Download - Sinter Write Up
Richardson & Cruddas (1972) Ltd. II-1
CHAPTER – I
INTRODUCTION
1.1 Preamble
The growth of steel industry significantly contribute towards economic
progress of the country. However, any steel industry progress brings along
with it a number of environmental problems. Many of these problems can be
avoided, if adequate environmental control considerations are thought of
during conceptual stage of the project. Once the industry is set up, it
becomes very costly to install pollution control equipment and implement
other environmental control measures, if the same are not considered in the
conceptual stage.
Any industry exerts both positive and negative environmental impacts.
Negative impact cause environmental degradation. It is the responsibility of
Planners, Scientists and Environmentalists to document these impacts
separately so that these can be identified, quantified and attempts may be
made to minimize negative impacts and maximize the positive impacts for
better development with least environmental degradation.
1.2 Background of M/s. BMM Ispat ltd
M/s BMM Ispat Ltd. (BMMI) is a company promoted by Mr. Dinesh Kumar Singhi,
proprietor of Singhi Group of companies in Bellary District, Karnataka State.
The Singhi group is a well known business group in the field of mining of iron
ore and the group is also operating a mini steel plant producing sponge iron,
TMT bars and electric power. The Group has sales turnover exceeding Rs 442
crore and has its mining operations in Bellary-Hospet-Sandur belt and mini
steel plant at Danapur, Hospet Taluk in Bellary district of Karnataka State.
The companies belonging to Singhi Group are
1) BMM Ispat Ltd., Danapur
2) HKT Mining Pvt Ltd., Danapur
3) Bharat Mines and Minerals, Bellary
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These companies are growth centres in the field of iron ore mining and
manufacture of TMT bars and pellets.
Mining
BMM group is in the Business of mining of iron ore and exporting
approximately 2.50 Mt/yr of iron ore. BMM Group is working in three Iron
ore lease areas in Sandur Taluk, Bellary District having all statuary clearance
to produce totally 3.6 mt/yr of iron ore. They have applied for lease for
mining in additional area and the acquiring process is in progress. All the
existing mines are well connected by rail to steel plants, ports etc.
HKT Mining Pvt. Ltd
The promoters of BMM Group are the promoters of HKT Mining Pvt. Ltd. HKT
have set up sponge iron plant, induction furnaces and rolling mill and as on
date are running the plant with all statuary clearances.
BMM Ispat Ltd
BMM Ispat Ltd. have established pellet plant, power plant and beneficiation
plant adjacent to the above HKT plant near Hospet and are running these
plants with all statuary clearances.
Overseas Venture
In addition, BMM group have acquired coal mine deposits over 3696.57 Ha in
Tanah Groqet province in Indonesia.
BMMI intend to put up a 2.0 Mt/yr integrated steel plant to produce rolled
steel products and BF slag based cement. The power requirement for the
steel plant will be met by captive power plant.
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1.3 Present Project Proposal
Manufacturing Units Unit Capacity
Iron ore beneficiation plant Mt/year 3.4
Pelletization Plant Mt/year 1.20
DRI Plant Mt/year 0.7
Coke ovens Mt/year 0.8
Sinter plant Mt/year 2.5
Blast furnace Mt/year 1.7
EAF & BOF steel making Mt/year 2.3
Continuous casting machines • Slab Caster • Billet caster
Mt/year 1.10 1.10
Rolling Mills • Hot strip mill • Structural / wire rods
Mt/year
1.00 1.00
Oxygen Plant t/year 2x500
Calcining kilns t/year 1080
Cement Plant Mt/year 1.4
Power Plant MW 230
Estimated Investment : Rs. 6151.3 Crores
Project Completion Target : September 2012
1.4 Importance of the Proposed Project
Steel is the material of choice for industrial applications due to its high
specific strength and relatively low cost per unit weight. Present per capita
steel consumption in India is around 39 kg as compared to per capita steel
consumption of around 500 kg to 700 kg in countries like Japan, EU
Countries, South Korea, USA etc. Even Brazil, Mexico and China have per
capita consumption of around 110 kg to 150 kg and the world average is
about 150 kg.
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Steel is made through Blast Furnace/Basic Oxygen Furnace Route (BF-BOF-
CC) or Sponge Iron/Electric Arc Furnace Route (DR-EAF-CC). Principal raw
material in BF route is iron ore lumps/sinter and in DR route iron ore
lumps/pellets. Depletion of high grade iron ore reserves and metallurgical
coal reserves, environmental concerns in coke making, sinter plant and blast
furnace have forced the industry to look into steel making through EAF
route. Shortages, quality and price fluctuations of steel scrap and
availability of huge quantities of non coking coal have led to increase in DRI
capacity.
Domestic Steel Demand Projection
In India, apparent consumption of steel increased from 14.8 million tonnes
in 1991-92 to 43.5 million tonnes in 2006-07.
Production of steel
As per the National Steel Policy - 2005 of Govt. of India, the demand-supply
scenario for steel upto 2020 is as given below:
National Steel Policy of Government of India have considered growth rate of
7.3% per annum. The actual growth of consumption during 2005-2006,
according to Steel Ministry, was 13.88%. Even if we assume a lower growth
rate of 10% per annum, the demand for the year 2014-15, it will be 97.67
million tons.
In terms of crude steel, the demand works out 105.5 million tons for 2015.
Production of crude steel during 2005-06 was 42.1 million tonnes. It can be
seen from the above that demand is likely to be more than double in the
next ten years.
Though a number of green field steel plants have been announced, because
of various constraints, there is likely to be delay in creation of new
capacities. Thus the supply side may not meet the growth in domestic
demand.
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Based on the assessment of steel market (considering the boom in
construction sector and industrial applications) and the resources available
to the promoters, it is recommended to set up a 2.0 Mt/yr integrated steel
plant with flat (hot rolled coils and plates) and non flat products (TMT/wire
rods and Structural) in equal amount.
Demand for cement
Boom in the construction activities and infrastructure development have
lead to increased demand for cement. It is also in great demand in the
neighbouring countries like those in the gulf region and Far East. Hence, it is
proposed to convert the entire blast furnace slag into cement and produce
about 1.4 million ton per annum of cement.
Thus the proposed steel plant will facilitate in catalyzing the development
of small-scale industries around it. These may be spares and metal based.
These will be complimented by the service units. The project is also
expected to serve as center of significant small-scale industrial economy
around it. This is expected to play a major role in the future economic and
social development of this area.
1.5 Rationale for choice of Mariammanahalli hobli for Location of BMM
Ispat Complex
The Karnataka state Govt. have recommended for approval to establish
2.0 MT/YEAR integrated steal and Power plant in the State High Level
Clearance Meeting ( SHLCC ) Held on 21.08.2008 ( given in Annexure-I –
Sanction and Approvals).
Raw material availability at competitive price around the proposed
project.
Nearer to the allotted mine to BMM Ispat (25–30 Km from the proposed
industry).
Port facilities at Chennai, Krishnappattanam, Mangalore and Goa which is
well connected by rail route.
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Tungabhadra river water availability (within 5 km)
Railway facilities within 1 km .
Availability of sufficient land to cater to all needs of integrated steel
industry.
Availability of skilled man power.
Mega industries/projects are eligible for exemption from entry tax (for
machinery and equipment during the project implementation).
Reduction of stamp duty and registration charges.
KPTCL, Kalyan steels, Kirloskar, JSW Steel & other Thermal power plants
near to the proposed site of BMM ISPAT LTD.
CBSE/ICSE schools, Engineering Colleges, Training Institutions, Hospitals,
etc. are at 12 – 15 km radius of the BMM Ispat.
1.6 Environmental Clearance
Environmental Impact Assessment (EIA) and Environmental Management
Plan (EMP) have been considered as the most important tools / documents
which can be utilized by the project proponent and Government Regulating
Agencies and Public to clearly understand the environmental implications of
the proposed project with respect to the overall developmental plan and to
take decisions in the interest of environment and the national economy. It
also helps to analyze the techno-environmental feasibility of the proposed
project. The corporate policy of BMM Ispat Ltd. requires Environmental Impact
Assessment (EIA) to be carried out for all new projects. This is primarily to
ascertain, beforehand the potential impact areas of the proposed project and
initiate necessary corrective actions at the design stage itself as well as the
appraise the environmental protection regulating authorities for issuing
Environmental Clearance for the project, as required under the relevant
provisions of Environment Protection Act, 1986, Rules and EIA Notification 2006.
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1.7 Scope of the study
The present EIA and EMP report for BMM Ispat Ltd., Bellary has been
prepared based on the following TOR provided by MoEF and the existing
guidelines of CPCB and Generic structure of Environmental Impact
Assessment Document as per EIA Notification 2006.
1. Present land use should be prepared based on satellite imagery.
2. Location of national parks / wildlife sanctuary within 10 km. radius
should specifically be mentioned.
3. Permission and recommendations of the State Forest Department
regarding impact of proposed expansion on the surrounding reserve
forests viz. Hospet RF (4 Km), Nandibanda RF (4 Km) and Sandur RF (4
Km) should be included.
4. Permission from the Railway Department, if any, should be included.
5. Actual land requirement, classification of land, acquisition status,
rehabilitation and resettlement, if any, as per the policy of the Govt. of
Karnataka should be incorporated.
6. Status of environmental clearance for the captive mines and copies of
the letters should be included.
7. Clearance from the Railway Department regarding location of the
project should also be included.
8. Site-specific micro-meteorological data using temperature, relative
humidity, hourly wind speed and direction and rainfall should be
collected.
9. A list of industries containing name and type in 25 km radius should be
incorporated.
10. Residential colony should be located in upwind direction.
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11. List of raw material required and source should be included.
12. Fuel analysis, quantity of fuel required, its source and transportation.
13. Manufacturing process details for all the plants proposed should be
included.
14. A chapter on type and details of coke oven plant including pollution
control methods should be included.
15. Type of coke oven and full details and justification for installing non-
recovery type of coke oven should be included.
16. One season ambient air quality data (except monsoon) at 8 locations
within the study area of 10 km., aerial coverage from project site with
one AAQMS in downwind direction should be carried out. The monitoring
stations should take into account the pre-dominant wind direction,
population zone and sensitive receptors including reserved forests.
17. Coordinates of the plant site as well as ash pond with topo-sheet.
18. Details of all kind of fuel to be used and its impact on the ambient air
environment should be included.
19. The suspended particulate matter present in the ambient air must be
analysed for the presence of poly-aromatic hydrocarbons (PAH), i.e.
Benzene soluble fraction. Chemical characterization of RSPM and for
incorporating of RSPM data.
20. Impact of the transport of raw material and finished product on the
transport system should be assessed and provided.
21. Determination of atmospheric inversion level at the project site and
assessment of ground level concentration of pollutants from the stack
emission based on site-specific meteorological features. Air quality
modeling for steel and cement plant for specific pollutants needs to be
done.
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22. Plant-wise air pollution control measures proposed for the control of
gaseous emissions from all the sources should be incorporated.
23. A note on control of fugitive and secondary emissions from as per CPCB
guidelines from all the sources should be incorporated.
24. One season data for gaseous emissions during winter season is necessary.
25. Impact of the transport of the raw materials and end products on the
surrounding environment should be assessed and provided.
26. Alternate modes of transportation of coal for the project should be
examined and their relative merits and demerits in terms of
environmental impacts should be provided.
27. Permission for the drawl of 3,850 m3/day water from Tungbhadra Dam
and ground water sources from the concerned department and water
balance data including quantity of effluent generated, recycled and
reused and discharged should be provided. Methods adopted/to be
adopted for the water conservation.
28. Surface water quality of nearby rivers and dam (60 m upstream and
downstream) and other surface drains at eight locations must be
ascertained.
29. Ground water monitoring minimum at 8 locations and near solid waste
dump zone, Geological features and Geo-hydrological status of the study
area are essential as also. Ecological status (Terrestrial and Aquatic) is
vital.
30. A note on treatment of wastewater from different plants including coke
oven plant, recycle and reuse for different purposes should be included.
31. Action plan for solid/hazardous waste generation, storage, utilization
and disposal particularly tailings, slag, char and fly ash. Assurance that
100 % char will be used in the FBC boiler and copies of MOU regarding
utilization of ash should be included.
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32. A write up on use of high calorific hazardous wastes in the kiln should be
included.
33. Detailed plan of ash utilization / management, evacuation of ash, ash
pond impermeability and whether it would be lined, if so, details of the
lining etc. and MOU signed with the Cement manufacturers for utilizing
granulated BF slag should be included.
34. Generation and utilization of waste/fuel gases from BF plant and their
utilization in the CPP have to be set out.
35. Risk assessment and damage control needs to be addressed.
36. Occupational health of the workers needs elaboration.
37. Green belt development plan in 33 % area and a scheme for rainwater
harvesting have to be put in place.
38. Socio-economic development activities need to be elaborated upon.
39. A note on identification and implementation of Carbon Credit project
should be included.
40. An Action Plan for the implementation of the recommendations made for
the Steel and Cement Plants in the CREP guidelines must be prepared.
41. Total capital cost and recurring cost/annum for environmental pollution
control measures should also be included.
42. A tabular chart for the issues raised and addressed during public
hearing/public consultation should be provided.
43. Any litigation / court case pending against the proposal should also be
included.
1.8 Report Format
The project report covers
Introduction
Project Description
Description of the environment
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Anticipated Environmental Impacts and Mitigation measures.
Environmental monitoring programme.
Additional studies
Project benefits
Environmental impact statement
Environment management plan.
Summary and Conclusion
Consultant Credentials
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CHAPTER II
PROJECT DESCRIPTION
2.1 Preamble
BMMI are intending to install a 2.0 Mt/yr integrated steel plant, of which
1.0 Mt/yr will be hot rolled coils and the balance will be non flat products
like TMT/wire rods and structural. The former will be produced in a hot
strip mill and the latter in light structural mill/ bar and rod mills.
BMMI are also intending to install a cement plant to use the granulated blast
furnace slag. A power plant will be set up to utilize the waste heat in the
DRI kiln off gases.
2.2 Location of the proposed plant and accessibility
The proposed plant is located in Mariammanahalli hobli, Bellary (Dist.),
Karnataka. (The latitude and longitude of the project site is 15°5’ - 15°10’N
and 76°22’ – 76°27’E respectively in the Topo sheet no 57A/8. The proposed
plant area is surrounded by various industrial Units and iron ore mines. The
location map is shown in Fig 1.1 & Fig 1.2. The accessibility and
surroundings of the project site are as follows:
Nearest State Highway : Bellary – Hospet (1.2 km) Nearest Habitation : Dhanapura village (2.0 km) Nearest major Railway Station: Hospet (15.0 km) Nearest Industry : i) HKT Mining
ii) BMM spat Archaeological Importance : None within 10 km radius Environmental Sensitive Area: None within 10 km radius Nearest Surface Water Body : i) TB Dam (5 km)
ii) Danayanakere (1 km) iii) Gunda Kere (1/2 Km)
Altitude 1180 feet above MSL Max. day Temperature 44oC Min. day Temperature 18oC Max. Relative Humidity 86% Min. Relative Humidity 41% Annual Rainfall 760mm (Avg. 10 years) Topography Undulated Historical places None within 10Km radius
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2.3 Environmental Sensitivity
Sl. No. Areas Name
Aerial Distance
from (in km) 1. National Park Nil —
2. *Sanctuary / Tiger Reserve/ Elephant / any other Reserve
1. Gunda Reserve Forest 2. Nandibanda Reserve Forest 3. Ramgad Reserve Forest
4 km 7 km 4 km
3. Core Zone of Biosphere Reserve Nil —
4. Habitat for Migratory Birds Nil —
5. Archaeological Sites (i) Notified (ii) Others
Nil —
6. Water Bodies TB Dam 5.00
7. Defense Installation Nil —
8. Industries / Thermal Power Plants / Mines
Industries
Kirloskar Ferroys Ltd. Kalyani Steel Ltd. Hospet Steel Ltd. Ultratech Cements
10.0 9.0 10.0 10.0
Mines MSPL S.P. Minerals Other Mines (10 Nos.)
4.0 4.0
10 km radius
9 Airports M/s. Jindal Southwest 25
10 **Railway Lines Hospet – Swamihalli (Iron ore loading station only) 0.03
11 National / State Highways NH – 13 1.0
* Three Reserved Forest are situated within 10 Km radius of the proposed site and the permission and recommendations obtained from the State Forest Department for setting up of integrated steel plant is given in Annexure 1– Sanctions and approvals.
** The permission obtained from Railway department is given in
Annexure 1 – Sanctions and approvals.
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Fig.II.1 Location Map Bellary District
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Fig. II.2 Location Map of Project Site
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2.4 Resources / Infrastructure Requirements
2.4.1 Raw Materials
The Bellary district is well known for its availability of its low and high
grade iron ore. BMM Ispat group is having iron ore mines with a production
capacity of 250 MT/year. The environmental clearance obtained for the
above capacity is given in Annexure I - Sanctions and approvals. BMM have
already applied for lease for mining in additional area and acquiring
process is in progress. The raw materials required are given in Table 2.1.
Table – 2.1 List of Raw Materials
Raw material Quantity Mt/year Source
Low grade iron ore fines 4.4 Captive mines and from indigenous sources
Iron ore pellets 0.43 Indigenous source Bentonite 0.008 Indigenous source Non coking coal 1.243 Imported Coking coal 0.92 Imported Limestone 0.53 Indigenous source Dolomite 0.34 Indigenous source Quartzite 0.13 Indigenous source Clinker 0.73 Indigenous source Gypsum 0.04 Indigenous source
• While coking coal and non coking coal will be imported, all other materials are available indigenously.
2.4.2 Water requirement
The total water requirement will be about 3881 m3/hr. The Government of
Karnataka has already allotted 22 MGD of water from downstream of TB dam
and Almatti dam for the proposed project. The permission obtained for
drawl of the required quantity of fresh water is given in Annexure 1-
Sanctions and approvals. The quantities of water required for various units
of integrated steel plant and effluent generated are presented in Table 2.2.
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TABLE 2.2 Water requirement and Effluent generation Unit :
m3/hour
Plant unit Total water
Re-circulated water Make-up water Process loss Blow down
Iron ore beneficiation plant 7300 7123 177 171 6 Iron ore pelletising plant 1800 1747 53 45 8 DR plant 4610 4372 238 233 5 Coke plant 2200 2067 133 120 13 Iron ore sintering plant 6950 6822 128 128 0 BF plant 8880 8370 510 452 58 Steel melting shop 3870 3676 194 150 44 Continuous casting machines shop 800 718 82 66 16 Calcination plant & oxygen plant 5130 4976 154 139 15 Rolling mill 27520 26687 833 719 114 Power plant 51500 50350 1150 830 320 Cement plant 300 291 9 8 1 Drinking & sanitation 100 100 100 Evaporation & other losses 120 120 120 0 Total 121080 117199 3881 3281 600 Blow down water use Green belt maintenance 400 Dust control in raw materials yard 200
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Total 600
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2.4.3 Land requirement
The government of Karnataka has already allotted 3530 acres of land in
Danapura, Nagalapura, Danayana kere and Garaga villages in Hospet Taluk in
Bellary district and acquisition of land is in progress. The details of land
required for each unit is furnished in Table 2.3. The Lay-out plan is given in
Figure II.3.
TABLE 2.3 LAND-USE IN CORE ZONE
Sl. No Land description
Area in Hectare
% of Land requirement
1 Factory
Raw materials Storage Yard
• Lime stone • Dolomite • Coal • Iron Ore
1.00 3.00 10.0 3.0
Beneficiation plant
12.0
Pellet plant
12.0
Sinter Plant
10.0
DRI Plant
10.0
Blast Furnace
40.0 16.50
SMS
6.0
Calcination Plant
2.0
Oxygen plant
1.0
Rolling mill
20.0
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Power plant
4.0
Cement Plant & Grinding unit
18.0
Coke oven plant
26.0
Admin. Complex & Health Centers
2.0
Repair shop & Central stores
2.0
Landscaping, Garden and Tree curtains
54.0
2 Housing Colony 40 2.80 3 Water storage area 350 24.50 4 Roads & Railway station 121 8.50 5 Dump Yard 210 14.70 6 Green Belt 472 33.00 Total 1429 100.0
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Fig. II.3 Layout plan
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2.4.4 Power requirement
The energy requirement for various units is given in Table 2.4.
TABLE - 2.4 ENERGY REQUIREMENT
Manufacturing Units Power Consumption (MW)
Ore Beneficiation plant 7.5
Pelletising Plant 7.5
DR Plant 11.4
Coke ovens 4.8
Sinter plant 9.6
Blast furnace 28.9
Steel Making (EAF,BOF&LRF) 73.3
Continuous casting machines • Slab Caster • Billet caster
5.6
Rolling Mills • Hot strip mill • Structural/ wire rods
37.0
Auxiliaries ( Oxygen Plant, Calcining kilns etc.)
12.0
Cement Plant 11.4
Power Plant 21.0
Total 230
The annual electrical energy consumption in the plant is estimated to be
about 1740 million units. The average demand of the plant is estimated to be
230 MW. It is proposed to meet the entire requirement of electric power from
captive sources taking the support of State Electricity grid for stability. Power
generation will be effected by recovering the heat from waste gases from the
DR kilns and non recovery coke ovens and by firing coal and char from the kiln
discharge in suitable boilers. The purchased/ generated power will be
stepped down to 6.6 kV. The 6.6kV Switchgear will distribute power to the
6.6 kV motors and also to the LT substations located at load centers.
