033.5 million

Environmental Monitoring Lab Development : Rs 0070.0 million

Social Institutional Development : Rs 0070.0 million

Since Bhushan Steel & Strips Limited will be getting part of necessary

environmental monitoring requirement carried out by an external agency, capital

cost towards part of environmental monitoring facilities and occupational health

of personnel is not required.

The estimated annual cost of environmental mitigation measures for the

proposed modification-cum-expansion units has been estimated to be Rs. 350.0

Million. The annual estimated environmental mitigation costs include:

Cost of Air Pollution Control : Rs. 140.0 million

Cost of Water Pollution Control : Rs. 087.5 million

Cost of Solid Waste Management : Rs. 087.5 million

Cost of Green Belt Maintenance : Rs. 003.5 million




Cost of Environmental Monitoring : Rs. 014.0 million

Cost Towards maintenance of

Social infrastructure : Rs. 017.5 million

TOTAL : Rs. 350.0 million 10.2 Improvement In The Physical Infrastructure

Road Improvement and extension of the existing network is, essential to develop

remote areas, better connection between the economic centers of state, and also

cross-border transport and for personal mobility of the masses.

Rail Network Railways provided an important mode of transportation in the public sector

spreading over the entire country. It contributes to the country’s economic

development by catering to the needs of large-scale movement of freight as well

as passenger traffic and is a major source of promoting integration among the

masses. Railway provides transport facility to people and handles freight above

600 million tons annually. The Indian railway is intended to modernize the vast

railway network, keeping both the economic and social dimensions in mind.

10.3 Improvement In The Social Infrastructure

The project investment will vastly accelerate the development and use of the

country’s irrigation potential. But even after this, two-fifths of cultivated area will

still be rain-fed.

The BSSL will launch a special programme so as to ensure each household in

the surrounding village will have full access to reliable power in the next two to




three years. The private sector has a crucial role to play in power generation and

takes on an increased role in power distribution.

In order to supplement water availability and recharge the country’s groundwater

resources, a local community-based Rainwater Harvesting Programme will be

launched to capture at least an additional 1% of local rain resources every year.

BSSL will launch Social housing schemes in the surrounding village to meet the

needs of the local poor.

10.4 Employment Potential

It generates employment both directly and also due to development of

downstream industries. During the construction period, the project is going to

create substantial employment and income. A large portion of these is likely to

trickle down to the local people. Besides this, some persons from the study area

may get employment on permanent basis for actual operation of the plant in the

form of skilled or semi-skilled, or unskilled labour. Thus, substantial amount of

employment and income are expected to be generated for the local people.

Hence, it can be ascertained that the project is going to have significant

employment and income effects. The estimated manpower requirement at the full

development stage of the integrated complex has been estimated to be 2827.

Category wise breakup of manpower is indicated in the table:


1 Managerial 29

2 Executive 310

3 Skilled 938

4 Semi-skilled 735

5 Unskilled 775





6 Clerical 40

Total : 2827

In the case of indirect employment also, the effect is quite strong and

widespread. Besides direct employment, the project is expected to generate

substantial indirect employment in other sectors. So far indirect employment is

concerned, the effect is very strong and widespread specifically, in ancillary

industries, service and transport sectors. In view of the above, it can be justifiably

concluded that the present project has tremendous positive employment and

income effects. Overall assessment of the employment and income effects

indicates that the project has strong positive direct as well as indirect impact on

employment and income generation.

10.5 Other Tangible Benefits

The other tangible benefits will be in the form of plant township hospital and

schooling facilities which will also help local population to enjoy the fruit of better

facilities in nearby.




11.0 CONSULTANT CREDENTIALS

MECON LIMITED is a Public Sector Undertaking under Ministry of Steel,

Government of India, as one of the leading design, engineering and consultancy

organizations, with extensive in house and overseas experience. MECON has

wide exposure and infrastructure for carrying out detailed design engineering,

consultancy and site services or any other technical services for various sectors

including iron ore mining and steel.

MECON’s services include the whole range of work relating to setting up of

projects in the field of infrastructure, power, metallurgy both ferrous & non-

ferrous, chemicals/ petrochemicals and allied engineering complexes including

specialized fields such as hydro engineering, sewerage scheme, sewage

treatment, industrial effluent treatment, solid waste disposal including municipal

waste disposal system, ports, defense projects, mints/ currency note presses,

environmental engineering, system engineering, etc. Because of being under

Ministry of Steel MECON has wide exposure in iron ore mining in India and

abroad. MECON was involved in the planning stage of a number of important

iron ore deposits in India.