Provision will be made to sell the surplus power if any through the grid.
2.4.5 Fuel requirement
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The fuel requirement and sources of availability are as follows.
Production unit Fuel Quality Quantity
Pelletising plant Non coking coal Ash < 12%, VM 25 – 30%, Sulphur < 0.6%
0.048 Mt/year
DR plant Non coking coal Same as above 0.55 Mt/year
Sinter plant Coke breeze Ash < 15%, VM < 1%, Sulphur < 0.6%
0.137 Mt/year
BF coke Ash < 12%, VM < 1%, Sulphur < 0.6%
0.686 Mt/year
BF plant Non coking coal Same as that for
pelletising plant 0.257 Mt/year
Power plant Non coking coal Same as that for pelletising plant
0.3 Mt/year
Rolling mills Furnace oil Sulphur 3% (max) 100,000 kl/yr
Calcining units Furnace oil Sulphur 3% (max) 30 kl/yr
The source and mode of transportation of the fuels is indicated below:
Fuel Source Mode of transportation
Non coking coal Imported By sea to Indian port and by rail thereafter
BF coke Coke plant By conveyor
Coke breeze Coke plant By conveyor
Furnace oil From Indian public sector oil companies
By road
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2.4.6 Manpower requirement
The manpower required for the proposed integrated steel plant, cement
plant and Captive power plant are indicated below. A residential colony
with 500 quarters will be set up in the up wind direction of the plant site.
Adequate treated drinking water supply and sewage treatment system will
be established.
S.No Category Nos.
1 Managerial 340
2 Supervisory 1070
3 Skilled 2680
4 Unskilled 510
Total 4600
2.4.7 Construction materials requirement The details of chief construction materials are given below.
Sl.No. Materials 2 MT/YEAR
1 Coarse Aggregates (m3) 138,000
2 Sand (m3) 67500
3 Reinforcement 0-015 MT
7 Cement 0-06 MT
2.5 Details of Manufacturing Units
It is proposed to provide a iron ore beneficiation which can convert low
grade iron ore into a high grade concentrate to feed the pellet plant and
sinter plant. Depending on the characterization of the ore gravity and
magnetic separation methods will be employed to beneficiate the ore. Non
recovery type coke ovens plant will be installed to supply coke to blast
furnaces and coke breeze to sintering plant. The sensible heat in the coke
ovens gas will be used for power generation. A 230 MW captive power
generation using coke oven gases, DRI kiln gases and coal is proposed. A
pellet plant is proposed to manufacture pellets, which would be used to
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feed DR plant and replace lump iron ore in the blast furnace burden. Sinter
plant will supply fluxed sinter to the blast furnace and will aid in achieving
high productivity. Sinter plant will be supplied with high grade iron ore
concentrate from the beneficiation plant. Liquid iron or hot metal, as it is
known in steel industry, will be produced in highly energy efficient blast
furnaces, where coal dust injection will be practiced to reduce the
requirement of metallurgical coke.
Two options are available for steel making, electric steel making and oxygen
blown steel making. The former is electrical energy intensive and needs
solid charge at least partially while the latter can accept wholly liquid
charge and widely employed in large capacity integrated steel plants. Both
the process routes are considered to produce liquid steel and feed the
continuous casting machines. The feed to the hot strip mill will be slabs and
to non flat rolling mills, it will be billets. These will be produced in
universally accepted continuous casting machines to reduce casting losses
and for automated production as against ingot casting. The rolling mill will
be designed to produce both flat and non flat products utilizing the state of
the art technology. Granulated slag from Blast furnace, clinker, gypsum and
coal are used for manufacturing of Portland cement. A schematic process
flow diagram of integrated steel complex is presented in Fig II.4.
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Fig. II.4 Schematic process flow diagram – Integrated Steel Plant
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2.5.1 Iron Ore beneficiation plant
The route adopted for beneficiation in the proposed plant is a combination
of gravity separation in spirals and magnetic separation in low intensity
magnetic separator and high gradient magnetic system.
Iron ore fines of minus 10 mm size will be ground to the liberation size in
grinding mills and pressure rolls. The ground ore will be stored as slurry in a
buffer tank.
The ground ore will be subjected to low and high intensity magnetic
separation to recover the magnetite and hematite part of the ore. The size
of the ore fed to high intensity magnetic separation will be restricted to
below 45 microns by screening and regrinding.
The concentrate from magnetic separation will then be dewatered in filters
to ensure that the moisture in the product will be low enough for
pelletising. The water reclaimed will be clean enough to be recycled back to
plant directly.
The tailings will be first dewatered in hydro cyclones and then treated in
thickeners for water recovery. The thickener sludge will be filtered to
recover water and the solid waste will be transported in trucks to the dump
area. The beneficiation plant will treat about 4.4 Mt/yr (dry) of iron ore and
produce 3.2 Mt/yr of concentrate and 1.2 Mt/yr of tailings.
The schematic flow sheet of beneficiation plant is given in Fig. II.5.
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Fig. II.5. Bbeneficiation plant - Schematic flow sheet
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2.5.2 Pellet Plant
There are two principal process steps for the production of pellets. The first
step is the formation of green balls. Fine grained iron ores having adequate
size distribution are rolled with a binder and wetting agent in suitable
devices such as discs. In this way, wet balls are formed. These are called
green pellets. During ball formation, a binder like bentonite is used.
Additives like limestone may be added for changing the metallurgical
properties of the indurated pellets.
In the second step, the green pellets are dried and indurated to obtain the
typical features of pellets. This is achieved, in most cases, by careful
heating under oxidizing atmosphere to just below the softening point of the
ore used. During heating, not only the crystalline structure is changed, but
also other bonds appear such as reaction between slag forming constituents
– both between each other and with iron oxides. The hot pellets are
carefully cooled in order to maintain as far as possible the resulting
crystalline and other bonds as well to avoid tension cracks.
It is proposed to adopt the grate - kiln process in the pelletising plant. The
plant is rated to produce 1.2 Mt/yr of pellets.
The induration or heat hardening process for the pellets can be divided into
four distinct stages – Drying, Preheating, Firing and Cooling. In the grate kiln
process, these stages are separate and will be carried out in three separate
machines - drying and preheating on the traveling grate, firing in rotary kiln
and cooling in annular cooler.
Each unit is designed to withstand mechanical and thermal stresses imposed
by activities to be carried out in the unit. At the end of the grate machine,
the pellets will be sufficiently hardened to withstand the impact of fall from
grate machine into the kiln. The hot air from the cooler will go through
ducts into grate machine for drying and preheating.
The pre heated pellets will drop into the rotary kiln. The pellets will move
through the rotary kiln towards the discharge end where coal fired burner
Richardson & Cruddas (1972) Ltd. II-31
will be provided. Hot air from annular cooler will be sent to the kiln and
grate. Pulverized coal will be injected into the kiln together with hot air
from cooler. In the kiln, the temperature of the preheated pellets will be
raised to about 1300°C. The fired pellets will be discharged through a
bunker onto the cooler.
The pellets will be cooled in an annular cooler. The pellets are cooled to
less than 100°C. The cooled pellets will be collected on a heat resistant belt
conveyor and transported to product storage.
Coal pulverizing unit will receive coal from the storage yard and store in a
bunker upstream of the coal pulverise. Ground coal will be stored in a bin
and from there injected into the kiln.
Since iron ore concentrate is the feed to the proposed pellet plant, the
plant proper will start from iron ore concentrate storage.
The hourly material balance for the pelletising plant is indicated below:
Input, t Output, t Iron ore concentrate 157.5 Iron ore pellets 150.0 Bentonite 1.1 Process losses 5.3 Coal 6.0 Dust recycled 9.2 Dust loss 0.1
Total 164.6 Total 164.6
The schematic process flow chart of Pellet plant is given in Fig.II.6.
Richardson & Cruddas (1972) Ltd. II-32
Fig. II.6 Schematic Process Flow sheet – Pellet plant
Proportioning and Mixing
Iron ore Concentrate
Dust
Balling & Sizing
Drying & Prehealing
Firing
CoolingHot Air
Pellets To Storage
Water
Under Size Pellets
Over size Pellets
Green Balls
Gas Exhaust ESP
Dust
Stack
Grinding
Hot Air
Coal
Richardson & Cruddas (1972) Ltd. II-33
2.5.3 DRI
Sponge iron is the product of solid state reduction of iron ore. It is also
known as directly reduced iron or DRI. The process of manufacturing sponge
iron or DRI is known as DR process. These processes can use gaseous or solid
fuels for supply of heat and reducing gases. Coal based direct reduction
process using rotary kiln for reduction is proposed for this project.
One of the advantages in coal based DR processes is that it uses abundantly
available non coking coal and the heat in the flue gases from the reduction
kiln can be used for generation of electric power.
In the Coal based direct reduction process, a refractory lined rotary kiln is
used for reduction of iron ore in solid state. The size depends on the
production capacity of kiln. The kiln is mounted with a slope of 2.5%
downwards from the feed end to the discharge end. A central burner
located at the discharge end is used for initial heating of the kiln. Sized iron
ore is continuously fed into the kiln along with coal. Small quantities of
limestone/dolomite are added to absorb sulphur from the coal. A number of
air tubes are provided along the length of the kiln. Air is introduced through
these tubes axially in the free space over charge. The desired temperature
profile is maintained by controlling the volume of combustion air through
these tubes. The rotary kiln is broadly divided into two zones namely, the
pre-heating zone and the reduction zone. The pre-heating zone extends
over 40 to 50 percent of the length of the kiln. In this zone, the moisture in
the charge is driven off, and the volatile matter in the coal, liberating over
a temperature range of 600° C to 800° C, is burnt with the combustion air
supplied through the air tubes in the free space above the charge. Heat
from the combustion raises the temperature of the lining and the bed
surface. As the kiln rotates, the lining transfers the heat to the charge.
Charge material, preheated to about 1000°C enters the reduction zone.
Temperature of the order of 1050° C to 1100° C is maintained in the
reduction zone for reducing iron oxide to metallic iron.
Richardson & Cruddas (1972) Ltd. II-34
The established kiln sizes for production of sponge iron are 100 t/d, 350 t/d
and 500 t/d. Four 500 t/d kilns will be employed to produce DRI.
The main production units of the DR plant are
• Coal and flux preparation unit
• Day bins building
• Kiln and cooler area
• Product separation unit
• Gas handling system
Iron ore pellets will be delivered to the day bins from the pellet plant by a
group of conveyors. Coal will be received in – 150 mm size from the coal
storage area. It will be screened in a primary screen to separate out – 50
mm fraction. The + 50 mm fraction will be sent to an impact crusher
working in closed circuit with the screen, for reducing the size to below 50
mm. The – 50 mm fraction will be ground to – 20 mm size in a double roll
crusher operating in closed circuit with a screen, for reducing the size to
below 20 mm. This coal will be conveyed to the day bins building where it
will be screened into three fractions, coal fines, coarse coal and feed coal.
There are two bins for feed coal and one each for coarse coal and coal fines
in each row.
Weigh feeders will be used to proportion ore, feed coal and dolomite
charged to the kiln from the feed end. Injection coal will be injected into
the kiln from the discharge end with the help of compressed air supplied by
the lobe compressor. There will be two rows of bins in day bins building,
each feeding two kilns.
The raw materials will be charged into the rotary kiln from the inlet end by
means of a feed tube. The rotary kiln is of 4.3 m in diameter and 72 m long
An AC step-less speed variable motor will rotate the kiln at 0.2 to 1.0 rpm.
Due to the inclination and the rotary motion of the kiln, the material will
Richardson & Cruddas (1972) Ltd. II-35
move from the feed end of the kiln to the discharge end in approximately 10
to 12 hrs. The fine coal will be blown from the discharge end of the kiln to
maintain the required temperature and the carbon concentration in the
bed. The kiln has eight shell air fans mounted on the top which will blow air
in the respective zones to maintain the required temperature profile. The
material and the hot gasses move in the counter current direction; as a
result of which the iron ore gets pre-heated and gradually reduced by the
time it reaches the discharge end.
The hot material, after the reduction is complete, will be transferred to the
rotary cooler via the transfer chute. The cooler is 3.2 m in diameter and 44
m long. It will be rotated at 1.4 rpm. The water will be sprayed on the top
of the shell which will cool the material inside the cooler indirectly. The
material cooled to 80° C will discharge on a belt conveyor by a double
pendulum valve. This valve acts as the seal for the prevention of the
atmospheric air into the kiln cooler system. The total kiln cooler system is
kept under positive pressure of about 0.3–0.5 mbar. This prevents the
atmospheric air from getting into the system. The kiln has to be always
operated on positive pressure as any leakage into the system will cause the
re-oxidation of the sponge iron.
In the product separation building, double deck screen will separate the
cooler discharge into 0-3 mm and 3-20 mm and +20 mm size fractions. The
+20 mm fraction will be diverted to the sponge iron bin. The 0-3 mm sized
fraction will be fed to a drum type magnetic separator where the sponge
iron fines and the dolochar will get separated and will be fed to the
respective bins through the chutes and conveyor. The 3-20 mm fraction will
be similarly separated by another magnetic separator and fed to respective
bins. This magnetic fraction will be sponge iron lumps and the non-magnetic
will be char, which is the unburnt coal. This char will be used in the power
plant.
The gasses, which flow counter current to the material flow, will go to the
dust-settling chamber where the heavier particles settle down. These
Richardson & Cruddas (1972) Ltd. II-36
particles are continuously removed by the wet scrapper system. The gases
then pass to the after burner chamber where the residual carbon or carbon
monoxide are burnt by the excess air available. The gases at high
temperature will be sent to waste heat recovery boiler. The gas, after it
looses heat in boiler unit, will be cooled and then cleaned in electrostatic
precipitators and let into the atmosphere at about 120 deg C through the
chimney. Alternatively the hot gases can bypass the boilers and get cooled
in gas conditioning towers before they are sent to the electro static
precipitator.
The gases from the DR kilns will be used to generate steam in waste heat
recovery boilers. Each kiln will have one boiler. The steam generated will be
used to drive a turbo-generator and supply power to the plant.
The hourly material balance for the DR plant is indicated below:
Input, t Output, t Iron ore pellets 137.7 DRI 95.0 Non coking coal 71.3 Process losses 76.3 Dolomite 2.9 Char 28.5 Dust recovered 12.0 Dust loss 0.06
Total 211.9 Total 211.9
The schematic process & flow chart of DRI plants are shown in Fig. II.7.
Richardson & Cruddas (1972) Ltd. II-37
Fig.II.7 Schematic process flow chart - Sponge Iron Plant
GCT – Gas Conditioning Tower
Richardson & Cruddas (1972) Ltd. II-38
2.5.4 Coke oven Plant ( Non recovery type )
Metallurgical coke is a strong, porous, carbonaceous material which is
produced by the destructive distillation of coking coals in refractory
chambers called coke ovens or carbonization chambers. Over 90 percent of
the world's oven coke production is used for the manufacture of liquid iron
by the blast furnace process.
Coke influences most the economy of iron making in a blast furnace. In
India, over sixty percent of the cost of producing hot metal is on account of
coke alone. The cost of coke is determined by the coking coal price and
conversion cost at the coke ovens. Coal prices have substantially gone up
recently and there is a strong need to economize on coke making
operations. In addition, the demands to produce better quality coke are
becoming greater, not with-standing the scarcity of premium quality coking
coals. In this context, the prime objectives of coke making are:
• To produce coke of the best possible quality with available coals
• To maximize throughput of coke
• To minimize conversion cost
• To produce byproducts of desired quality with little environmental
pollution
The two proven processes for manufacturing metallurgical coke are the
beehive process and the byproduct process. In the beehive process, air is
admitted to the coking chamber in controlled amounts for the purpose of
burning therein, the volatile products distilled from coal to generate heat
for further distillation. In the byproduct method, air is excluded from the
coking chambers, and the necessary heat for distillation is supplied from
external combustion of some of the gas recovered from the coking process,
or in some instances, cleaned blast furnace gas or a mixture of coke oven
and blast furnace gas. With modern byproduct ovens, properly operated, all
the volatile products liberated during coking are recovered as gas and coal
chemicals.
Richardson & Cruddas (1972) Ltd. II-39
While the beehive process was the first leading method for manufacture of
coke, the byproduct process has gained wider acceptance and replaced
beehive units. Of late, a modification of the beehive technology, known as
non-recovery ovens, is gaining prominence especially as a low-capacity
economical coke producing unit.
During carbonization, a part of the initial charge of coal is evolved as mixed
gases and vapors. In non recovery type ovens, these are burnt to supply heat
to the process. Excess heat in flue gases is recovered in heat recovery
boilers and used to generate electric power. This process is considered for
the BMMI project.
Stamp charging is a process where the entire coal charge for coke making is
compressed and then pushed into the oven for coking. The stamping process
brings the coal particles into more intimate contact with each other, which
enhances the coking properties.
Non-recovery coke making produces a high quality blast furnace coke
without the generation of hazardous or toxic emissions, usually associated
with byproduct recovery coke ovens. In a non-recovery oven, all of the gas
generated is burnt in the process.
The ovens or carbonization chambers have a unique sole flue heating design
to equalize the coking rate from the top and bottom to produce a uniform
product. Because the chambers operate under negative pressure with a
horizontal design, it will be easier to comply with the requirements of the
emission regulations.
Primary air for combustion is introduced into the chamber above the charge
through ports located in the doors. The partially combusted flue gas exits
the chamber though down-comer passages in the wall to the sole flues.
The sole flue arrangement is divided into two sections, each with four
passes for combustion of the flue gas prior to exiting the heating system.
Thus, the coke side and the pusher side can be controlled independently for
uniform heating. An inlet air damper is installed at the turn from the first
Richardson & Cruddas (1972) Ltd. II-40
pass to the second pass of the sole flue. This additional damper permits the
introduction of air to complete combustion of the flue gas while still in the
sole flue. Waste gas is conducted to a common collecting tunnel through
uptake passages in the oven wall.
The common waste heat tunnel is located at the top along the centre line of
the battery and extends the entire length of the battery. The number of
ovens per exhaust stack can be varied by changing the diameter of the
common tunnel. Each stack has a pneumatically-operated lid which permits
closing off the battery should it be necessary for operating reasons.
Because the coking chambers operate under negative pressure at all times,
there is a minimum fugitive emissions to the atmosphere. Pushing and
quenching emissions are controlled with state-of-the-art equipment similar
to that used in a byproduct plant.
When the coal is fully coked, the doors on each side of the oven are
removed and the coke is pushed. A large mechanically operated ram
attached to a pusher machine pushes the coke out of the oven and into a
railroad car called the quench car.
The quench car moves down the battery to a "quench tower" where the hot
coke is cooled with water. The quenched coke is then dumped onto the coke
wharf, from which it is conveyed to the screening station for sizing, and
then to the blast furnace.
The hourly material balance for the coke plant is indicated below:
Input, t Output, t
Coking coal 116.7 BF Coke 87.6
Coke breeze 19.4
Coke oven gas 8.3
Dust recycled 1.3
Dust loss 0.1
Total 116.7 Total 116.7
The process flow sheet of coal carbonization is shown in Fig. II.8.
Richardson & Cruddas (1972) Ltd. II-41
Fig. II.8 – Process Flow sheet - Coke oven plant ( Non recovery )
Richardson & Cruddas (1972) Ltd. II-42
The advantages of Non recovery plant
• Economy of the plant at the intended scale of production (2 X 0.4
Mt/yr)
• Power generation potential using the heat in the flue gases and
thereby reducing the requirement of coal firing in the power plant
and the consequent pollutants. (65 MW of power from gases from
coke plant and 130 MW by coal firing)
• Because the coking chambers are operated under negative pressure
at all times, there is a minimum of fugitive emissions to the
atmosphere.
2.5.5 Sinter Plant
Iron ore lumps were the only iron bearing material initially used in blast
furnace for production of hot metal. While mining iron ore, fines are also
generated and the quantity of fines depends on the characteristics of ore.
To gainfully utilize these fines, agglomeration technologies like sintering
and pelletising were developed.
The down draft sintering is presently the most important agglomeration
process. It differs from pelletising by various characteristics such as
• Feed of coarser grained ore particles
• Coke breeze as main energy source
• Heating up of the materials mix to slightly above the softening
temperature
• The final product consists of a spongy sinter cake, partly molten and
solidified, which by crushing and screening brought to the necessary
grain size.
The major advantages of using sinter in blast furnace are:
• Use of iron ore fines, coke breeze, metallurgical wastes in steel plant
like blast furnace flue dust & mill scale, limestone, dolomite for hot
metal production
Richardson & Cruddas (1972) Ltd. II-43
• Better reducibility and other high temperature properties of burden
material
• Increased blast furnace productivity
• Improved quality of hot metal
• Reduction in coke rate in blast furnaces
The raw materials used for sintering are:
• Iron ore fines (-6 mm),
• Coke breeze (-3 mm),
• Limestone & dolomite fines (-3 mm)
and other metallurgical wastes like blast furnace flue dust, mill scale etc.
Originally the sintering process was used to sinter lead ores in up draft
sintering. Only in 1904, Dwight Lloyd developed straight line machine and
there after iron ore fines could be sintered. Initially, sinter plant was
proposed as a scavenging unit where all the metallurgical wastes are
recycled and charged into the blast furnace. Wastes are iron ore fines from
the mines, limestone and dolomite fines, coke breeze, mill scale, flue dust
from blast furnace, SMS sludge and mill scale from rolling mill. Now, straight
line sinter machines are available in varying sizes starting from 36 m2.
These are widely employed in integrated steel plants for feeding the blast
furnaces.
The entire requirement of sinter for blast furnaces will be met from straight
line machines. There will be two machines, each with 100 m2 sintering area
to produce around 2.5 million tons of sinter per annum.
The sinter plant will start from proportioning section which will have bins
for iron ore concentrate, coke and flux fines and lime. The above described
materials will be drawn in the proportion needed as per the calculation on
the blast furnace slag regime. The material will go to the primary mixing
drum wherein the mix will be homogenized and some amount of water will
be added. In the secondary mixing drum, steam will be added to the sinter
Richardson & Cruddas (1972) Ltd. II-44
mix, the moisture addition will be based on optimum permeability of the
sinter mix. There will be two sinter machines in the plant. The
proportioning section and mixing and balling section will supply the sinter
mix to both the machines. The sinter mix from secondary mixing drum will
be conveyed to the top of the machine where there will be a charging
hopper. Below the hopper will be the charging drum with a segregation
plate. Sinter mix will roll down as per the size and the bigger particles of
ore and return sinter will roll to the bottom. Before the charging hopper,
there will be a hearth layer bunker, from which the hearth layer will be
spread to the grate and then the charging of sinter mix will be done. Due to
the vertical segregation, coke fines will continuously decrease from top to
bottom of the bed. Bed height of the sinter mix could be between 600-750
mm. The sinter mix top layer will be dried by recycling hot air from the
cooler. Also, there will be line burners which will burn small amount of BF
gas. The top of the sinter mix will be ignited. Below the ignition part, the
wind box will be closed by damper so that there is no suction. There after
the dampers will be open and continuously air will be sucked through sinter
mix. The sinter plant will have a high degree of instrumentation and
automation level 2. There will be specific models for return sinter control
and coke rate control and sinter machine speed control linked to burn raise
point of the sinter bed. There will be additional controls to regulate the
heat to ignition and moisture control based on permeability measure of the
sinter mix.
Sinter will be discharged at the end of the sintering machine on to a hot
sinter crusher. After the crushing, the sinter will be conveyed to the deep
bed, deep rail circular cooler is provided with a segregating arrangement
plates. The coarsest size sinter fractions will segregate to the bottom of the
cooler. The small size sinter which normally would fly away and create dust
pollution problem will segregate above the big pieces of sinter and on top of
the smaller pieces medium sized lumps of sinter will segregate. By doing
this, the air required for cooling can be optimized and the hot air so
recovered can be utilised for heating the top layer of sinter mix before
ignition. After the sinter is cooled, it will be screened on the cold screen
Richardson & Cruddas (1972) Ltd. II-45
where return fines, hearth layer and product sinter will be separated. The
hearth layer will be sent to the hearth layer bunker. The return sinter will
be sent back to the sinter plant. Sinter will be conveyed to blast furnace by
conveyors. The tumbler index of the sinter will be more than 70% + 10mm.
The FeO in sinter is around 7%. The basicity of the sinter will depend on the
percentage of sinter in the burden and will vary between 1.6 and 1.8.
The hourly material balance for the sinter plant is indicated below:
Input, t Output, t
Iron ore fines 242.3 Sinter 288.9
Dolomite 34.6 Process losses 28.6
Lime 20.5 Dust recycled 4.7
Coke breeze 17.5 Dust loss 0.05
Quartzite 7.2
Total 322.2 Total 322.2
The process and flow sheet are shown in Fig. II.9 .
Richardson & Cruddas (1972) Ltd. II-46
Fig. II.9 Process flow sheet - Sintering Plant
Richardson & Cruddas (1972) Ltd. II-47
2.5.6 Blast Furnace
The blast furnace is one of the most ancient and most modern energy
efficient processing units. Metallic iron was produced by man almost four to
five thousand years ago. From that time, the basic principle of reducing iron
oxides using carbonaceous reducing agent at high temperatures has
remained unchanged. The main change has been an increase in the size of
the operation and improving fuel efficiency and environment control
measures. The change has been mainly due to improved understanding of
the process. Modern day big blast furnaces produce even 15,000-16,000 tons
hot metal/day/ furnace.
Four 350 m3 blast furnaces are envisaged for producing hot metal. These
furnaces will have bell less top, high top pressure, coal dust injection, high
blast temperatures, oxygen enrichment etc.
The blast furnaces will use prepared burden such as sinter (75 - 85%) and
pellets (0-25%). Blast temperature will be 1050 – 1200 degree C. The blast
furnaces will have the latest in instrumentation and Computerization and
automation to achieve maximum production and fuel rate.
The blast furnace plant will consist of the following production units:
• Stock house
• Furnace charging system
• Furnace proper with cast house
• Hot blast stoves
• Cast house slag granulation unit and emergency slag pits
• Hot metal ladles and ladle repair shop
• Pig casting machine shop
• Dust catcher and dry gas cleaning system
• Water recirculation system
• Control rooms
Richardson & Cruddas (1972) Ltd. II-48
Raw materials will be supplied to the stock house by conveyor systems.
Sinter and pellets will be delivered from the sintering plant and pelletising
plant respectively. Coke will be delivered from the coke plant. Quartzite
will be supplied from the raw materials storage yard. Separate dedusting
systems with bag filers will be provided to control the dust in materials
transfer points for stock house and cast house.
The hourly material balance for the BF plant is indicated below:
Input, t Output, t Sinter 272.4 Hot metal to SMS 202.4 Iron ore pellets 68.1 Cold pig iron 1.7 Coke 81.7 Granulated slag 73.6 Quartzite, t 8.0 BF gas 175.6 Injection coal, t 30.6 Flue dust 7.4 Dust loss 0.0 PCM skull loss 0.1
Total 460.8 Total 460.8
The process and flow sheet are shown in Fig. II.10.
Richardson & Cruddas (1972) Ltd. II-49
Fig. II.10 Process Flow sheet – Blast Furnace
2.5.7 Steel Making plant and CCM
Two options are available for producing liquid steel.
• Basic oxygen furnace route
• Electric arc furnace route
Captive Power generation
Richardson & Cruddas (1972) Ltd. II-50
Both the routes of steel making have been considered for this plant. Electric
steel making has been adopted so as to enable production alloy steel at a
future date. Basic oxygen furnace route is selected as it is less electrical
energy intensive and more suited for production of large tonnages. It is
proposed to produce about 0.95 Mt/yr of steel through electric route and
about 1.26 Mt/yr through basic oxygen route.
Electric arc furnace
Basic electric arc furnaces are used to produce practically all types of steel,
both for continuous casting and foundry purposes. Basic electric arc
furnaces employ a bottom consisting of burned magnesite brick. Side walls
are also magnesite lined. The furnace roofs are generally constructed with
high alumina refractory.
Two electric arc furnaces of 60 t heat size have been envisaged. The
furnace will be of AC electric arc type with ultra high power transformer.
Main features of the electric arc furnace include EBT, water cooled side
walls and roof, water spray cooling of electrodes, hot heel, foamy slag,
continuous charging of DRI etc.
The metallic charge of the furnace will consist of hot metal, DRI and steel
scrap. Hot metal will be charged through launder from the ladle. DRI will be
continuously charged from the storage bins. Scrap will be charged from
buckets. Additives will be charged through roof continuously.
Bins will be provided for storing DRI and additives from where weighed
quantities will be charged into the furnace. Hot heel and foamy slag
practice will be followed to hasten the process.
The steel making shop will have the furnace bay, charging bay, tapping bay.
Each bay will be provided with necessary electric over head travelling
cranes to handle hot metal, liquid steel and scrap.
Richardson & Cruddas (1972) Ltd. II-51
The liquid steel from the electric arc furnace will be tapped into the casting
ladle placed on a ladle transfer car. The casting ladle will be moved to the
ladle furnace station for refining.
Basic oxygen furnace
This route is well established for steel making. The feed will be mainly
liquid iron from blast furnace. It will be refined by blowing high purity
oxygen into the liquid bath. The process is very fast and the production
capacity can be as high as 500 tons of steel in less than 45 minutes. The
basic oxygen furnace can be used to produce almost all grades of steel.
It is proposed to install two basic oxygen furnaces of 60 t capacity along
with f inclusions in the stream. Prior to start of casting, dummy bars will be
introduced into the moulds. The gaps between a dummy bar and mould
walls will be sealed and small pieces of steel scrap will be placed over the
dummy bar head for chilling of liquid steel.
Water supply to moulds, secondary cooling zone and machine cooling will be
commenced. In the liquid steel level in the tundish reaches a predetermined
level the nozzles of the tundish will be opened. The liquid steel stream from
tundish to mould will be protected by shroud system to ensure good quality
slabs/billets.
The partially solidified strands after leaving the moulds will pass through
the strand guide roller segments where intensive but controlled cooling of
the strands will be achieved by direct water spray with the help of water
nozzles. The solidified strands will be guided through withdrawal and
straightening unit before entering the gas cutting zone.
The dummy bars will be separated from the cast strands when dummy bars
reach beyond the withdrawal and straightening unit and will be stored in a
dummy bar storage device till their introduction is required for the next
cast.
Richardson & Cruddas (1972) Ltd. II-52
The cast slabs/billets will be cut into predetermined length by automatic
oxy-acetylene gas cutting torches. The cut slabs/billets will be delivered to
cooling bed through run-out roller tables. Pusher will be provided for
pushing slabs/billets on the cooling bed where these slabs/billets will be
marked. The marked slabs/billets will be lifted by slab/billet handling
magnet crane for storage in the slab/billet storage bay.
The flowsheet for the steel making and continuous casting is given in
Fig. II.11.
The hourly material balance for the steel making shop is given below:
Input, t Output, t
Hot metal 202.4 Liquid steel 263.8
Scrap 14.8 SMS slag 30.5
DRI 78.1 SMS gas 2.1
Lime 15.4 Dust recycled 17.3
Calcined dolomite 3.0 Dust loss 0.017
Total 313.7 Total 313.7
The hourly material balance for the continuous casting plant is given below:
Input, t Output, t
Liquid steel 263.8 Slabs & billets 250.6
Recycled scrap 8.6
Scale & muck 4.6
Total 263.8 Total 263.8
Richardson & Cruddas (1972) Ltd. II-53
Fig. II.11. Process flowsheet - steel making and continuous casting
Richardson & Cruddas (1972) Ltd. II-54
2.5.8 Rolling Mill
The rolled products of an integrated steel plant fall into two categories,
flats and non flats. Sheets and plates belong to the first category.
Construction steel like angles, channels, I-beams, wide flange beams,
special sections such as zees and tees, wires, bars and rods belong to non
flat category.
Production of flat products
The hot strip mill is used to produce sheets and coils. The usual steel
composition is
C – 0.03 – 0.12%
P - 0.04 % max
S – 0.02% max.
This range of composition provides the best reliability. Such steels can be
produced in basic oxygen furnaces or electric arc furnaces working together
with ladle refining furnaces. Steels are usually killed, as slabs are cast in
continuous casting. Slabs can be thin slabs or thick slabs ranging from 80mm
– 250mm thick. The width could be 1200 – 2500 mm. The slabs must be
accurate enough in dimensions and sound enough in structure to permit
conversion rolling operations and their edges and surfaces should be free of
defects.
The slabs from the casting plant will be cooled, sheared to length,
inspected, edge defect eliminated, then charged to reheating furnaces and
then rolled in hot strip mill.
This method provides full flexibility of hot strip mill scheduling, permits
closer metallurgical control of steel rolling temperatures and minimizes
injurious steel surface defects resulting from defects in slab areas.
Slabs are heated in continuous reheating furnaces. The plant will consist of
roughing scale breaker and four 4-high roughing stands, finishing scale
Richardson & Cruddas (1972) Ltd. II-55
breaker and six 4-high finishing stands, driven table rolls conveyor from
furnace to mill and also from stand to stand. If the mill is to produce strips
or sheets of greater width than the maximum width of slab available, the
first roughing stand is a broad side mill, in which the width of the slab is
increased in a single pass by cross rolling. In this case, turn tables for
manipulating the slabs must precede and follow the stand. A slab squeezer
also follows the broad side mill. The next three roughing stands are usually
provided with integral vertical edgers in front of each stand. Separating the
roughing train from finishing train is a holding cable while the finishing ends
is a closely grooved tandem train composed of finishing scale breaker and its
finishing stands.
High pressure, hydraulic sprays are located after the two scale breakers and
at several roughing stands to remove scale from the hot slab.
A flying shear is usually provided following the last finishing stand for
cutting the rolled product into lengths, if so desired. This is called the cut
to length sheets. As the steel proceeds from mill, it is carried over a long
table called the run-out table consisting of individually driven rollers. Two
or more coilers are located in this table. They operate to coil the strips
when continuous long lengths are required. When the coilers are in
operation and the steam passes over them on to a piler at the end of the
table. Additional tables may be installed parallel to the center run out table
with suitable transverse for moving material to them. This equipment if
used principally when heavier gauges are being rolled. The above desired
hot strip mill provides high rolling capacity and rapid steel travel with little
loss of heat but entitles a high installation cost and fixed number of passes
with some loss of flexibility in making rapid changes in the mill set up when
size of the product to be rolled is changed. Depending on the scheduling
alternate arrangement can be made to make the mill more flexible.
The first strip is taken, while rolling, to determine the proper grade of steel
and the size and surface quality of the slab, and then the scheduling is made
Richardson & Cruddas (1972) Ltd. II-56
for a proper rolling sequence. The factors taken into consideration at this
stage are rolling width, gauge and steel consumption.
The next step is getting slabs heated to the correct rolling temperature. The
slab should have uniform “scale jacket” that will clean up readily in rolling.
The next step is to rough down the slab to a predetermined intermediate
thickness. As the slab leaves last roughing stand, it should be flat, straight,
free of furnace scale, true to width and after cross section, suitable for
further reduction at the finishing stands. The first rolling pass on the slab is
done on a scale breaker followed immediately with a high pressure hydraulic
spray to remove furnace scale. There are usually one or two more descaling
sprays following the second or third roughing stands and numerous steam
and air sprays provided to remove any further scale that may be loosened
during rolling or edging. Proper use of broadened mill slab squeezer and
three vertical edges normally guarantee the uniform width necessary.
The finishing stand is to be operated with careful regulation to obtain a
finished hot rolled product of fine quality. Various automatic control
elements have been incorporated to assist operators to produce strip to
uniformly high quality. Surface gauge width, finishing temperature and cross
sectional contour of the direction are all required to meet the given
standards. The final step in rolling on a strip mill is the disc position of the
hot rolled product and in some mills the product may be cut into required
lengths on a plain shear located at the exit end of the mill and sheared
pieces move along the rundown table to a hot piler. Greater portion of hot
rolled flat material is coiled by the hot coiling machine. This includes the
semi finished product designated as hot rolled break down, for subsequent
cold reduction as well as hot rolled sheets in coils which may be shipped as
such or transferred to the finishing department. The essential requirements
of the coiler are to receive the material at mill speeds, should coil it tightly
without excessive tension, telescoping, scratching or marking and finally
discharge finished coil quickly without damage.
About 1 million tons per annum of hot rolled coils will be produced.
Richardson & Cruddas (1972) Ltd. II-57
Production of non flat products
Billets are rolled into non flat products in merchant mills and bar mills. Most
modern of all bar mill designs is the continuous mill with alternate
horizontal and vertical rolls, which obviate the need for twisting the bars
and the twist guides and eliminate the tendency to scratch bars. The stands
of the mill are spaced apart far enough so that a slight loop can be formed
between stands. Slight loop eliminates all push and pull between stands.
Flat thin material of narrow width can be produced on various types of bar
mills.
Continuous mills produce rods from 100 mm square billets. There are two
types of rod mills. In one type, a group of roughing or breaking down rolls is
provided and the rod is directly rolled from the billet. The draw back in this
method is that if the rolls are speeded up to correspond to elongated bar,
speed of the first roughing group is very slow. Long pieces are thus kept in
contact with cold rolls, resulting in cooling to a point where it becomes
difficult to finish. If the first roughing group is speeded up, then the piece
must be held ahead of the first intermediate and is cooled faster and more
unevenly than in the former instance. In some cases, solution to this has
been done by placing a heat retainer, a long narrow brick chamber heated
by gas, between roughing and intermediate groups of rolls. Best plan
involves use of reheating furnaces between two groups of rolls. Efficient
operation at the mill depends largely upon the skills of operating groups, for
best results roll diameter for different stands must be carefully selected and
maintained in proper proportions. The roll passes especially for the finishing
group of rolls must be skillfully adjusted and accurately tuned. The rolls and
guides must be carefully set in the housings and there after the draft must
be regulated through the mill screws to suit the conditions.
Uniform heating of the billet is also important. Modern rod mills employ
both continuous and looping features to get the best out of the mills. The
modern mills have a considerable number of stands arranged in a line
similar to continuous type rolls. However, instead of these stands being
Richardson & Cruddas (1972) Ltd. II-58
driven by a single motor, the stands are arranged in units of 1, 2, 3 or more,
each unit driven by a separate variable speed motor. The length of this mill
is greater than that of continuous mill but shorter than the mills where
loops are used in spite of variable speed motors. These mills also employ 2-5
loops and the stands driven by variable speed motors to maintain short
loops.
The rebar mill will roll rebars, plain rounds, low alloy rounds and squares
from continuously cast billets. The mill will be of modern design and will
have the following features so that superior surface finish, good dimensional
tolerances and specified metallurgical properties of the final products are
ensured:
• Hot billet charging
• Billet weighing
• Mill floor level at +0.0 m
• Reheating furnace of walking beam type
• High pressure water jet de-scaling
• Billet welding
• Single strand high speed continuous H-V configured mill for twist-free rolling
• Housing- less stands for ease of maintenance and rigidity
• Quick roll change carpet in finishing stands
• Inter stand tension control rolling
• Convertible stands for slit rolling of smaller size re-rebars
• Online water quenching for production of TMT rebars in straight length
• Two Nos. 6-stand high speed finishing block for smaller rebar production
• High speed discharge facility at cooling bed entry side for rebars coming from 6-stand finishing block
• Automatic bundling and tying facilities for straight length rolled products.
Richardson & Cruddas (1972) Ltd. II-59
Thus rolling mill complex envisaged for the plant will have a hot strip mill,
wire rod mill with a TMT section and light structural mill. The capacity of
the hot strip mill will be slightly higher and the other mills are of nearest
standard size. This is done to ensure flexibility in production of various
products to meet the market demand.
The hourly material balance for the rolling mills is given below:
Input, t Output, t
Slabs & billets 350.9 HR coils 166.7
Non flat products 166.7
Recycled scrap 8.8
Scale & muck 8.8
Total 350.9 Total 350.9
The process and flow sheet are shown in Fig. II.12 & II. 13.
Richardson & Cruddas (1972) Ltd. II-60
Fig. II.12 Process Flow sheet - Rolling Mill
Reheating Furnace
Rolling Mills
Oil Firing
Rolled Products
Slabs / Billets
Steel Scrap
Combustion Gases to stack
Hot Billets / Slabs
To SMS To Sintering Plant
Mill Scale & Sludge
Richardson & Cruddas (1972) Ltd. II-61
Fig. II.13 Process Flow diagram - Rolling Mill
Richardson & Cruddas (1972) Ltd. III-62
2.5.9 Calcining Plant
A calcination plant is envisaged to produce lime and calcined dolomite. There
will be two 500 t/d kilns for calcining limestone and one 80 t/d kiln for
calcining dolomite.
The calcining plant will consist of limestone/ dolomite storage bunkers, kiln
charging system, screens for calcined product and storage bins for calcined
materials from where they will be sent to the consumers. The plant will receive
screened limestone and dolomite from the raw materials storage yard. The
calcined product will be sent to the consumers in covered belt conveyors. The
process flow sheet is given in Fig. II.14.
Richardson & Cruddas (1972) Ltd. III-63
Fig. II.14 Process flow sheet – Calcination Plant
Screening
Calcining Kiln
Oil Firing
Lime stone / Dolomite
Lumps
Calcined products
Screening
Lumps
TO SMS
GasesGas Cleaning
Dust
To Sintering Plant
Stack
Cleangas
Fines
Fines
To Sinter Plant
Dusty air
The hourly material balance for the calcination plant is given below:
Input, t Output, t Limestone/ dolomite 72.2 Calcined products 40.1 Process losses 30.4 Dust recycled 1.7 Dust loss 0.008
Total 72.2 Total 72.2
2.5.10 Cement Plant
Richardson & Cruddas (1972) Ltd. III-64
Portland Slag Cement is manufactured either by intimately inter grinding a
mixture of Portland cement clinker and granulated slag with addition of
gypsum (natural or chemical) or calcium sulphate, or by an intimate and
uniform blending of Portland cement and finely ground granulated slag, so that
the resultant mixture would produce a cement capable of complying with
required specification. No material is added other than gypsum (natural or
chemical) or water or both. However, when gypsum is added it shall be in such
amounts that sulphur trioxide (SO3) in the cement produced does not exceed
the limits specified in Indian Standards. Besides, not more than one percent of
air-entraining agents or surfactants, which have proved not to be harmful, may
be added. The slag constituent shall be not less than 25 percent nor more than
65 percent of the Portland slag cement. The Portland slag cement should
confirm to Indian standard specification IS. 455-1976.
Portland slag cements (PSC) is a blended cement. SC, when used in
construction, will contribute to higher ultimate strength in concrete structures,
which can be constructed more economically than with ordinary Portland
cement. It can also be used in construction of dams where low heat of
hydration is needed. Cementitious material such as Blast furnace slag and
pozzolanic materials such as calcined pozzalana clay, fly ash, rice husk ash etc.
are used to blend with ordinary Portland cement clinker and appropriate
quantity of gypsum to produce blended cements such as PSC.