MECON is registered with World Bank, ADB, EBRD, African Development Bank,

UNIDO, etc. MECON has collaboration agreements with the leading firms from

USA, Germany, France, Italy, erstwhile U.S.S.R etc. in various fields and

possesses process know-how & intend to make alliances & agreements to pool

up and offer the best resources as may be available for specific requirement.

MECON is the first engineering & consultancy organization in the country to be

accredited with ISO: 9001 by RW TUV of Germany in the field of design,

engineering, consultancy, contracting & supplying, inspection and project

management services.




MECON’s Engineering Resources

MECON has a large set up with about 1900 strong workforce, of which about

1600 are graduate/ postgraduate engineers and technical staff in 39 technical

disciplines. We possess our own in-house mainframe computer and host of

LANS, mini computers, PCs, latest facilities of CAD/ CAM and other design &

engineering aids. MECON is equipped with laboratories including electro-

technological laboratory (ETL), environmental laboratory and R & D laboratory

and E-Mail connectivity though VSAT of NICNET.

With head office at Ranchi; 6 regional engineering offices at Bangalore, KolKata,

New Delhi, Hyderabad, Chennai and Mumbai, 15 project site offices and liaison

offices spread all over the country including Pune, Raigad & Mehsana , MECON

can assist very effectively in executing projects.

11.1 Environmental Engineering Division of MECON

Environmental Engineering Division of MECON provides specialized services

starting from project conceptualization to commissioning of pollution control

system. The services include base line data generation, Environmental Impact

Assessment studies and formulation of Environmental Management Plan, safety

audits & disaster management plan, toxic & hazardous waste inventory &

management and solid waste disposal, industrial effluent treatment, domestic

sewage treatment & disposal system, dust extraction & dust suppression

systems and other air pollution control system.

A large number of our environmental engineers/ scientists have been trained in

UK, USA, erstwhile USSR, Canada, Japan and Germany. They have also

assimilated the latest knowledge by extensive association with various foreign




companies including WYLE Laboratories-USA, Metchem-Canada, Cremer &

Warner- UK, WS Atkins- UK, TUV Rheinlnd- Germany etc.

MECON has been rendering comprehensive services in the mining sector for last

four decades. MECON offers complete spectrum of consultancy & engineering

services in exploration, exploitation, processing and coal washing, material

handling and transportation, information technology and environmental

engineering in mining and mineral industry including coal sector. MECON has an

experienced group of geologists, mining engineers, mine environmentalists and

mineral engineers specialist in exploration planning computer aided geological

modeling, deposit evaluation mine designing and planning and production

scheduling, mineral beneficiation and coal washing, preparation of EIA/EMP

reports etc. The geological sore body modeling and mine planning including

production scheduling are carried out by utilizing SURPAC 2000 and Whittle

Scheduler software. The above services are supported by in-house engineering

departments like Material Handling, Electrical, Hydro-Engineering, Energy

Engineering, Civil, Structural, Repair shops and maintenance garage,

Environmental engineering, Information Technology etc. MECON has rendered

engineering and consultancy for most of the mechanized iron ore mining in the

country.

MECON has prepared more than 250 EIA reports both in public and private

sectors Clearances for almost all the reports prepared by MECON have been

obtained from MOE&F in the shortest possible time. At present we are carrying

out EIA studies for Steel plant of Bhushan Power & Steel limited at Rengali,

Orissa, BSSL at Meramandali (Orissa) and Bhilai steel plant at Bhilai, DSP at

Durgapur, RSP at Rourkela, Bokaro Steel Limited, BSL, Bokaro; IISCO Steel

Plant ISP; Burnpur; JVSL at Torangallu, JSL at Kalinga nagar, Adhunik Steel &

Alloy Limited, Kolkata, Ramsarup Loh Udyog, at Khadagpur, etc.




MECON does possess a record of successfully undertaken development of clean

technology and environmental standards for Coke-oven plants and also

development of clean technology in the areas of iron ore beneficiation.

We are confident that with MECON’s established track record & long experience

in design, engineering & consultancy of various projects and extensive

experience in executing sizable environmental and mining assignments in India

and abroad, we shall be able to meaningfully contribute and supplement client

team in order to realize their endeavor successfully.

bhushan steels or

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