Grinding process
The three raw materials required for manufacture of Portland slag cement, as
per Bureau of Indian Standards are clinker, blast furnace slag and gypsum. Ash
collected in power plant is also used in the mix. Weighed quantities of these
materials are fed to the vertical roller mill through a set of material handling
equipments like weigh feeders, belt conveyors, bucket elevator to the inlet of
the vertical roller mill. The mixture is ground to desired fineness by regulating
the speed of the circuit classifier. The classifier separates coarser and finer
Richardson & Cruddas (1972) Ltd. III-65
particles of cement. The finer particles are drawn out through vent, whereas
the coarser particles are returned to the mill for grinding. The fine cement is
collected by an ESP into a silo. This process is called inter grinding process.
Sometimes, instead of mixing ground granulated blast furnace slag (GGBS) with
clinker, it can also be traded separately.
The hourly material balance for the cement grinding plant is given below:
Input, t Output, t
BF slag 78.0 PS cement 176.1
Clinker 91.7 Exhaust gas 1.7
Gypsum 5.3 Dust recycled 1.6
Coal 4.4 Dust loss 0.002
Total 179.4 Total 179.4
The process flow sheet for cement plant is given in fig. II.15.
Richardson & Cruddas (1972) Ltd. III-66
Fig. II.15 Process Flow Sheet – Cement Plant
Proportioning
Grinding
Purchased Clinker
Dusty Air
Bag Filter
Cement
Stack
CleanGas
GranulatedBF Slag
Gypsum
DryingDusty Gas Gas Cleaning
Dust
Hot Gas
Hot Air Generation
Coal
Ash to Dump
Ash from Power Plant
Richardson & Cruddas (1972) Ltd. III-67
2.5.11 Power Plant
It is estimated that 230 MW of power shall be generated to meet the
requirement of the entire steel plant. Steam will be generated using the waste
heat in the flue gases from DR plant and coke plant and this is sufficient to
generate about 100 MW. To generate the balance power, coal fired,
atmospheric/ circulating fluidized bed combustion type boiler will be used. It is
possible to use char produced in the DR plant in this boiler.
The main units of the plant will be coal handling system, steam generator and
associated systems, steam turbine and associated systems and steam
condenser. The auxiliary systems include generator and electrical facilities,
control & instrumentation water treatment system, air conditioning system,
compressed air system, ventilation system and ash handling system.
It is proposed to use low ash imported coal. The coal will be supplied to the
power plant from the coal storage yard by a system of conveyors. Coal will be
sized and then fed to the boiler.
The steam generator system will produce superheated steam with desired
pressure and temperature. There will be two types of steam generators, waste
heat recovery type and fluidized bed combustion type. The former will be of
unfired, natural circulation, vertical tube, horizontal or vertical gas flow
multiple parallel pass type, ensuring uniform inlet gas flow distribution to all
the parallel processes. The latter will be of the natural circulation single drum
type and is a radiant, single reheat, balanced draft, semi-outdoor type system.
The flue gas from the boilers will be cleaned in electrostatic precipitators. The
dust collected from the flue gases from the coke plant ts recycled to the coke
making process. The dust collected from the flue gases from the DR plant is
Richardson & Cruddas (1972) Ltd. III-68
sent to sintering plant. The fly ash will be collected in the hoppers and used in
cement grinding unit.
Two steam turbine generators, rated for 120/ 130MW maximum continuous
output at the generator terminals, have been proposed. The generator will be
a two/ three cylinder tandem compound, reheat, extraction and condensing
type system. The turbine generators will be complete with lube oil system,
control oil system, jacking oil system, seal steam system, turbine drain system,
HP/ LP bypass system, Instrumentation and control devices, Turbine
supervisory instruments, Automatic turbine run-up system and protection
system.
The steam condenser will be designed to handle the entire exhaust steam
including that of the HP/LP bypass system and all the drains and vents under
all modes of operation. The condenser will consist of a divided water box, a
hot well and vacuum pumps.
There will be condensate pumps, low pressure heaters, high pressure heaters,
deaerator, boiler feed pumps and gland steam condenser.
The pressure pneumatic type ash handling system has been envisaged for both
bed ash and fly ash removal. Ash silos will be used to store ash for use in
cement grinding unit.
The hourly material balance (coal firing) for the power plant is given below:
Input, t Output, t Coal 44.9 Exhaust gas 55.9 Char 27.6 Dust recycled Fly ash 13.2 Bottom ash 3.3 Dust loss 0.046
Total 72.5 Total 72.5
Richardson & Cruddas (1972) Ltd. III-69
2.6 Statutory Regulatory Compliance
Air
Sl.No. Units Stack emission
1 Integrated Steel Units
<100 mg/Nm3
Combustion efficiency >99.9%
2 De-dusting units < 100 mg/Nm3
3 Fugitive emission < 2000 µg/m3
at a distance of 10.0m 4 Captive Power plant < 100 mg/Nm3 5 General Ambient air quality to be maintained at BMM
ISPAT LTD (Core zone) i. SPM ii. RPM iii. SO2 iv. NOx
< 500 µg/m3
< 150 µg/m3
< 120 µg/m3
< 120 µg/m3 6 General Ambient air quality to be maintained at
buffer zone v. SPM vi. RPM vii. SO2 viii. NOx
< 200 µg/m3
< 100 µg/m3
< 80 µg/m3
< 80 µg/m3
Waste water : General discharge Standards
Sl.No Parameter Inland surface
water Public sewers
Land for irrigation Marine/ coastal areas
(a) (b) (c) (d)
Richardson & Cruddas (1972) Ltd. III-70
1 Suspended solids mg/l, max. < 100 600 200
(a) For process waste water (b) For cooling water effluent 10 per cent above total suspended matter of influent.
2 pH value 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0
3 Temperature shall not exceed 5oC above the receiving water temperature
shall not exceed 5oCabove the receiving water temperature
4 Oil and grease, mg/l max, 10 20 10 20
5
Chemical oxygen demand, mg/l, max.
250 - - 250
Noise
Noise Level [dB(A)] Standards at Industrial establishment
i) Day Time (6.00 AM – 10.00 PM) = < 75 dB(A)
ii) Night Time (10.00 PM – 6.00 AM) = < 70 dB(A)
Noise Level [ dB(A) ] Standards in buffer zones
i) Day Time (6.00 AM – 10.00 PM) = < 60 dB(A)
ii) Night Time (10.00 PM – 6.00 AM) = < 55 dB(A)
2.7 Charter on Corporate Responsibility for Environmental Protection (CREP): Integrated Iron & Steel Industry
Richardson & Cruddas (1972) Ltd. III-71
Coke Oven Plant
The parameters like PLD (% leaking doors), PLL (%leaking lids), PLO (% leaking
off take) will be meet the notified standards under EPA. Industry will submit
time bound action plan and PERT Chart for the implementation of the same
after detailed engineering of the plant. The coke oven plant is expected to be
implemented with all latest technology and shall meet all guidelines given in
CREP
Steel Melting Shop
Controll of fugitive emissions by installation of secondary de-dusting facilities.
The primary fume extraction system and secondary dedusting facilties will be
installed.
Blast Furnace
The plant will be installed with latest available technology. Direct injection of
reducing agents will be provided.
Sponge Iron Plants
The draft guidelines of Central Pollution Control Board for the installation of
sponge iron plant will be followed and strictly amended
Solid Waste / Hazardous Waste Management
SMS slag will be initially dumped suitably and then will be used for road making
and ballast for railway track. BF slag will be granulated and it will be utilized in
captive cement plant.
Richardson & Cruddas (1972) Ltd. III-72
Water Conservation / Water Pollution
Reducing specific water consumption to 5 m3/t for long products and 8 m3/t
for flat products. The effluent generated will be treated, if required and will
be reused for gardening and dust suppression. The zero discharge system will
be implemented.
Air Pollution Monitoring
Continuous stack monitoring system & its calibration in major stacks shall be
provided. 3 nos. of permanent AAQ monitoring stations around plant is also
envisaged. To operate the proposed pollution control equipment efficiently and
to keep proper record of run hours, failure time and efficiency with immediate
effect during operational phase. Compliance report will be submitted to CPCB
/ SPCB every three months. A best equipped Env.laboratory for analysis of air,
water and other pollutants in addition to on line monitoring of stacks. Training
for related employee will be given. The entire activity will be managed by an
independent Environmental Management Cell.
Clean technologies/ measures
Energy recovery from top Blast Furnace (BF) gas, Committed to adapt best
available technology. Tar-free runner linings will be used. Best available
indigenous materials will be used. Suppression of fugitive emissions using
nitrogen gas or other inert gas will be done as per the best available
technology. Reduction of Green House Gases by reduction in power
consumption by regular energy auditing.
Use of by-products gases for power generation
Richardson & Cruddas (1972) Ltd. III-73
It is included in the project that flue gases from DRI plant & Coke plant will be
used for power Generation scheme, Plant will be one of the best example for
promotion of energy optimization technology
Resource Conservation such as Raw material, energy and water consumption to
match International Standards.
2.8 Implementation of Carbon Credit project
BMM intend to put up a 2.0 Mt/yr integrated steel plant to produce rolled steel
products and BF slag based cement. The power requirement for the steel plant
will be met by captive power plant. The total power requirement of the
integrated steel plant has been estimated as 230 MW. BMM could meet this
power requirement either by setting up a fossil fuel based power plant or by
importing the required power from the state grid. However both these
alternatives would have resulted in increased GHG emission due to fossil fuel
combustion. BMM realize that installation of a Waste Heat Recovery based
captive power generation facility is a step towards environmental sustainability
by saving exploitation and depletion of natural and non-renewable resource
like coal. The DR plant will have four kilns, each of 500 TPD capacity. The heat
in the flue gases from these kilns will support 60 MW power generation. The
heat in the flue gases from the coke making chambers is estimated to support
60 MW generation. Thus, 120 MW power can be generated using Waste Heat
Recovery boilers in the captive power plant. The balance 110 MW will be
generated by using coal.
There will be twelve Waste Heat Recovery boilers with different steam
generating capacity i.e., four no’s in the DR plant of each 60 TPH capacity and
eight no’s in coke plant of 30 TPH capacity. The boilers will be designed to
take care of the fluctuations in the volume and temperature of flue gases
exiting the DR kilns and batteries of coke making chambers.
Richardson & Cruddas (1972) Ltd. III-74
The project activity is expected to generate around 808 million kWh of
electrical energy per year based on the heat energy recovered from the waste
gases. The auxiliary power consumption is estimated at about 10% of total
electricity generation.
The equipment for power generation will consist of waste heat recovery
boilers, bleed cum condensing turbo-generator, water treatment system,
condensate system, air cooled condenser system, auxiliary cooling water
system, compressed air system and electrical system consisting of switch gears,
low tension distribution panels, step-down transformer for meeting the in-
house power requirements of the power plant.
The waste gases generated in the sponge iron kilns, at temperatures of about
950°C, will be passed through heat recovery boilers and then passed through
electrostatic precipitator, before being released to the atmosphere. The flue
gases from the coke plant will be passed through heat recovery boilers and
then released to the atmosphere. In the heat recovery boilers, the heat energy
of the waste gases will convert the feed water into steam at 114 kg/cm2 and
540+5˚C. The steam so generated will be passed through the turbo generator
for power generation. A portion of the steam passing through the turbine is
bled-off and the remaining portion undergoes further expansion before being
exhausted to the air cooled condenser. The feed water to all the boilers is
heated to a temperature of 140°C in the deaerator which receives the steam
bled from the turbine. All equipments used in the project will be designed for
satisfactory operation for a lifetime of 30 years under specified site conditions.
In the absence of the aforesaid activity, the power requirement of the plant
would have been met by power generated from a more GHG intensive source
like a fossil fuel based captive power plant. The power generated from the
project activity would reduce the power generation from other fossil fuels
which are more GHG intensive.
Richardson & Cruddas (1972) Ltd. III-75
Further, the use of iron ore concentrate obtained by beneficiation of low grade
iron ore reduces the requirement of coal for production of DRI and coke for the
production of hot metal in the blast furnaces. This also leads to less GHG
intensive production practices.
Hence, projects like this contribute to the global cause of control and
mitigation of climate change.
Since utilization of energy in the waste gases coming from the sponge iron kilns
and the coke plant result in real and measurable reduction in GHG emission,
the proposed activity can be considered as a potential Clean Development
Mechanism (CDM) project of United Nations Framework Convention on Climate
Change (UNFCCC) under its Kyoto Protocol. Ernst & Young Pvt. Ltd. has been
appointed as the CDM consultant to guide the company through the CDM
procedure to avail any possible benefits from emission reduction.
CHAPTER - III
Richardson & Cruddas (1972) Ltd. III-76
DESCRIPTION OF ENVIRONMENT
The present environmental status of the proposed projects has been studied
covering 10 Km radius and presented in this chapter. It is necessary to know the
present quality of the environment with respect to the various aspects considered
under impact identification. These factors include air, water, noise, soil,
meteorology, land use, flora & fauna, socio-economic and demographic pattern.
For this purpose, a monitoring schedule covering three months of the year was
chalked out during December 2007 – February 2008 to generate baseline data on
ambient air quality, quality of ground water / surface water, soil, ambient noise
and meteorological parameters like temperature, humidity, wind speed and
direction, cloud cover etc. The baseline data on flora & fauna, socio-economic and
demographic factors, land use pattern, forests, geology, hydro-geology, soil and
agriculture, mineral resources etc. was carried out by field survey and secondary
data has been collected from the State Government authorities. The baseline
environmental data generation (air, water) were continued during summer season
(March – May 2008) and presented in this report.
3.1 Air Environment
Identification of different pollutants, which are expected to be released into the
atmosphere and having significant impact on the neighborhood, is an essential
component in impact assessment of the air environment. The ambient air quality
status of the study area of 10 km radial distance from the existing project will form
the baseline information. The predicted impacts due to the project will be
superimposed to find out the net (final) impacts (post-project scenario) on
environment.
If the final impacts due to the proposed project are known at the planning stage of the
project, a viable Environmental Management Plan (EMP) can be proposed to mitigate
and minimize adverse effects on the environment. The design of the ambient air
quality-monitoring network in the air quality surveillance programme is based on the
following considerations.
Richardson & Cruddas (1972) Ltd. III-77
- Micro-meteorological conditions of the study area on synoptic scale
- Topography of the study area
- Representation of regional background levels
- Representation of core zone
- Representation of cross sectional distribution in the downwind directions
- Influences of the existing sources, if any.
3.1.1 CLIMATE AND METEOROLOGY
Regional climate and meteorology:
The study area lies in sub-tropical region where climate is characterized by hot and
humid summer, moderate monsoon and mild winter seasons. Summer is typically from
March to June, when temperature ranges from a maximum of 44°C during daytime to a
minimum of 27°C at night. Winter from December to February, when the maximum
temperature during day time goes upto 38°C and minimum temperature 17°C at night.
The mean maximum and minimum temperatures of study area are presented in
table 3.1
TABLE - 3.1
MEAN MAXIMUM AND MINIMUM TEMPERATURES OF STUDY AREA
(DISTRICT CENSUS HAND BOOK, 2005)
Mean monthly maximum temperature °C
Mean monthly minimum temperature °C Sl.
No. Month 2002-03 2003-04 2004-05 2002-03 2003-04 2004-05
1. January 30.8 32.1 32.8 19 19.6 18.7 2. February 34.3 35.5 35.9 20.7 22.5 21.5 3. March 37.9 37.9 40 23.8 24.8 23 4. April 40.1 41.4 40.3 27.2 27.3 25.8 5. May 40 42.2 42.1 28.4 30.3 24.7 6. June 36.7 39.2 36.8 26.9 28.6 25.7 7. July 34.3 32.9 33.5 25.7 24.9 24.1 8. August 33.6 32.9 34.8 25.2 23.7 25.7 9. September 33.5 34.4 31.9 24.9 25.1 23.5 10. October 32.2 32.2 31.8 23.8 23.5 23.9 11. November 30.5 31.5 31.5 21.4 21.3 19.5 12. December 29.4 30.9 32.5 19.3 17.6 17.1
Richardson & Cruddas (1972) Ltd. III-78
The area receives annual rainfall varying between 490 to 870 mm. The rains
predominantly occur between June to September due to south-west monsoon. Rains
also occur in the months of October to December due to north-east monsoon. Table3.2
presents month-wise average rainfall in (District census hand book, 2005).
TABLE - 3.2 MONTHLY RAINFALL (mm)
Month 2000- 01 2001- 02 2002- 03 2003- 04 2004- 05 January 4.9 5.0 0 0 0 February 2.2 0.6 0 0.8 2.7
March 5.5 0.3 9.5 10.3 3.4 April 17.2 9.0 3.9 24.6 19.1 May 46.4 49.6 0 136.1 36.2 June 76.8 14.9 68.4 20.9 20.9 July 94.9 60.1 31.1 175 138.2
August 249.8 94 43.8 89.8 10.4 September 58.9 185.8 57.1 123 169.2
October 111.75 404.4 174.9 236.1 64.4 November 22.0 25.2 27 3.4 30.1 December 35.0 16.6 0.9 3.1 0
Total 730.0 865.6 416.6 822.3 494.6
The pattern of rainfall is highly irregular and varies significantly from year to year.
Humidity is the percent water vapour content of the atmospheric air. Its content
changes the nature and characteristics of the pollutants. Fog provides surface area for
suspended particles to Coalesce and also enhance chemical reactions of the gaseous
pollutants. The monthly average of relative humidity recorded at 8.30 AM and 5.30 PM
is presented in Table 3.3.
TABLE - 3.3 RELATIVE HUMIDITY IN DIFFERENT MONTHS (2000 TO 2005) Relative humidity (%) Sl. No. Month
8.30 AM 5.30 PM 1. January 78.4 54.2 2. February 72.8 44.0 3. March 64.6 32.8 4. April 64 34.4 5. May 58 37.2 6. June 60.6 46.4 7. July 67.2 54.2 8. August 68.8 53.4 9. September 69.0 54.4 10. October 77.60 59.2 11. November 82.40 72.6
Richardson & Cruddas (1972) Ltd. III-79
12. December 78.2 61.0
The following observations can be made from the secondary data.
• The morning relative humidity (RH) attains the maximum in the month of
November (82.4%) and minimum in the month of May (58.0%).
• The evening humidity attains the maximum in the month of November (72.6%)
and a minimum in the month of March (32.8%).
• The variations in the relative humidity throughout the year reflect the tropical
semi arid climate.
Wind speed and wind direction have a significant role on the dispersion of atmospheric
pollutants and therefore the air quality of area. Ground level concentrations for the
pollutants are inversely proportional to the wind speed in down wind direction while in
upwind direction no effect will be observed and in cross wind directions partial effect
due to the emission source is observed.
Micrometeorology at site
Prevailing micro-meteorological conditions at site regulate the dispersion (and hence
dilution) of air pollutants in the atmosphere. Therefore, study of meteorological
conditions is an integral part of environmental impact assessment studies.
Accordingly, a meteorological station was set up at project site. The following
parameters were recorded at hourly intervals during December`07 – February`08.
• Air temperature (°C)
• Relative humidity (%)
• Wind speed (m/s)
• Wind direction (eight quadrants)
The data collected on wind speed and wind direction was used for computation of
wind percentage frequencies in all the sixteen directions for wind speed in the range
of 1.0 -5.0, 5.1-11.0, 11.0-19.0 and 19-29 kmph. Wind speed <1.0 kmph was
considered as calm condition. Table 3.4 through 3.6 show the wind frequency pattern
of 06-17, 17-05 and 0-24 hours.
Richardson & Cruddas (1972) Ltd. III-80
TABLE - 3.4
WIND FREQUENCY, DISTRIBUTION (06 -17 hrs)
Wind frequency (%) Direction of wind Calm 1-5
km/h 5-11 km/h
11-19 km/h
19-29 km/h Total
N - 0.27 0.09 - 0.36
NNE 0.64 1.01 - - 1.65
NE 2.02 7.33 1.28 - 10.63
ENE 4.12 13.83 2.11 - 20.06
E 1.56 4.95 0.82 - 7.33
ESE 4.85 12.09 4.76 - 21.70
SE 7.88 12.09 5.14 - 25.11
SSE 1.92 4.49 1.83 - 8.24
S 1.37 2.28 0.82 - 4.47
SSW - 0.18 - - 0.18
SW - - - - -
WSW 0.18 0.09 - - 0.27
W - - - - -
WNW - - - - -
NW - - - - -
NNW
-
- - - - -
Richardson & Cruddas (1972) Ltd. III-81
TABLE - 3.5
WIND FREQUENCY, DISTRIBUTION (17-05 HRS)
Wind frequency (%) Direction of wind Calm 1-5
km/h 5-11 km/h
11-19 km/h
19-29 km/h Total
N 0.09 0.27 - - 0.36
NNE 0.09 1.19 0.45 - 1.73
NE 1.56 6.41 1.55 - 9.52
ENE 3.95 10.35 4.40 - 18.70
E 1.10 3.40 1.28 - 5.78
ESE 7.78 10.07 4.58 - 22.43
SE 8.88 10.90 4.95 - 24.73
SSE 2.38 5.31 2.84 - 10.53
S 2.56 2.47 0.92 - 5.95
SSW - - - - -
SW - - - - -
WSW 0.09 - - - 0.09
W - - - - -
WNW - 0.09 - - 0.09
NW - - - - -
NNW
-
- 0.09 - - 0.09
Richardson & Cruddas (1972) Ltd. III-82
TABLE – 3.6
WIND FREQUENCY, DISTRIBUTION (overall)
Wind frequency (%) Direction of wind Calm 1-5
km/h 5-11 km/h
11-19 km/h
19-29 km/h Total
N 0.05 0.27 0.05 - 0.37
NNE 0.37 1.10 0.23 - 1.70
NE 1.79 6.87 1.42 - 10.08
ENE 4.02 12.08 3.25 - 19.35
E 1.32 4.17 1.05 - 6.54
ESE 6.32 11.08 4.67 - 22.07
SE 8.38 11.49 5.04 - 24.91
SSE 2.15 4.90 2.34 - 9.39
S 1.97 2.38 0.86 - 5.21
SSW - 0.09 - - 0.09
SW - - - - -
WSW 0.14 0.05 - - 0.19
W - - - - -
WNW - 0.05 - - 0.05
NW - - - - -
NNW
-
- 0.05 - - 0.05
Wind pattern during the season (Winter 2006- 2007) the summary of wind pattern is
given below:
The annual wind rose is given in Fig. III.1. The seasonal and shift-wise wind rose
diagrams are presented in Fig. III.2 and III.3.The abstract of micro-meteorological
status of the project site is furnished in Table 3.7. The micro-meteorological data are
given in Annexure II.
Richardson & Cruddas (1972) Ltd. III-83
Fig. III.1
Richardson & Cruddas (1972) Ltd. III-84
Fig. III.2
Richardson & Cruddas (1972) Ltd. III-85
Fig. III.3
Richardson & Cruddas (1972) Ltd. III-86
Table 3.7 Abstract of Micro-meteorological data
Wind speed KM/Hour
Temperature (°C)
Date Min Max Avg
Predominant Wind
direction Min. Max.
Mean Relative Humidity
(%)
Rainfall mm
Sky Appeara
nce
1.12.07 2.3 12.6 7.5 SE 18.5 25.5 67 0 Clear
2.12.07 2.1 11.3 6.1 SE 18.5 26.0 67.74 0 Clear
3.12.07 1.9 15.9 6.6 SE 19.0 27.0 65.0 0 Clear
3.12.07 1.6 9.5 5.8 SE 19.0 27.5 68.5 0 Clear
5.12.07 2.4 16.1 7.2 S 18.0 26.5 62.3 0 Clear
6.12.07 1.6 18.6 7.9 SE 17.5 27.0 61.8 0 Clear
7.12.07 1.6 9.2 4.5 SE 18.0 26.0 65.8 0 Clear
8.12.07 1.3 9.6 3.5 SE 18.0 27.0 70.5 0 Clear
9.12.07 1.3 14.5 5.3 SE 18.5 26.0 69.2 0 Clear
10.12.07 1.8 17.5 6.0 SE 18.0 27.5 68.0 0 Clear
1112.07 1.6 16.1 7.9 ESE 18.0 27.5 68.1 0 Clear
12.12.07 1.6 14.6 6.7 SE 17.0 27.0 71.8 0 Clear
13.12.07 3.8 15.5 8.3 SE 17.5 26.5 73.6 0 Clear
14.12.07 4.1 18.5 11.0 SAE 17.0 26.5 73.1 0 Clear
15.12.07 6.9 16.2 12.0 ESE 17.5 26.5 74.3 0 Clear
16.12.07 1.9 18.8 11.4 SE 17.0 26.0 77.2 0 Clear
17.12.07 5.4 18.6 12.6 SE 17.5 24.5 76.8 0 Clear
18.12.07 1.9 12.1 7.9 SE 16.5 22.5 78.9 3.0 Rainy
19.12.07 2.4 17.3 8.5 ESE 15.0 20.0 91.6 3.8 Rainy
20.12.07 3.9 14.8 9.6 SE 15.0 26.0 93.9 10.5 Rainy
21.12.07 1.3 17.9 10.2 SE 16.0 27.0 77.9 0 Clear
22.12.07 2.6 15.1 6.2 SE 18.0 26.0 74.8 0 Clear
23.12.07 1.3 7.7 4.0 SE 18.0 27.5 72.8 0 Clear
24.12.07 1.5 13.6 5.2 ESE 18.0 27.0 71.2 0 Clear
25.12.07 1.2 7.5 4.2 SE 18.5 26.5 70.9 0 Clear
26.12.07 1.7 11.7 5.1 ESE 19.0 27.5 71.0 0 Clear
27.12.07 1.3 12.1 5.9 SE 19.5 27.0 70.0 0 Clear
28.12.07 1.3 8.7 3.8 SE 19.5 27.5 69.8 0 Clear
29.12.07 1.4 5.4 3.4 SE 19.5 28.0 68.3 0 Clear
30.12.07 2.2 18.4 10.0 ESE 20.5 28.5 68.3 0 Clear
31.12.07 1.6 15.2 7.5 ESE 20.0 30.0 68.7 0 Clear
Richardson & Cruddas (1972) Ltd. III-87
Table -3.7 Abstract of Micro-meteorological data (Contd.,)
Wind speed, KM/Hour Temperature
(°C) Date
Min Max Avg.
Predominant Wind direction
Min. Max.
Mean Relative Humidity
(%)
Rainfall mm
Sky Appearance
1.01.08 3.3 15.8 8.7 ESE 18.5 28.0 70.3 0 Clear
2.01.08 4.6 15.6 8.4 ESE 19.0 27.0 74.4 0 Clear
3.01.08 3.1 14.5 8.7 ENE 17.0 26.0 74.0 0 Clear
3.01.08 3.1 15.3 9.3 SE 16.5 26.0 79.0 0 Clear
5.01.08 6.5 12.1 9.5 ESE 16.5 25.5 77.0 0 Clear
6.01.08 5.2 14.5 10.9 ESE 17.5 26.0 76.1 0 Clear
7.01.08 5.4 18.0 10.4 ESE 17.5 24.5 77.3 0 Clear
8.01.08 5.2 17.3 10.4 ESE 17.5 26.0 77.4 0 Clear
9.01.08 3.3 13.6 8.1 ENE 18.0 24.5 69.6 0 Clear
10.01.08 3.3 14.4 7.0 ENE 18.0 25.5 67.8 0 Clear
1112.07 5.9 15.4 10.7 ESE 18.5 25.5 65.3 0 Clear
12.01.08 5.9 13.4 10.0 ESE 17.5 25.5 67.1 0 Clear
13.01.08 4.0 13.6 8.8 ESE 18.5 26.0 68.5 0 Clear
14.01.08 4.4 13.6 10.1 ENE 18.5 25.5 67.0 0 Clear
15.01.08 4.1 14.6 9.1 ESE 19.0 26.5 65.3 0 Clear
16.01.08 3.6 13.0 7.8 ENE 19.0 26.5 68.0 0 Clear
17.01.08 2.2 11.2 6.7 ESE 18.5 26.0 68.3 0 Clear
18.01.08 2.9 12.7 7.9 ESE 18.5 25.5 66.6 0 Clear
19.01.08 2.7 13.3 7.6 ESE 19.0 27.5 62.8 0 Clear
20.01.08 2.5 10.0 7.2 ESE 19.0 27.5 61.0 0 Clear
21.01.08 2.3 10.4 5.9 ESE 19.0 28.0 61.7 0 Clear
22.01.08 2.5 10.8 5.2 ESE 19.5 28.5 59.0 0 Clear
23.01.08 1.3 9.6 4.6 SE 20.0 27.5 60.4 0 Clear
24.01.08 1.9 10.1 5.3 ESE 19.0 26.5 63.0 0 Clear
25.01.08 7.8 16.9 11.4 ESE 19.0 27.0 65.3 0 Clear
26.01.08 1.7 11.8 5.8 SE 19.0 27.0 63.4 0 Clear
27.01.08 1.4 9.8 5.0 SE 18.5 26.5 63.6 0 Clear
28.01.08 1.2 9.1 4.9 ESE 19.0 28.0 64.5 0 Clear
29.01.08 1.5 11.4 5.1 ESE 18.5 28.0 61.5 0 Clear
30.01.08 2.9 13.4 8.4 ESE 19.0 28.0 62.0 0 Clear
31.01.08 1.3 8.9 4.3 SE 18.5 26.0 62.8 0 Clear
Richardson & Cruddas (1972) Ltd. III-88
Table - 3.7 : Abstract of Micro-meteorological data (Contd.,)
Wind speed KM/Hour
Temperature (°C) Date
Min Max Avg
Predominant Wind
direction Min. Max.
Mean Relative Humidity
(%)
Rainfall mm
Sky Appearanc
e
1.02.08 3.9 13.5 8.7 ESE 19.5 28.5 63.1 0 Clear
2.02.08 5.7 14.8 9.0 ESE 19.0 28.0 63.1 0 Clear
3.02.08 3.1 12.9 7.4 ENE 19.0 28.5 60.8 0 Clear
3.02.08 1.9 15.1 8.8 SE 19.0 27.5 65.8 0 Clear
5.02.08 3.8 15.1 9.4 ESE 19.0 28.0 65.0 0 Clear
6.02.08 2.1 16.5 19.0 ESE 19.0 28.5 59.3 0 Clear
7.02.08 1.9 13.5 8.5 ESE 19.0 28.5 59.8 0 Clear
8.02.08 2.9 13.5 8.7 ESE 20.0 29.0 62.3 0 Clear
9.02.08 2.9 13.8 9.0 ENE 19.5 29.0 61.8 0 Clear
10.02.08 1.6 14.0 8.9 ENE 19.5 29.0 62.3 0 Clear
1112.07 2.6 13.1 8.5 ESE 19.5 29.0 61.0 0 Clear
12.02.08 1.6 10.3 8.5 ESE 19.5 29.5 62.0 0 Clear
13.02.08 1.9 12.6 7.7 ESE 19.5 12.6 59.9 0 Clear
14.02.08 1.6 11.6 7.7 ENE 20.0 29.5 60.1 0 Clear
15.02.08 2.9 14.9 8.6 ESE 19.5 29.5 61.5 0 Clear
16.02.08 2.9 13.5 7.1 ENE 20.0 29.0 61.0 0 Clear
17.02.08 2.4 12.6 8.6 ESE 20.0 30.0 60.3 0 Clear
18.02.08 3.2 15.4 8.8 ENE 20.0 30.0 60.8 0 Clear
19.02.08 1.9 14.5 8.1 ESE/ENE 20.5 29.5 57.7 0 Clear
20.02.08 1.6 10.6 6.9 ESE 20.0 30.0 58.8 0 Clear
21.02.08 2.6 14.9 8.1 ESE 20.0 30.0 61.6 0 Clear
22.02.08 1.6 16.5 7.8 WSW 19.5 30.0 59.4 0 Clear
23.02.08 2.6 13.8 7.3 WNW 20.0 30.0 56.9 0 Clear
24.02.08 1.6 12.6 6.5 WSW 21.0 30.0 59.1 0 Clear
25.02.08 1.6 13.5 8.8 WNW 21.0 30.5 58.0 0 Clear
26.02.08 2.8 11.6 7.4 WSW 20.5 30.5 59.0 0 Clear
27.02.08 1.9 11.9 7.2 WSW 20.0 30.0 58.2 0 Clear
28.02.08 1.8 11.5 7.1 WNW 21.0 30.5 56.7 0 Clear
29.02.08 2.1 11.6 6.2 WSW 21.0 30.5 57.4 0 Clear
Season 1.2 18.8 7.8 SE 15 30.5 66.7 17.3 Clear
Richardson & Cruddas (1972) Ltd. III-89
Data Analysis
Meteorological data collected during the study reveals the following status.
Wind Direction: Predominant wind was from Northeast quadrant.
Wind Speed : Wind velocity readings were ranging from 1.2 to 18.8 Kmph.
Temperature : Temperature values were ranging from 15.0 °C to 30.5°C.
Relative Humidity: The mean relative humidity value was found to be 66.7%.
Cloud cover : Sky was clear during the study period.
Atm. pressure: The mean atmospheric pressure was found to be 752 mm of Hg.
Rainfall: A total rainfall of 17.3 mm was recorded during the study period.
3.1.2 Existing Ambient Air Quality
Methodology for Ambient Air Quality
The ambient air quality monitoring stations are shown in Fig. III.4 and given in Table 3.8.
Based on the project activities the parameters chosen for assessment of ambient air
quality were Suspended Particulate Matter (SPM), Respirable Particulate Matter (RPM),
Sulphur di-oxide (SO2), Oxides of Nitrogen (NOx) and Carbon Monoxide (CO). Random
sampling for Poly Aromatic Hydro-carbons (PAH) and Chemical characteristic of RSPM
at one location in core zone and four locations at buffer zone were carried out. A field
laboratory for the purpose of calibration of equipments and standardization of
analytical procedures was established and the samples were analyzed on the day of
sample collection. SPM were monitored on 24 hourly basis and all gaseous pollutants
(SO2, NOx & CO) were monitored on 8 hourly basis to meet the requirements of Central
Pollution Control Board (CPCB).
Richardson & Cruddas (1972) Ltd. III-90
Fig. III.4
Richardson & Cruddas (1972) Ltd. III-91
Table - 3.8 Ambient air quality monitoring stations (Distance & Bearing directions)
Sl.No Location name & code Distance in Km Direction
1 Project Site (A1) - -
2 Existing Plant (A2) - -
3 Dhanapura (A3) 2.5 NNW
4 Marimanhalli (A4) 3.0 NW
5 Nagalapura (A5) 3.0 SSW
6 Mugimavinahalli (A6) 9.5 SW
7 Haravanahalli (A7) 7.5 SW
8 Ramgad (A8) 6.0 E
9 Medarahalli (A9) 7.5 NE
10 Vysankari (A10) 9.5 NW
Data Analysis
Winter Season ( Dec06-Feb07)
The ambient air quality status is given in Table 3.9 and data are given in Annexure III.
At all location, the SPM and RPM values were ranging between 85 and 186 µg/m3 and
30 and 69 µg/m3 respectively. The SO2 and NOx values ere ranging between 5 and
16 µg/m3 and 6 and 30 µg/m3 respectively. Analysis report on PAH and chemical
characterization of RSPM are presented in Annexure III.The CO values were found to be
below the detectable limit of <114.5 µg/m3.
Summer Season ( March – May 2007)
The ambient air quality status is given in Table 3.10. At all location, the SPM and RPM
values were ranging between 102 and 185 µg/m3 and 32 and 69 µg/m3 respectively.
The SO2 and NOx values ere ranging between 5 and 16 µg/m3 and 7 and 25 µg/m3
respectively. The CO values were found to be below the detectable limit of
<114.5 µg/m3
Richardson & Cruddas (1972) Ltd. III-92
Table 3.9 Ambient air quality status Unit : µg/m3
Location name & code Min 98th
Per. Max AM GM Std. dev
CPCB Limit
SPM
Project Site (A1) 136 170 176 153.21 152.8 10.1 500
Existing Plant (A2) 135 172 186 157.9 157.3 13.7 500
Dhanapura (A3) 110 142 146 123.4 123.1 9.7 200
Marimanhalli (A4) 108 135 145 123.8 123.6 8.5 200
Nagalapura (A5) 102 131 132 117.7 117.4 8.6 200
Mugimavinahalli (A6) 118 141 146 129.4 129.2 7.2 200
Haravanahalli (A7) 96 115 115 101.5 101.3 6.5 200
Ramgad (A8) 96 126 132 115.1 114.6 10.1 200
Medarahalli (A9) 95 126 134 107.6 107.2 9.1 200
Vysankari (A10) 85 102 112 96.8 96.6 5.9 200
RPM Project Site (A1) 32 62 63 52.8 52.4 6.5 150
Existing Plant (A2) 48 68 69 58.9 58.5 6.8 150
Dhanapura (A3) 42 57 58 46.9 46.8 3.7 100
Marimanhalli (A4) 36 47 48 43.2 43.1 2.7 100
Nagalapura (A5) 39 48 49 43.4 43.3 3.0 100
Mugimavinahalli (A6) 39 52 54 45.8 45.7 3.4 100
Haravanahalli (A7) 30 38 38 34.4 34.3 2.0 100
Ramgad (A8) 31 41 42 36.6 36.5 2.7 100
Medarahalli (A9) 30 38 38 34.8 34.7 2.1 100
Vysankari (A10) 31 40 41 36.0 35.9 2.8 100
SO2 Project Site (A1) 6 8 9 6.8 6.8 0.8 120
Existing Plant (A2) 8 16 16 12.0 11.8 2.2 120
Dhanapura (A3) 6 7 7 6.3 6.3 0.5 80
Marimanhalli (A4) 6 8 8 6.3 6.2 0.6 80
Nagalapura (A5) 6 7 7 6.2 6.2 0.4 80
Mugimavinahalli (A6) 6 8 8 7.2 7.1 1.0 80
Haravanahalli (A7) 6 7 7 6.2 6.2 0.4 80
Richardson & Cruddas (1972) Ltd. III-93
Location name & code Min 98th
Per. Max AM GM Std. dev
CPCB Limit
Ramgad (A8) 5 8 8 6.7 6.6 1.0 80
Medarahalli (A9) 6 7 8 6.3 6.3 0.5 80
Vysankari (A10) 6 7 7 6.3 6.3 0.5 80 NOx
Project Site (A1) 8 18 18 13.7 13.4 2.4 120
Existing Plant (A2) 16 28 30 24.2 24.1 3.2 120
Dhanapura (A3) 6 10 10 8.4 8.2 1.7 80
Marimanhalli (A4) 10 18 18 14.2 14.1 2.1 80
Nagalapura (A5) 6 12 12 8.7 8.6 1.7 80
Mugimavinahalli (A6) 10 16 18 13.8 13.5 1.9 80
Haravanahalli (A7) 6 10 10 8.3 8.3 0.9 80
Ramgad (A8) 10 16 16 13.2 13.0 2.1 80
Medarahalli (A9) 8 12 14 10.8 10.7 1.4 80
Vysankari (A10) 8 10 12 9.0 9.0 1.1 80
Note : All CO values were found to be below the detectable limit of <114.5µg/m3 (0.1ppm)
Table 3.10 Ambient air quality status
Unit : µg/m3
Location name & code Min 98th
Per. Max AM GM Std. dev
CPCB Limit
SPM Project Site (A1) 142 182 184 158.4 153.8 11.2 500 Existing Plant (A2) 146 176 185 159.2 158.3 14.2 500 Dhanapura (A3) 120 145 152 132.4 131.8 10.2 200 Marimanhalli (A4) 108 151 151 126.4 124.6 9.5 200 Nagalapura (A5) 108 141 142 120.2 119.4 9.6 200 Mugimavinahalli (A6) 124 141 145 130.2 129.2 8.2 200
Haravanahalli (A7) 102 125 125 108.5 107.3 7.5 200 Ramgad (A8) 112 126 130 118.1 116.6 9.1 200 Medarahalli (A9) 110 125 134 117.2 115.2 9.4 200 Vysankari (A10) 110 112 114 106.5 104.2 6.2 200
RPM Project Site (A1) 36 64 65 52.8 51.6 6.2 150
Richardson & Cruddas (1972) Ltd. III-94
Location name & code Min 98th
Per. Max AM GM Std. dev
CPCB Limit
Existing Plant (A2) 41 69 69 58.9 57.5 6.5 150 Dhanapura (A3) 40 55 58 46.9 45.2 3.8 100 Marimanhalli (A4) 36 50 52 43.2 43.1 2.8 100 Nagalapura (A5) 37 45 49 43.4 42.5 2.7 100 Mugimavinahalli (A6) 38 54 56 45.8 44.5 3.3 100
Haravanahalli (A7) 32 36 40 34.4 35.2 2.1 100 Ramgad (A8) 33 42 42 36.6 36.1 2.6 100 Medarahalli (A9) 34 37 39 34.8 33.2 2.2 100
Vysankari (A10) 32 42 43 36.0 35.2 2.5 100
SO2 Project Site (A1) 6 9 9 6.8 6.5 0.7 120 Existing Plant (A2) 7 15 16 12.0 11.8 2.3 120 Dhanapura (A3) 7 9 10 6.3 6.2 0.8 80 Marimanhalli (A4) 6 9 9 6.3 6.2 0.7 80 Nagalapura (A5) 6 8 8 6.2 6.2 0.5 80 Mugimavinahalli (A6) 6 8 8 7.2 7.1 1.2 80
Haravanahalli (A7) 5 7 7 6.2 6.0 0.9 80 Ramgad (A8) 5 8 8 6.7 6.5 1.2 80 Medarahalli (A9) 6 8 8 6.3 6.1 0.8 80 Vysankari (A10) 6 8 9 6.3 6.0 0.7 80
NOx Project Site (A1) 8 16 18 13.7 13.4 2.9 120 Existing Plant (A2) 10 24 25 24.2 24.0 3.8 120 Dhanapura (A3) 7 12 13 8.4 8.0 1.8 80 Marimanhalli (A4) 9 14 15 14.2 13.8 2.4 80 Nagalapura (A5) 6 11 12 8.7 8.4 1.8 80 Mugimavinahalli (A6) 9 15 16 13.8 13.1 2.1 80
Haravanahalli (A7) 6 14 15 8.3 8.0 1.9 80 Ramgad (A8) 9 15 16 13.2 12.8 2.4 80 Medarahalli (A9) 8 11 14 10.8 10.2 1.8 80 Vysankari (A10) 8 11 12 9.0 8.2 1.7 80
Note : All CO values were found to be below the detectable limit of <114.5µg/m3 (0.1ppm)
Richardson & Cruddas (1972) Ltd. III-95
3.2 Noise Levels
Methodology
Noise levels were monitored at twelve locations within and outside the project
premises. Noise readings were taken for daytime as well as nighttime. CYGNET 100X data
logging Sound level meter was used for recording noise levels.
Data Analysis
The ambient noise level monitoring stations are shown in Fig. III.4. The noise level
abstract is given in Table 3.11.
The Day and night time Leq Noise levels were ranging from 42.1 dB(A) to 68.9 dB(A) and
34.8 dB(A) to 49.6 dB(A) respectively. It is observed that noise levels varied at different
sampling stations. The noise levels are found to be within the prescribed limits.
Table – 3.11 Noise Level status
Noise Level, dB(A) Day Time Night Time
S. No Location Name
Min Max Leq Min Max Leq 1 Project Site (N1) 49.7 54.7 52.4 40.8 47.6 43.3 2 Existing Plant (N2) 65.6 72.6 68.9 60.2 68.6 63.4 3 Dhanapura (N3) 46.5 53.8 49.1 38.3 44.8 41.6 4 Marimanhalli (N4) 55.6 65.4 60.1 38.1 44.5 41.3 5 Nagalapura (N5) 47.6 53.2 50.5 39.5 46.6 43.4 6 Mugimavinahalli (N6) 46.2 52.9 49.3 38.6 43.9 40.2 7 Haravanahalli (N7) 48.1 53.6 51.0 39.9 45.3 40.8 8 Ramgad (N8) 45.3 52.1 48.4 38.3 44.2 40.7 9 Medarahalli (N9) 45.1 50.8 48.3 36.5 42.4 38.4 10 Kalahalli (N10) 50.1 58.6 52.4 46.8 51.2 48.2 11 Ayinahalli (N11) 44.5 49.6 42.1 34.2 39.6 34.8 12 Devalapura (N12) 50.8 57.2 51.8 43.2 53.8 46.1
3.3 Water Environment
Reconnaissance survey was carried out based on the location of ground and surface
water bodies, which represent baseline condition. A total of 16 water samples Viz., 8
ground/drinking water samples (W1 – W8) and 8 surface water samples (W9–W16)
Richardson & Cruddas (1972) Ltd. III-96
were collected and analyzed as per standard methods. The water quality monitoring
stations are shown in Fig. III.5 and Table 3.12. The ground and surface water quality
data are given Annexure IV.
Methodology
Seven no. of water samples and two no of surface water were collected during the
study period for Physico-chemical and Bacteriological parameters after taking suitable
precautions and analysed as per Standard methods. Samples were collected for
Chemical analysis as per procedure outlined in IS: 2488. Sterilised bottles were used for
collection of water samples for bacteriological analysis, stored in icebox and
transported to the laboratory for the analysis. Parameters like pH, Temperature, DO
etc. were measured in the field while collecting the samples. MPN index of coliforms
were determined in the laboratory as per Standard methods.
Richardson & Cruddas (1972) Ltd. III-97
Fig. III.5
Richardson & Cruddas (1972) Ltd. III-98
Table – 3.12 Water / Surface water quality monitoring stations
S.No. Location name Location Code
1 Borewell, Existing Plant W1
2 Borewell, Devalapura W2
3 Handpump, Mariyammanahalli Tanda W3
4 Handpump, Nagalapura W4
5 Borewell, Marimanhalli W5
6 Borewell, Mugimavinahalli W6
7 Handpump, Danapura W7
9 Borewell, Hanumanahalli W8
9 Pond, Dayanakhere W9
10 TB Dam W10
11 Pond, near Gunda W11
12 Pond, near Nagalapura W12
13 Tank water, Dhanapura W13
14 Tank water, Marimanhalli W14
15 Pond, near Nandipanda W15
16 Pond, near Vysankari W16
Data Analysis
Ground water
Winter : At all locations, pH values were in the range of 7.28 – 8.12 with agreeable
colour, taste and odour. Chloride and Sulphate values were in the range of 18 – 386
mg/l and 12 – 180 mg/l respectively. Hardness values were found to be in the range of
30 – 380 mg/l. Fluoride values were found to the maximum extend of 0.90 mg/l. At
all locations, oil and grease, phenolic compounds, cyanides, sulphides and insecticides
were found to be absent and all heavy metal except iron values were found to be
below the detection limit. Iron value was found to be a maximum extent of 0.16 mg/l.
The maximum total coliforms were found to be 8 MPN/100 ml. While comparing with
IS: 10500 – 1991 norms, all values except total coliforms were found to be well within
the limits.
Richardson & Cruddas (1972) Ltd. III-99
Summer : At all locations, pH values were in the range of 7.13 – 8.42 with agreeable
colour, taste and odour. Chloride and Sulphate values were in the range of 22 – 408
mg/l and 18 – 215 mg/l respectively. Hardness values were found to be in the range of
38 – 396 mg/l. Fluoride values were found to the maximum extend of 0.98 mg/l. At
all locations, oil and grease, phenolic compounds, cyanides, sulphides and insecticides
were found to be absent and all heavy metal except iron values were found to be
below the detection limit. Iron value was found to be a maximum extent of 0.25 mg/l.
The maximum total coliforms were found to be 21 MPN/100 ml. While comparing with
IS: 10500 – 1991 norms, all values except total coliforms were found to be well within
the limits.
Surface water
pH values were found to be in the range of 8.1 – 8.24. At all locations Oil & Grease,
Phenols, Cyanides, Sulphides and insecticides were found to be absent and most of the
heavy metals values were found to be below the detectable limits. Also, low BOD/COD
values and good D.O. content at these locations indicate that the natural restoration
of water quality is maintained.
3.4 Soil Environment
In order to assess the baseline status of soil quality of the project site and
neighborhood, four sampling locations were selected. At each location, samples were
collected using augers and analyzed for nutrient and engineering parameters. The
location of Soil Sampling station is shown in III.5.The soil quality status is given in
Table No. 3.13.
Richardson & Cruddas (1972) Ltd. III-100
Table 3.13 Soil quality status
Sl. No Parameters Project
Site (S1) Danapura
(S2) Gunda (S3)
Mariaman-halli (S4)
Nagalapura (S5)
1 pH 8.58 8.4 8.68 8.54 8.60
2 Electrical Conductivity (m-mhos/cm) 0.3 0.4 0.3 0.3 0.3
3 Nitrogen (Kg/ha) 102.0 110.4 124.0 104 114 4 Phosphorus (Kg/ha) 3.8 5.0 5.4 5.0 5.1 5 Potassium (Kg/ha) 140 168 170 155 162 6 Available Magnesium (%) 4.0 4.4 5.1 4.2 5.2 7 Organic Carbon (%) 1.02 1.0 1.4 0.9 1.6
8
Grain Size Distribution Gravel (%) Sand (%) Silt & Clay (%)
8.0 70.0 22.0
20.0 60.0 20.0
10.0 70.0 20.0
10.0 60.0 30.0
11.0 80.0 9.0
9 Textural Class Sandy Loam
Sandy Loam
Sandy Loam Sandy Loam Sandy Loam
10 Bulk Density (g/cc) 1.4 1.5 1.3 1.8 1.2 11 Liquid Limit (%) 16 14 18 15 16 12 Plastic Limit (%) 8.0 8.0 8.0 12.0 10.0 13 Infiltration Rate (cm/hr) 2.4 2.8 3.1 3.0 2.8 14 Field Capacity (%) 11.0 11.4 11.2 10.4 10.8 15 Wilting Co-efficient (%) 0.9 0.8 1.2 0.9 1.4
16 Available Water Storage Capacity (%) 10.1 10.6 10.4 9.5 9.8
At all locations, pH ranges from 8.4 to 8.68. The sand content of the soil ranged
between 60.0 and 80.0 %. Nitrogen, Potassium and Phosphorus are found to be in the
range of 102 – 124 Kg/Ha, 140 – 170 Kg/Ha and 3.8 – 5.4 Kg/Ha respectively. Organic
Carbon was found to be in the range of 0.9 – 1.4 %. Texture Class was found to be
Sandy Loam.
Richardson & Cruddas (1972) Ltd. III-101
3.5 Land Environment
The area is a rugged and undulating terrain with an average elevation of 525 m above
MSL with the general slope towards north. In general the slope is moderate but steep
slopes are observed close to the Sandur hill ranges, which is the main topographic
feature in the area. The Sandur hills trend NW and are found east of the site forming a
spoon shaped hill range rising to a height of 1000 m above MSL. It is a doubly plunging
synform forming a structural basin broad in the south-eastern part and tapers in the
northwest. In the middle of the hill range a valley is found and hence it forms a spoon
shaped hill system. Isolated hillocks with sheet rocks or rocky knobs rising to a height
ranging from 75 to 100 m above the ground level and boulder outcrops are found
around the site as a result the area has an undulating topography.
Drainage and water bodies
The drainage system forms part of the Tungabadra river basin. The Tungabadra river
flows in the north-western part of the region and the construction of a dam west of
Hospet Town has formed a large reservoir with a water spread. The reservoir covers
much of the north western part of the area examined. The drainage pattern is
dendritic and the drainage density is moderate and is formed by the network of
several streams originating from the hillocks. Minor streams originating from the
Sandur hills, flows directly into the Tungabadra reservoir.
Lakes were formed by the construction of bunds across minor streams for storage of
water for irrigation. The Dhanayakana Kere is the largest and is located southeast of the
site. Several smaller lakes are found through out the area supplying water for irrigation.
However, most of the lakes go dry during summer which is fairly severe in this region.
Ground water in the region occurs in unconfined conditions in shallow weathered
portions and in semi confined conditions, in the fractured horizon. There are twenty
seven borewells, drilled within the existing industry area. Examination of the data
collected from these borewells indicate that the depth to water table varies from 6 to
10 m, the depth of borewell varies from 40 to 75 m and casing depth varies from 15 to
20 m. In these borewells water has been struck at depths of 25 m to 45 m. Yield of
borewell varies from 1 to 14 m3 per hour.
Richardson & Cruddas (1972) Ltd. III-102
As per the Hydrogeological survey carried out for the area, it is noticed that “there is
ample scope for extracting Ground water in the premises of the Industrial Area.” The
depth of water table being very shallow there is a needed to depress the water table
to safer limit of 20 Mtr to prevent water logging conditions and create scope for
recharge.
Geology
The area is part of the Karnataka cratonic nuclei that exposes the oldest rocks of
Archaean age (4000 to 2.500 Ma (million years)). The Greenstone belts or schist belts
that are metamorphosed under varying grade occur as linear enclaves within grey
gneissic complex. These enclaves represent volcano-sedimentary sequences that were
formed in shallow seas that were existed during the Precambrian. They are linear belts
elongated in N-S and NNW-SSE directions and have been classified into three groups as
1) Ancient Supracrustals, 2) Auriferous Schist Belts and 3) Younger Schist Belts based
on the differences in age, metamorphism and mineralisation. The Ancient
Supracrustals are the oldest (>3000 Ma) and are metamorphosed under high grade
ranging from amphibolite to granulite facies. Occurrences of these schist belts are
found in the southern part of the state. Sargur, Krishnarajpet, Holenarasipur, Hadnur,
Nuggihalli, Kalyadi, Nagamangala, Ghattihosalli, Kunigal, Gundulupet and Gurgunta
belts. The mineralisations include Chromium, titanium, vanadium and tungsten. The
Auriferous Schist belts have formed during the time interval 3000 to 2500 Ma and hosts
the valuable gold deposits. They include the Kolar and Hutti-Maski, Pennar-Hagari,
Mangalur, Hungud-Kushtagi and Raichur-Deodurg schist belts. They are confined to the
eastern part of the state separated from the Younger schist belts by the Closepet
granite which forms a linear intrusion.
The younger schist belts also known as Dharwar type schist belts host bulk of the iron
ore deposits and include the Shimoga, Bhababudan, Kudremukh, Chitradurga and
Sandur schist belts. While volcanic rocks predominate in the other group of schist
belts, bulk of the younger schist belt are composed of metamorphosed sedimentary
rocks that were deposited in shallow basins. The volcano-sedimentary sequence is
deposited over the tonalitic-trondhjemitic gneisses that intruded the terrain after the
formation of the Ancient Supracrustals and Auriferous Greenstone belts.
Richardson & Cruddas (1972) Ltd. III-103
The tonalitic – trondhjemitic gneisses hence form the basement for the Younger
Greenstone Belts. Intrusion of granites called as Closepet granite is an important event
in the evolution of the Dharwar craton and forms a linear intrusion extending in N-S
direction for nearly 500 km with an average width of 20 km almost parallel to the
alignment of the greenstone belts located in the region. The age of the granite is
inferred by radiometric dating methods as 2,528 ± 5 Ma.
The Sandur Schist Belt:
The Sandur schist belt is located in the eastern margin of the area and it contains
valuable iron and manganese deposits and has transformed the region into an
industrial belt. The Sandur schist belt is the smallest of the Younger Greenstone belts
covering an area of 960 sq. km. Its structure is highly disturbed by the regional
tectonics and the intrusion of the Closepet granite and has been squeezed out into two
parts. The eastern part known as Copper Mountain Range volumetrically is dominated
by mafic volcanic material and on the other hand the western part Sandur Belt
contains metasedimentary rocks in abundance. The metasedimentary rocks include
basal conglomerates, quartzites, manganiferous graywake, phyllite and numerous
bands of banded magnetite and haematite quartzites. The basin is known for its
richness in both iron and manganese ores.
The important deposits of iron ore in Sandur Belt are located in Donimalai, Devadari,
Kumaraswamy and Ramadurg ranges with proved reserves of over 500 million tonnes
with more than 62% Fe.
The area investigated comprise the rocks of the Sandur Schish belt forming the linear
hill ranges located in the eastern part of the area. The region west of the hill ranges
form the basement gneisses and the younger granites belonging to the Closepet
granite intrusion are found forming isolated hillocks and boulder outcrops in the
southern part of the area.
About the Site:
The area is covered by Clospet granite, greywacke and metabasalts, belonging to
Archean to lower Proterozoic. In particular the western part is covered by pink granite
Richardson & Cruddas (1972) Ltd. III-104
and grey granite of Archean group and the eastern part is covered by argillites, Meta
volcanics of Chitradurga group. In geohydrological parallance the rocks are termed as
hard rock, which have been dissected by joint planes and have undergone weathering
and erosion. Granites in the area are medium to coarse grained, having pale pink and
grey color, rocks exposed in the area are bouldery in nature. They have two to three
sets of joints at places. Meta volcanics exposed outside the industry area are having
defined schistocity. It is generally NNW-SSE. (In the engineering geological context,
the rock formations are found out to serves as stable foundation).
Land-use Pattern
Remote sensing satellite Imageries were collected and interpreted for the 10 Km
radius study area with project site as center. Based on the satellite data land -use /
land cover maps have been prepared.
Land –use / Land cover classification system
The present land–use / land cover maps were prepared based on the classification
system of National standards. For explanation for each of the land –use category the
two references were used. Viz. 1.Manual of land use / land cover mapping satellite
imagery and 2. Manual procedures for waste land mapping. The details are given in
Table 3.14.
Table – 3.14 Land –use / Land cover classification system
Sl. No. Level 1 Level 2 1 Built up land Town / cities Villages 2 Agriculture land Crop land (Irrigated / rainfed) Plantations 3 Forest Evergreen / Semi evergreen Deciduous 4 Waste lands Saline / Sandy Marchy / Swampy 5 Water bodies Rivers / Stream Lake / Reservoir / Tanks 6 Others Shifting cultivation Grass land Salt pans Snow covered / glacial
Richardson & Cruddas (1972) Ltd. III-105
Data requirement
IRS-1B Geo Coded False colour composite (FCC) products on 1:50000 scale of path 30
and row 45 with data were acquired from National Remote Sensing Agency, Hyderabad
and used for the mapping and interpretation. Besides other collateral data as available
in the form of maps, charts, census records other reports and especially topographical
survey of India maps on 1:50000 were used. In addition to this, ground truth survey
was also collected to verify and confirm the ground features.
Methodology
The methodology adopted for preparation of land use / land cover maps is
mono-scopic interpretation of geo-coded scenes of IRS -1B satellite, Sensor L2A2, L2B2
and field observations taken. The various steps involved in the study area are
preparatory fieldwork, field survey and post fieldwork.
Pre-field interpretation of Satellite details
The false colour Composite (FCC) of IRS-1B Satellite data at 1:50000 scale has been
used for pre-field interpretation work. Taking the help of topo sheets, geology, geo-
morphology and by using the image elements the features were identified and
delineated the boundaries roughly. Each feature is identified on image by their image
elements like tone, texture, colour, shape, size, pattern and association. A tentative
legend in terms and erosion was formulated. The sample areas for field check were
selected covering all the physio-graphic land-use / land cover features cum image
characteristics.
Ground Truth Collection
Ground truth field verification was conducted using both topo sheets and imagery.
Representative sample areas were traversed to observe the broad land–use features
and the sample areas were adjusted according to the field conditions. Detailed field
observations and investigations were carried out and land–use features on the imagery
were recorded.
Richardson & Cruddas (1972) Ltd. III-106
Post field work
The base maps of the study area were prepared with the help of Survey of India Topo
sheet at 1:50000 scale. Preliminary interpreted land use and the land cover features
boundaries from IRS-1B FCC were modified in light of field information and the final
thematic details were transferred on to the base maps. The tentative legend during
the pre-field work were finalized. The final interpreted and classified thematic map
was prepared using standard colour coding and detailed description of features with
Standard symbols. All the classes are noted and marked by the standard legend on the
map. Visual interpretation of multi-sensor false colour imagery composite of the area
was prepared using LANDSAT satellite data (Fig. III.6).
Final output.
The final out put would be the land use / land cover on 1:50000 scale numerals are
given different colour code for each category as shown in map. Area estimation of all
the features of land –use / land cover categories are noted
Observations
The main interpreted Land use / land cover classes of the study area are presented in
Table 3.15
Table 3.15 Land-Use in buffer zone
Sl.No. Land use / Land cover Percentage of composition
1 Agricultural area 3.45 2 Forest 24.87 3 Scrubland (Open and Dense) 15.65 4 Fallow/Wetland 25.21 5 Built-up Area 4.58 6 Rocky Outcrop/Stony waste/Mining 2.50 7 Water body 6.10 8 Hilly tract 11.34 9 Proposed Industrial Plant 4.90 10 Existing Plant/dumping Yard 1.40
Richardson & Cruddas (1972) Ltd. III-107
Richardson & Cruddas (1972) Ltd. III-108
FIG. III.6 LANDUSE MAP
Please show the location of proposed colony in thia figure. As per TOR
NO.10 .
Richardson & Cruddas (1972) Ltd. III-109
3.6 Biological Environment
Flora Analysis
The structure and composition of plant community depends on the factors like
location, temperature, water resource etc. A complete structure of plant community
could be obtained by studying both the terrestrial and aquatic flora of that particular
area. Since they are prone to be disturbed by the socio-economical status, it is
necessary to review or analysis their establishment.
Hence, the present study was carried out meticulously covering a distance of 10Sq.Km,
adopting the standard methodology of quadrant construction (Clements, 1898). It
includes laying down square sample plots or units for detailed analysis of vegetation.
Quadrants sizes of 1m × 1m, 5m × 5m and 100m × 100m were constructed for herbs,
shrubs and trees respectively, giving a replication of 10 numbers.
Data Analysis
Field survey was carried out at 9 locations in and around the plant site (10 Km radius)
Site – 1
Ramgad Reserve Forest
Herbs Abutilon indicum, G. Don. Abutilon neilghereinse, Munro. Acanthus sp. Achyranthus aspera, L. Achyranthus bidentata, Bl. Amaranthus viridis, L. Aristida depressa, Retz. Boerhaavia diffusa, L. Boerhaavia rependa, Willd Chloris barbata, Sw. Chloris bournei, Rang & Tad. Chloris polystachya, Roxb. Hyptis sp. Hyptis suaveolens, Poit. Indigofera tinctoria, L Justicia simplex, D. Don Mimosa pudica, L. Parthenium Paspalum conjugatum, Berg. Paspalum longifolium, Roxb Pavonia zelanica, Cav.
Pergularia pallida, W. & A. Phyllanthus neruri, L. Ruellia patula, Jacq. Ruellia prostrata, Poir Sida cordifolia, L. Sida rhombifolia, L.
Stachytarpheta indica, Vahl. Teliocora acuminata, Miers. Tephrosia purpurea, Pers. Tinospora cordifolia, Miers. Tridax procumbens, L. Tridax Sp. Triphyllus oxalis Tylophora asthmatica, W. & A. Vernonia cinerea, Less.
Medicinal herbs Indigofera tinctoria, L Justicia simplex, D. Don Justicia, Phyllanthus neruri, L.
Richardson & Cruddas (1972) Ltd. III-110
Ruellia patula, Jacq. Ruellia prostrata, Poir Tridax procumbens, L. Tridax Sp. Triphyllus oxalis
Climbing Medicinally important herbs Abrus precatorius, L Gymnema sylvestre, R,Br Pergularia pallida, W. & A. Tinospora cordifolia, Miers. Tylophora asthmatica, W. & A Wattacaca volublis
Shrub Leea sp. Cassia sp. Cassia tora, L. Crotalaria juncea, L. Dichrostachys cinerea, W.&A. Glycine pentaphylla, Dalz. Lantana indica, Roxb. Pavetta indica, L. Pavetta parviflora Strobilanthes sp Tecoma stans Ipomaea sp. Zizyphus jujuba, Lam
Medicinally Important
Shrubs Anona squamosa, L. Atalantia monophylla, Corr. Azima tetragantha, L. Canthium parviflorum, Lam. Capparis zeylanica, L. Carissa diffusa, L. Cassia auriuilata, L. Fluggea leucopyrus, Willd. Glycosmis cochinchinensis, R,Br. Jatropha glandulifera, Roxb. Phyllanthus reticulates, Poir. Toddalia asiatica, Lam. Todonia viscosa Ipomaea sp.
Ornamental shrubs Dendrocalamus strictus, Nees.
Duranta repens, Nerium odorum, Soland.
Exotic shrubs Prosopis spicigera. L Lantana camara, L
Trees
Azadirachta indica, A. Juss. Bambusa arundinacea, Willd. Bassia latifolia, Roxb. Bauhinia purpurea, L. Borassus flabelliformis, L. Cassia alata, L. Crataeva religiosa, Forst. Dalbergia sissoo, Roxb. Emblica officinalis, Gaertn. Eucalyptus globules, Labill. Hardwicka binata,Roxb. Kigelia pinnata, Dc Maba buxifolia, Cl. Mangifera indica, L. Millingtonia hortensis, L. F. Morinda tinctoria, Roxb. Pongamia glabra, Vent. Santalum album, L. Swietenia mahagoni, L. Syzigium alternifolium, Walp. Syzigium jombolanum, DC. Terminalia catappa, L. Tinospora cordifolia, Miers. Wrghitia tinctoria, R. Br. Zizyphus jujuba var. fruticosa,Hains. Zizyphus jujuba, Lam Zizyphus oenoplia, Mill.
Dominant plants Amaranthus viridis, L. Cassia auriuilata, L. Techoma stans Hardwicka binata,Roxb. Kigelia pinnata, Dc Wrghitia tinctoria, R. Br
Rare occurrence Bambusa arundinacea, Willd. Dendrocalamus strictus, Nees. Leea sp
Richardson & Cruddas (1972) Ltd. III-111
Endangered flora - Nil
Richardson & Cruddas (1972) Ltd. III-112
Site - 2
Hanumanahalli Village Herbs
Boerhaavia diffusa, L. Boerhaavia rependa, Willd Clerodendron sp Gomphrena Sp. Ipomaea carnea, Jacq. Sch..&Wendle Sida rhombifolia, L.
Medicinal herbs Phyllanthus maderaspatensis, L. Solanum xanthocarpum, Sch. Todonia viscosa, Linn. Tridax sp
Climbing Medicinally important herbs
Coccinia indica, W.&A Solanum trilobatum, L
Shrub Agave americana, L. Cactus sp. Gajanus gajan, L Ipomaea sp. Zizyphus jujuba, Lam
Medicinally Important
Shrubs Cassia auriculata, L. Calotropis gigantea, R. Br. Fluggea leucopyrus, Willd. Jatropha glandulifera, L.. Randia dumetorum, Lam.
Exotic shrubs
Prosopis spicigera. L Lantana camara, L
Trees
Euphorbia antiquorum, Linn. Eucalyptus globulus, Labill Hardwickia binata,Roxb. Phoenix sylvestris, Roxb. Syzigium jambolanum, DC Moringa oleifera, Lam.
Dominant plants
Prosopis spicigera. L. Amaranthus viridis, L.
Rare occurrence Solanum xanthocarpum, Sch.
Endangered flora – Nil
Site - 3 Project site Herbs
Achyranthes aspera, L Amarantus sp.
Borreria hispida, K.Sch. Cassia fistula, L. Cassytha sp. Chloris barbata, Sw. Chloris bournei, Rang & Tad. Chloris polystachya, Roxb. Cyperus sp. L. .Duranta repens, Eclipta alba, Hassk Euphorbia heterophylla, Linn. Gomphrena decumbens, Jacq.
Amaranthus viridis, L. Ipomaea batatas, Poir
Ipomaea carnea, Jacq. Leucas aspera, Spr. Salvia sp. Lycopersicum esculentum, Mill. Melochia umbellate, Stapf. Mollugo sp. L. Ocimum canum, L Oldenlandia biflora, L. Paspalum longifolium, Roxb. Sesamum indicum, L. Sesamum prostratum, Retz Sida acuta, L. Sida cordifolia, L Sida rhombifolia, L.
Richardson & Cruddas (1972) Ltd. III-113
Teliocora acumunata ,L Tephrosia purpurea, Pers. Threophonum sp
Trianthema decandra, L. Vernonia cinera, Lees. Waltheria indica, L Abutilon indicum, G. Don. Acanthus sp. Achyranthus aspera, L. Aristida depressa, Retz. Boerhaavia diffusa, L. Indigofera tinctoria, L Phyllanthus neruri, L. Triphyllus oxalis Tridax procumbens, L.
Medicinal herbs Catheranthus roseus Croton sparsiflorus, Mor
Cyanodon dactylon, Pers. Evolvulus alsinoides, L Phyllanthus maderaspatensis, L. Physalis minima, L Solanum nigrum, L. Solanum xanthocarpum, Sch.&Wendle
Climbing Medicinally important herbs Cardiospermum halicacabum, L. Dolichos lablab, L. Solanum trilobatum, L
Aquatic herbs.
Marselia sp Shrub
Ehretia buxifolia, Roxb Jatropha glandulifera, Roxb. Lawsonia alba, Lam Carissa diffusa, L. Cassia auriculata,L. Cassia sp. Cassia tora, L. Crotalaria juncea, L. Dichrostachys cinerea, W.&A. Glycine pentaphylla, Dalz. Hyptis suaveolens, Poit. Tecoma stans Ipomaea sp.
Medicinally Important
Shrubs Calotropis gigantea, R. Br Canthium parviflorum, Lam. Euphorbia tirucalli, L. Nerium odorum, Soland.
Ornamental shrubs
Rosa sp. Hibiscus rosasinensis, L. Thuja Duranta repens, Nerium odorum, Soland.
Ixora corymbosa ,Ham
Exotic shrubs Prosopis spicigera. L Lantana camara, L
Trees
Terminalia catappa, L Wrightia tinctoria, R. Br. Mangifera indica, L. Pongamia glabra, Vent. Syzigium jambolanum, DC. Tectona grandis, L. Acacia arabica, Willd Acacia leucophloea, Willd Acrus Sapota Albizzia lebeck, Benth. Areca catechu, L. Azadirachta indica, A. Juss. Borassus flabelliformis, L. Cocos nucifera, L Dichrostachys cinerea, W.&A Emblica officinalis, Gaertn Bassia latifolia, Roxb.
Dominant plants
Amaranthus viridis, L. Cassia auriuilata, L. Parthenium
Rare occurrence Acrus Sapota Bassia latifolia, Roxb. Mangifera indica, L.
Richardson & Cruddas (1972) Ltd. III-114
Endangered flora - Nil
Site – 4 Mariyammanahalli Tanda village
Herbs
Abutilon indicum, G. Don. Amaranths sp Commelina sp. L.
Cymbopogon citrates, Stapf. Cyperus sp. L. Eragosistis sp. Justicia simplex, D. Don. Lagenaria vulgaris, Ser. Martinia sp. Mimosa pudica, L. Mirabilis jalaba, L. Ocimum canum, L Sida acuta, L. Sida cordifolia, L Sida rhombifolia, L. Stachytarpheta indica, Vahl Teliocora acumunata ,L Vernonia cinerea, Less.
Climbing herbs Antigonon leptopus, Hk&A. Ipomaea staphylina R.&S.
Medicinal herbs Acalypha indica,L. Andropogon nadus,Linn Croton sparsiflorus, Mor Cyanodon dactylon, Pers. Datura stramonium, L Ocimum sanctum, L. Phyllanthus neruri, L.
Climbing Medicinal herbs Cardiospermum helicacabum, L. Pergularia pallida, W. & A. Solanum trilobatum, L Tylophora indica, L.
Aquatic herbs Hygrophilla angustifolia,R. Br. Typha angustata, B.& Ch Food crops Oryze sativa, L. Gajanus gajan, L. Dolichos lablab, L. Cucurbita melo, L. Arachis hypogaea, Willd Zea mays, L.
Shrubs Cactus sp. Dichrostachys cinerea, W&A. Zizyphus jujuba, Lam
Medicinal shrubs Calotropis gigantea, R. Br. Carissa diffusa, Roxb Cassia auriculata, L. Ehretia buxifolia,Roxb. Jatropha glandulifera, L Phyllanthus reticulates, Poir Randia dumetorum, Lam Todonia viscosa, Linn. Vitex negundo, L.
Ornamental shrubs Bougainvillaea glabara, Choisy
Exotic shrubs Prosopis spicigera. L Lantana camara, L
Exotic invasive weed
Parthenium hysterophorus L.
Trees Acacia leucophloea, Willt
Richardson & Cruddas (1972) Ltd. III-115
Albizzia lebeck, Benth Borassus flabelliformis, L. Cassia fistula, L. Cocos nucifera, L Dalbergia sissoo, Roxb. Mangifera indica, L. Morinda tinctoria, Roxb. Moringa olefera, Lam Muraya konigii, Spr Pavetta hispidula,W&A. Pavetta indica, L. Phoenix sylvestris, Roxb. Pithocelobium saman, Nees. Pongamia glabra, Vent Strobilanthus sp Tamarindus indica, L.
Thespesia populnea, Cav.
Dominant plants Eragosistis sp. Abutilon indicum, G. Don. Sida acuta, L. Sida cordifolia, L Sida rhombifolia, L.
Rare occurrence Phoenix sylvestris, Roxb. Strobilanthus sp Hygrophilla angustifolia,R. Br.
Endangered flora - Nil
Site – 5 MariamanahalliI
Herbs
Accanthus sp. Achyranthes aspera, L Clerodendron sp Cyperus sp. L. Gomphrena sp.Jacq. Scoporia dulsis,L. Sida acuta, L. Sida cordifolia, L Sida rhombifolia, L. Teliacora acuminata, Miers.
Medicinal herbs Aerva tomentosa, Forsk. Catheranthus roseus Croton sparsiflorus, Mor Euphorbia hirta, Linn. Ocimum sanctum, L. Tridax procumbens, Ham Solanum nigrum, L.
Climbing medicinal herbs Coccinia indica, W&A. Solanum nigrum, L.
Aquatic herbs.
Marselia sp Hygrophilla angustifolia,R. Br. Apanogeton monostachyon, L. Marselia sp Nymphaea sp. Typha angustata, B.& Ch
Food crops Cucumis melo, L. Zea mays. L. Sacharum officinarum, L.
Exotic invasive weed Parthenium hysterophorus L. Kyllinga sp.
Shrubs Anona squamosa, L. Cactus sp. Cassia alata, L. Cassia tora, L Hyptis suaveolens, Poit.
Medicinal shrubs Canthium parviflorum, Lam. Carissa diffusa, Roxb Fluggea leucopyrus, Willd Nerium odorum, Soland. Randia dumetorum, Lam Ricinus communis, L. Cassia auriculata, L. Jatropha glandulifera, L
Richardson & Cruddas (1972) Ltd. III-116
Exotic shrubs
Prosopis spicigera. L Lantana camara, L
Trees Acacia arabica, Willd Azadiracta indica, A. Juss Bassia latifolia, Roxb. Cassia fistula, L. Delonix regia, Raf. Euphorbia antiquorum, Linn. Ficus Cretovara, Roxb. Ficus religiosa, L Phoenix sylvestris, Roxb. Pithecolobium dulce, Benth. Polyalthia longifolia, Hk.F&T.
Pongamia glabra, Vent Strobilanthus sp Tamarindus indica, L. Tectona grandis, L. Terminalia catappa, L.
Dominant plants Amaranthus viridis, L. Cassia auriuilata, L. Parthenium hysterophorus L.
Rare occurrence Marselia sp Nymphaea sp
Endangered flora - Nil
Site – 6 Nandibanda
Herbs Abutilon indicum, G.Don. Achyranthes aspera, L Amaranths sp. Clerodendron sp Cyprus sp. Gomphrena procumbens, Jacq. Amaranthus viridis, L. Ipomaea sp. Sida cordifolia, L. Sida rhombifolia, L. Stachytarpheta indica, Vahl. Tephrosia pupurea, Pers Waltheria indica, L.
Medicinal herbs Aerva tomentosa, Forsk Croton sparsiflorus, Mor. Cyanodon dactylon, Pers. Eclipta alba, Hassk. Evolvulus alsinoides, L. Physalis minima, Linn Tridax procumbens, Ham
Climbing medicinal herbs Lagenaria vulgaris, Ser. Coccinia indica, W&A. Tinospora cardifolia, Miers.
Tylophora indica, Thw Pergularia pallida, W&A.
Food crops Arachis hypogaea, Willd Lycopersicum esculentum, Mill. Phaseolus mungo, L.
Exotic invasive weed Parthenium hysterophorus L.
Shrubs Cassia alata, L. Cassia auriculata, L. Cassia tora, L Clerodendron sp
Medicinal shrubs Calotropis gigantea, R. Br Euphorbia tirucalli, L. Phyllanthus rediculatus, Poir. Todonia viscosa, Linn. Vitex negundo, L.
Exotic shrubs Prosopis spicigera. L Lantana camara, L
Trees Acacia leucophloea, Willt. Albizzia lebeck, Benth. Azadiracta indica, A. Juss
Richardson & Cruddas (1972) Ltd. III-117
Borassus flabelliformis, L Cocos nucifera, L Euphorbia antiquorum, Linn. Ficus religiosa, L Syzigium jambolanum, Dc Tamarindus indica, L. Wrightia tinctoria, R. Br.
Dominant plants
Amaranthus viridis, L. Cassia auriuilata, L. Parthenium hysterophorus L. Sida cordifolia, L. Sida rhombifolia, L.
Rare occurrence Lagenaria vulgaris, Ser.
Site – 7 Dhanapura village Herbs
Abutilon indicum, G.Don. Accanthus sp. Achyranthes aspera, L Amaranthus sp. Crotoloria ternatea, L. Dolichos lablab, L. Paspalum longifolium, Roxb. Salvia sp. Sida acuta, L. Sida cordifolia, L
Climbing medicinal herbs
Tinospora cordifolia, Miers Pergularia damea
Shrubs Crotoloria ternatea, L.
Medicinal Shrubs Fluggea leucopyrus, Willd Ricinus communis, L.
Exotic invasive weed Parthenium hysterophorus L.
Exotic shrubs Prosopis spicigera. L
Lantana camara, L Trees
Aegle marmelos, Corr. Albizzia lebeck, Benth. Atlantia sp. Azadiracta indica, A. Juss Carica papaya, L. Cocos nucifera, L Dalbergia sissoo, Roxb. Eucalyptus globulus, Labill Fluggea leucopyrus, Willd Strobilanthus sp Psidium guajava, L. Syzigium jambolanum, Dc. Tamarindus indica, L. Tectona grandis, L.
Dominant plants Paspalum longifolium, Roxb. Salvia sp.
Rare occurrence Aegle marmelos, Corr. Atlantia sp.
Endangered flora - Nil Site – 8 Gaaga village
Accanthus sp. Amaranthus viridis, L. Commelina sp. Hygrophilla angustifolia,R. Br.
Ipomaea sp. Jasminum sp
Marselia sp Merremia vitifolia, Hall.f.. Mirabilis jalaba, L. Sida rhombifolia, L. Vernonia cinerea, Less.
Medicinal herbs
Richardson & Cruddas (1972) Ltd. III-118
Acalypha indica,L. Boerhaavia diffusa, L Brassica campestris, L. Croton sparsiflorus, Mor Cyanodon dactylon, Pers Datura stramonium, L. Ocimum sanctum, L. Tribulus terrestris, L. Tridax procumbens, L
Climbing medicinal herbs Coccinia indica, W&A. Catheranthus roseus Cucurbita sp. Lagenaria vulgaris, Ser. Tinospora cardifolia, Miers. Tylophora indica, Thw Crotoloria ternatea, L.
Aquatic herbs. Marselia sp Hygrophilla angustifolia,R. Br. Typha angustata, B.& Ch
Exotic invasive weed Parthenium hysterophorus L.
Shrubs
Cassia alata, L. Cassia tora, L Clerodendron sp Zizyphus jujuba, Lam. Zizyphus sp.
Medicinal shrubs Calotropis gigantea, R. Br Cassia auriculata, L. Randia dumetorum, Lam. Ricinus communis Todonia viscosa, Linn.
Ornamental shrubs Bougainvillaea glabara, Choisy Hibiscus rosasinensis, L. Ixora corymbosa ,Ham Jasminum sp Nerium odorum, Soland Rosa sp.
Tecoma stans Thuja
Exotic shrubs Prosopis spicigera. L Lantana camara, L
Trees Acacia arabica, Willd.
Acacia leucophloea, Willt. Aegle marmelos, Corr. Anona squamosa, L. Areca catechu, L. Azadiracta indica, A. Juss. Bauhinia diphylla, Ham. Bauhinia purpurea, Ham. Carica papaya, L Cassia fistula, L Casuarina equisetifolia, Forst. Cocos nucifera, L
Croton sparsiflorus, Mor Dalbergia sissoo, Roxb. Delonix regia, Raf. Emblica officinalis, Gaertn. Eucalyptus globulus, Labill Euphorbia antiquorum, Linn. Ficus bengalensis.L Ficus Cretovara, Roxb Ficus religiosa, L Mangifera indica, L. Millingtonia hartensis, L Morinda tinctoria, Roxb. Moringa olefera, Lam Nyctanthes arbor-tristis. L. Pithecolobium dulce, Benth. Pongamia glabra, Vent Strobilanthus sp Tamarindus indica, L. Tectona grandis, L. Terminalia catappa, L. Thespesia populnea, Cav.
Dominant plants Sida rhombifolia, L Eucalyptus globulus, Labill
Rare occurrence
Typha angustata, B.& Ch Hygrophilla angustifolia,R. Br.
Endangered flora - Nil
Richardson & Cruddas (1972) Ltd. III-119
Site – 9 TB DAM Herbs
Abutilon indicum, G.Don Accanthus sp. Canna indica, L. Cimbopogon citrates, Staf Crossandra sp. Crysanthimum sp. .Dendrobium sp. Ecbolium viridi Heliotropium brevifolium, Wall. Ipomea sp. Justicia simplex, D. Don. Salvia sp. Merremia vitifolia, Hall.f.. Paspalum longifolium, Roxb. Pongamia glabra, Vent Stachytarpheta indica, Vahl. Tephrosia pupurea, Pers Threophonum sp. Thuja Triphyllus oxalis, L. Vernonia cinerea, Less
Aquatic herbs. Typha angustata, B.& Ch
Medicinal herbs Acalypha indica,L Androphogon nadus, Linn. Brassica campestris, L. Euphorbia hirta, Linn. Evolvulus alsinoides, L. Leucas aspera, Spr. Ocimum sanctum, L. Cynodon dactylon, Pers Phyllanthus niruri, L. Ruellia paniculata, Nees Solanum nigrum, L. Tridax procumbens, Ham
Climbing herbs Dolichos lablab, L. Crotoloria ternatea, L
Climbing medicinal herbs
Tinospora cardifolia, Miers.
Exotic invasive weed Parthenium hysterophorus L.
Shrubs Anona squamosa, L.
Brassica campestris, L. Cassia alata, L. Cassia auriculata, L. Cassia tora, L Clerodendron sp
Medicinal shrubs
Todonia viscosa, Linn Phyllanthus rediculatus,Roxb Ricinus communis Calotropis gigantea, R. Br Jatropha glandulifera, L
Ornamental shrubs
Bougainvillaea glabara, Choisy Ixora corymbosa ,Ham Ixora chinensis ,Ham Thuja Tecoma stans Duranda repens
Exotic shrubs Prosopis spicigera. L Lantana camara, L
Trees Acrus sapota Azadirachta indica, A. Juss. Callistemon rigidus, L Caesalpinia pulcherrima, L. Carica papaya, L. Cassia fistula, L. Casuarina equisetifolia, Forst. Cycas sp. Delonix regia, Raf. Ficus bengalensis.L Ficus glomerata, Roxb. Ficus religiosa, L Mangifera indica, L. Morinda tinctoria, Roxb. Odina sp. Pongamia glabra, Vent Tamarindus indica, L. Terminalia catappa, L.
Dominant plants Salvia sp. Cassia alata, L. Cassia auriculata, L.
Richardson & Cruddas (1972) Ltd. III-120
Rare occurrence
Caesalpinia pulcherrima, L. Casuarina equisetifolia, Forst. Typha angustata, B.& Ch
Endangered flora - Nil
Richardson & Cruddas (1972) Ltd. III-121
Fauna Analysis
Based on actual field verification and interaction with local people and forest staff it is
observed that very few of the listed common wild animals and common birds are actually
found in the project area. Also because of high anthropogenic pressure due to the highway and
consequent development of human and industrial / mining activity it is not been conducive for
wildlife to inhabit the area. The list of wild mammals and reptiles found in the study area are
listed in Table 3.16.
Table 3.16 List of Wild Mammals Found in the Study Area
Common Name Scientific Name Schedule of Protection Act in which listed
A. Mammals
Common jungle cat Felis chans II
Common mongoose Herpestres edwardsii -
Jackal Canis aureus II,V
Wild dog Cuon alpinus II
Fox Vulpes bengalensis II
Porcupine Hystrix indica IV
Common hares Lepas sp. IV
Wild boar Sus scrofa III
Barking deer Muntiacus muntiacus III
Sambar Cervus unicolor III
Spotted deer Axis axis III
Striped Palm Squirrel Funambulus palmatum IV
Rhesus monkey Macaca mulata II
B. Reptiles
Indian Cobra Naja naja II
Yellow rat Snake Ptyas mucosus II
Common Krait Bungarus caeruleus IV
Russel’s Viper Vipera russelii II
Checkered Keelback Xenochropis piscator II
Richardson & Cruddas (1972) Ltd. III-122
The common snakes found in the region are Kraits and Cobras.
The main T.B. Dam lies some 5 km away from site. Many of the duck like bird are seen in
main reservoir water near the project site. The birds found in the area are given in
Table 3.17.
Table 3.17 List of Birds Commonly Found in the Area
Common Name Scientific Name Schedule of Wildlife
Protection Act in which listed
Paddy Bird Ardeola grayii IV
Large Indian Parakeet P. eupatria IV
Rose Ringed Parakeet P. krameri IV
Brahminy Duck Tadorna ferrugninea IV
Red Wattled Lapwing Vannelus indicus IV
Crow Pheasant Centropus sinensis IV
Koel Eudynamis scolopacea IV
White Breasted kingfisher Halcyon smyrnansis IV
Small green Bee-eater Merops orientalis IV
Coot Fulica atra IV
Common Crow C. splendens V
Hill Mynah Gracula religiosa IV
Common Mynah Acridotheres tristis IV
House Sparrow Passer domesticus -
Golden Backed Woodpecker Dinopium benghalense IV
Red Vent Bulbul Pycnonotus cafer IV
Spotted Dove Streptopelia chinensis IV Spur Fowl Galloperdix spp IV
Auatic Ecology
The main water bodies in the area are T.B. Dam & Darojikere Reservoir.The data on
ecology of the aquatic ecosystem in the study area is based on literature and field survey.
There are a number of ponds in the villages in the study area. On visual observation these
ponds seems to be oligo-trophic to mesotrophic in nutrients status. The common rooted
plants and hydrophytes on the edges of these pons are Nelumbo sp., Potamogeton sp.,
Aponogeton sp.,Ipomea sp., Dichanthium sp., etc. The water in these ponds are colourless
to slight greenish in color.
Richardson & Cruddas (1972) Ltd. III-123
The Phytoplanktons in the rivers are basically dominated by filamantous forms.
The dominant ones are, Chaetophora sp., Cladophora sp., Pithephora sp.,
Oscillatoria so., Spirogyra sp., Cymbella sp., etc.
The Zooplanktons are basically dominated by Crustaceans and Rotifers. The
dominant ones are Crustaceans : Crustacean eggs, Moinodaphina, Chydorus, Cyclops.
Rptifers : Brachionus, Rotiferan, etc. Others : Nematodes, Dipteran larvae, etc.
Fishes
The T.B. Dam is the main ecosystem supporting fishes in the area. The maximum abundance
of fishes was reported during April to July. The fishes observed in the T.B . Dam and the
nearby reservoirs is given in Table 3.18.
Table 3.18 Fish Fauna observed in the Study Area
Sl. No. Name of fish 1 Catla catla
2 Labeo fimbriatus
3 Labeo calbasu
4 Cirrhinus mrigala
5 C. reba
6 Barbus tor
7 Puntius sarana
8 Mystus seenghala
9 Mystus sor
10 Silonia silondia
11 Wallago attu
12 Pangasius pangasius
13 Rita chrysea
14 Eutropiichthys vacha
15 Bagarius bagarius
16 Notopterus notopterus
17 Notopterus chitala
18 Gudusia chapra
19 Rohtee cotio
20 Pama pama
21 Glossogobius guiris
22 Rhinomugil corsula
23 Xenentodon cancila
Richardson & Cruddas (1972) Ltd. III-124
Sl. No. Name of fish 24 Chela sp.
25 Chela bacailla
26 Ailea coilfa
27 Ambassis nama
28 Ambassis sp
29 Puntius sophore
30 Puntius ticto
31 Puntius chola
32 Puntius dorsalis
33 Mastacembelus armatus
34 Mastacembelus pancalus
Conclusion
No endangered and endemic species ( flora & fauna ) recorded in the project site and its
surroundings, hence conservation plan is not required.
3.7 Socio Economic Study
Socio-economic development is closely linked with the growth of industrialization. The
industrial policy resolution in the year 1956 stressed the need of reducing regional disparities
in levels of development in order that industrialization may benefit the country as a whole.
This view was further endorsed in the new industrial policy statement (1980) which further
felt that revival of the economy was inhibited by infrastructure gaps such as shortage in
major industries. The policy also emphasized the need to promote suitable industries in rural
areas. The process of industrial transitions where new industrial units are setup in a
primarily agrarian economy is bound to create its impact on the socio-economic aspects of
the local people. Therefore studies on the socio-economic impact of industrialization on the
local population no doubt deserve considerable attention. The present study is being carried
out to ascertain the impacts of proposed plant on the socio-economic conditions of local
people. The data required to study the above aspects has been collected from secondary
sources.
3.7.1 Methodology The methodology adopted for the study is based on Review of secondary data (2001 District
Census) with respect to population, occupational structure and infrastructure facilities
available in the region.
Richardson & Cruddas (1972) Ltd. III-125
3.7.2 Review of Socio-economic Profile
The information on socio-economic aspects of the study area has been compiled from
secondary sources, which include information from various public and semi-public offices.
The demographic data has mainly been compiled from Census of India 2001 data as this
document is comprehensive and authentic. The sociological aspects like human settlements,
demography and other socio-economic aspects in the study area have been covered in this
study. The socio-economic details are briefly described in the following sections.
Study area of 10 km falls in Hospet Taluk and part of study area falls in Sandur and
Hagaribommanahalli Taluk [H.B. Halli], Bellary District. Major portion of the study area
comprises only rural area. Study area contains 21 villages. Of these, 15 villages are in Hospet
Taluka, 5 villages are in Sandur Taluk and 1 village is in H.B. Halli Taluk. The villages that
come partly within study area of 10 km are also covered in the present study.
3.7.3 Demography As per 2001 census, the study area consisted of 51210 persons inhabited in 21 villages. The statistics
regarding the list of villages, number of households and human population is given in Table 3.19.
TABLE- 3.19 DEMOGRAPHY IN STUDY AREA
Sr. No. Name of Village No of Households Population 1 Ayyanahalli 160 927 2 Byalakundi 162 865 3 Danapuram 939 5083 4 Danayakanakere 392 2263 5 Devalapura 789 4563 6 Garga 348 1907 7 Gollarahalli 272 1533 8 Hanumanahalli 0 0 9 Haravanahalli 159 995 10 Kallahalli 391 2132 11 Mariyammanahalli 2277 12195 12 Mariyammanahalli Thanda 294 2089 13 Medarahalli (Jaisingapur) 335 1814 14 Nagalapura 735 4320 15 Nandibanda 198 1137 16 Rajapura 348 1922 17 Ramgad 111 553 18 Siddapur 181 1118 19 Varadapura 387 2252 20 Venkatapuram Colony 202 1314 21 Vyasanakere 445 2228 TOTAL 9125 51210
Richardson & Cruddas (1972) Ltd. III-126
Source: Census 2001 Karnataka State PCA2912 The distribution of population in the study area is shown in Table-3.20.
TABLE- 3.20 DISTRIBUTION OF POPULATION
Particulars Rural Urban Total
Total Population 51210 0 51210 Male Population (% with total population)
25794 (50.37%) 0 25794
(50.37%) Female Population (% with total population)
25416 (49.63%) 0 25416
(49.63%) No. of Households 9125 0 9125 Average Household Size 5.6 0 5.6 Sex ratio (Female/1000 male) 985.34 0 985.34
Source: Census of India 2001 The configuration of male and females indicates that the males constitute to about 50.37%
and females to about 49.63% of the study area population. The sex ratio i.e. the number of
females per 1000 males indirectly reveals certain sociological aspects in relation with female
births, infant mortality among female children and single person family structure, a
resultant of migration of industrial workers. The study area at an average has 985.34 females
per 1000 males.
3.7.4 Social Structure Majority of the people in the study area belong to Hindu religion. The study area also
contains Scheduled Castes (SC) and Scheduled Tribes (ST). The distribution of population of
socially weaker sections in the study area is shown in Table-3.21
TABLE-3.21 DISTRIBUTION OF POPULATION BY SOCIAL STRUCTURE
Category Rural Urban Total
Total Population 51210 0 51210 Scheduled Castes 12599 0 12599 % to total population 24.60% 0 24.60% Scheduled Tribes 11751 0 11751 % to total population 22.94% 0 22.94% Total SC and ST 24350 0 24350 % to total population 47.54% 0 47.54%
In the study area 24.60% of the population belongs to Scheduled Castes (SC) while 22.94% to
Scheduled Tribes (ST), thus indicating that about 47.54% of the population is formed by SC and
ST population. Scheduled Caste and Scheduled Tribe sections are predominant in this area.
3.7.5 Literacy Levels
Richardson & Cruddas (1972) Ltd. III-127
The distribution of literates and literacy rates in the study area are given in Table- 3.22
Richardson & Cruddas (1972) Ltd. III-128
TABLE-3.22 LITERACY LEVEL
Particulars Rural Urban Total Total Population 51210 0 51210 Male population 25794 0 25794 Male literates 13383 0 13383 Female population 25416 0 25416 Female literates 7825 0 7825 Total literates 21208 0 21208 % of study area literates to total population 41.41% 0 41.41% Male literacy rate 51.88% 0 51.88% Female literacy rate 30.79% 0 30.79%
Source::Census of India 2001 The study area experiences a moderate literacy rate of 41.41%. The male literacy i.e. the
percentage of literate males to the total males of the study area is observed as 51.88% while
female literacy rate, which is an important indicator for social change, is observed as 30.79%
in the study area.
3.7.6 Occupational Structure The occupational structure of the study area is studied with reference to main workers,
marginal workers and non-workers. The main workers include 10 categories of workers
defined by the Census Department consisting of cultivators, agricultural laborers, those
engaged in live-stock, forestry, fishing etc. mining and quarrying; manufacturing, processing
and repairs in household industry; and other than household industry, construction, trade &
commerce, transport & communication and other services.
Due to boom in Iron Ore in recent years majority of farmers as well as agriculture laborers
are engaged in the mining activity. This information is not forthcoming from the Published
Census Data.
The marginal workers are those engaged in some work for a period of less than six months
during the reference year prior to the census survey. The non-workers include those engaged
in unpaid household duties, students, retired persons, dependents, beggars, vagrants etc.;
institutional inmates or all other non-workers who do not fall under the above categories.
The occupational structure of the study area is shown in Table-3.23.
Richardson & Cruddas (1972) Ltd. III-129
TABLE-3.23 OCCUPATIONAL STRUCTURE OF STUDY AREA
Rural Urban Total Occupation No. % to
population No. % to
population No. % to
population Total Workers 25634 50.05 0 0 25634 50.05 Cultivators 6810 13.29 0 0 6810 13.29 Agricultural laborers 7527 14.69 0 0 7527 14.69
Household industries laborers 771 1.5 0 0 771 1.5
Others 5284 10.31 0 0 5284 10.31 Total main workers 20392 39.82 0 0 20392 39.82
Marginal workers 5242 10.23 0 0 5242 10.23 Non-workers 25576 49.94 0 0 25576 49.94 Total population 51210 100 0 0 51210 100
Source:Census of India 2001 Altogether the main workers work out to be 39.82% of the area population. The marginal
workers and non-workers constitute to 10.23% and 49.94% of the population respectively.
The distribution of workers by occupation indicates that the workers in the other category
are (10.31%) followed by cultivator’s laborers and household industries laborers respectively.
The cultivators and agricultural laborers together form 27.98% of the total population. The
occupational profile of total workers and their proportion to the total population of the
study area is shown graphically in the figure III.7.
FIG. III.7 Distribution of Total Workers in Study Area
Richardson & Cruddas (1972) Ltd. III-130
3.7.7 Amenities Available Amenities available in the villages considered in the Study Area have been collected from
Census Book for the District. Educational facilities, Healthcare facilities, Water supply,
Communication facilities, Banking facilities, Road and Transportation facilities, availability
of news papers & magazines etc., are covered in these amenities. It is noticed that villages
have majority of all these facilities. A bigger town namely Mariyammanahalli is located
within distance of 8 to 10 Km from these villages were all these facilities are available.
Mariyammanahalli town is located at the intersection of National Highway-13 and State
Highway. The facilities available for all the villages in the Study Area and such
facilities available in respect of 5 villages in whose jurisdiction lands for the project is
being procured is furnished in Table:3.24 and 3.25 respectively.
Richardson & Cruddas (1972) Ltd. III-131
TABLE 3.24 AMENITIES AVAILABLE IN THE STUDY AREA
AMENITIES AVAILABLE IN THE STUDY AREA
DISTRICT CENSUS HANDBOOK
SL. No VILLAGE NAME
Ayy
anah
alli
Dev
alap
ura
Gol
lara
halli
Han
uman
ahal
li
Har
avan
ahal
li
Kalla
halli
Mar
iyam
man
ahal
li
Mar
iyam
man
ahal
li
Than
da
M
edar
ahal
li (J
aisi
ngap
ur)
Nan
diba
nda
Raja
pura
Ram
gad
Sidd
apur
(H
unis
avut
i)
Vara
dapu
ra
Venk
atap
uram
Co
lony
Vyas
anak
ere
1 Number of Primary School 2 2 2 0 2 0 6 2 2 2 0 0 2 0 2 1
2 Number of Middle School 1 1 1 0 1 0 6 1 1 1 0 0 1 0 1 0
3 Number of Secondary School 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0
4 Number of Senior Secondary School 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 1
5 Number of Maternity Home 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
6 Number of Primary Health Sub Centre 0 1 0 0 0 0 2 0 0 0 0 0 0 1 0 0
7 Tap Water (T) √ x √ x √ x √ √ √ √ √ x x √ √ √
8 Well Water (W) x √ √ x √ x √ √ x √ √ x x √ √ x 9 Tank Water (TK) √ √ √ x x x √ √ x √ x √ x √ √ x 10 Tubewell Water (TW) √ √ √ √ x √ √ √ √ √ √ x √ √ √ √ 11 Handpumb (HP) √ √ √ x √ √ √ √ √ √ √ x √ √ √ √
12 Number of Telephone connections 0 15 1 0 1 1 50 5 0 1 0 0 0 8 1 3
13 Bus services x √ √ 0 √ √ √ √ 0 √ √ √ √ √ x √
14 Number of Co-operative Commercial Bank 0 √ 0 0 0 0 √ 0 x 0 0 0 0 0 0 0
15 Number of Agricultural Credit Societies 0 0 0 0 0 0 √ 0 x 0 0 0 0 0 0 0
16 Approach - Paved Road 0 √ √ 0 √ 0 √ √ √ √ √ √ √ √ √ √
17 Approach - Mud Road √ 0 √ 0 √ √ √ √ 0 √ √ 0 0 √ √ √ 18 Approach - Foot Path √ 0 √ 0 √ 0 √ √ 0 √ 0 0 0 √ √ √ 19 Electricity for all purposes √ √ √ 0 √ √ √ √ √ √ √ √ √ √ √ √
20 News Paper (Indicate N, if arrived) √ √ √ x x x √ √ √ √ √ x x √ √ √
21 Magazine (indicate M, if arrived) x √ x x x x √ √ x x x x x √ x X
Source: Census of India 2001 (Note: √ = Available, x = Not Available)
Richardson & Cruddas (1972) Ltd. III-132
TABLE 3.25 AMENITIES AVAILABLE IN 5 VILLAGES FROM WHOM LAND IS TO BE PURCHASED
AMENITIES AVAILABLE IN 5 VILLAGES FROM WHOM LAND IS TO BE PURCHASED DISTRICT CENSUS HANDBOOK
Village Name SL.No Amenities available Byalakundi Danapuram Danayakanakere Garaga Nagalapura
1 Number of Primary School 2 3 2 2 2 2 Number of Middle School 1 3 2 1 2 3 Number of Secondary School 0 1 0 0 1 4 Number of Senior Secondary School 0 1 0 0 0 5 Number of Maternity Home 0 1 0 0 0 6 Number of Primary Health Sub Centre 0 1 1 0 1 7 Tap Water (T) √ √ √ √ √ 8 Well Water (W) √ √ x √ √ 9 Tank Water (TK) √ √ √ √ √ 10 Tubewell Water (TW) √ √ √ √ √ 11 Handpumb (HP) √ √ √ √ √ 12 Number of Telephone connections 1 26 3 1 4 13 Bus services √ √ √ √ √ 14 Number of Co-operative Commercial Bank x √ x x x 15 Number of Agricultural Credit Societies x √ x x x 16 Approach - Paved Road √ √ √ √ √ 17 Approach - Mud Road √ √ √ √ √ 18 Approach - Foot Path √ √ √ x √ 19 Electricity for all purposes √ √ √ √ √ 20 News Paper (Indicate N, if arrived) √ √ √ √ √ 21 Magazine (indicate M, if arrived) √ √ √ √ √
Source: Census of India 2001 (Note: √ = Available, x = Not Available)
Richardson & Cruddas (1972) Ltd. IV-1
3.7.8 Industries in the Neighborhood Although marked by forests and considered as one of the backward districts of the
state, the Hospet region has a number of industries. The principals among them
are Vijayanagar Steel Plant of M/s Jindal Steel Ltd located about 30 km from the
area. One Ferro-Manganese Plant of Sandur Manganese and Iron Ore Industry is
located SW of the area. Since the area produces high grade iron ore, there are a
few steel producing units, about 10 km from the Hospet Town. The principals
among them are M/s Kiroloskar Ferrous Industries Ltd and Kalyani Steels. There are
more than 50 mines working in the area, most of them produce iron ore. Thus
mining still forms main industry of the area. The list of industries in the study area
is given in Annexure 3 E
Hospet town has a number of small scale and medium scale units fulfilling the
‘service’ needs of the area. They total nearly 500. Besides this, there is also a
Sugar Mill and a Distillery outside Hospet Town.The Hospet Town is rail head to
visit Hampi the “World Heritage Site”. Thus there are number of Hospitality
related facilities like Hotels, Taxi Services etc.
3.7.9 Places of Archaeological and Religious Interest
The area is famous for the ruins of Hampi the erstwhile capital of Vijayanagar
Empire, which is, located about 15 km from the project site as the crow flies. It is
declared World Heritage Site. There are also several old ruins of that era in the
Tungabhadra River Valley. Almost all major villages and Hospet town have a
number of old temples, some of them as old as Vijayanagar time. However, none
of them is listed as Archaeological monument.
Richardson & Cruddas (1972) Ltd. IV-2
CHAPTER IV
ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES
4.1 Identification of Impacts
General
An essential step in Environmental Impact Assessment (EIA) is to identify all the
potential environmental impacts by the proposed steel production on environment.
These are then examined critically and the major impacts (both beneficial and
adverse) are analyzed in detail. Of the various techniques available for impact
identification like checklists, matrices networks, cause effect diagram, computer
simulation models etc., the matrix method has been chosen for the present project
impacts identifications.
Identification of Impact
The impact identification matrix is given in Table 4.1. The environmental attributes
include ambient air quality, water resources & quality, Noise levels, flora & fauna
(ecology), soil and land-use, socio-economic environment and infrastructure
development, health etc., Various stages viz., siting, operation of Steel production and
secondary activities and also post operational phase.
The activities have been arranged in columns and environmental attributes in rows in
the matrix. A preliminary scrutiny has been made and the cells, which fall at the
junction of activity and attribute that have possible interaction with each other, have
been marked with proper notation.
The matrix thus, identifies the environmental attributes likely to be affected and the
activities responsible for this. The impacts may be beneficial or adverse. These will be
analyzed in detail during assessment of the impacts.
Richardson & Cruddas (1972) Ltd. IV-3
Table - 4.1 Impact Identification Matrix
Actions Raw material storage and handling, Steel production and other allied activities
Post Operationa
l Phase
Environmental Attributes
Cons
truc
tion
Ph
ase
Ope
rati
onal
Ph
ase
Mat
eria
l H
andl
ing
Ore
Sto
rage
/
hand
ing
Wat
er d
raw
l (S
urfa
ce w
ater
)
Wat
er d
isch
arge
Mai
nten
ance
W
orks
hop
Pow
er
gene
rati
on b
y D
G s
et
Gre
en B
elt
deve
lopm
ent
Empl
oym
ent
Urb
aniz
atio
n (B
uffe
r zo
ne)
Tran
spor
tati
on
Ambient air
Water resources
Water quality
Ambient Noise
Flora & Fauna
Soil & Land use
Infrastructure
Health & Safety
Socio-economics
Aesthetics
Adverse Impact Beneficial Impact Identification of Impact during Construction Phase The following are the impacts identified during construction phase.
Air : Grading of land, excavation, backfilling, storing and storage & handling of
construction materials, etc. The impact is temporary only during
construction period.
Noise : Blasting, Bore well drilling Concrete mixers, mobility of trucks and machinery
Water : Water consumption
Land use: Piling of debris, surface earth, waste packing material
Socio-economic: Employment, demand for goods and other off site infra structural facilities
Biological: Displacement of native fauna (snakes, frogs, Amphibians, etc.)
Richardson & Cruddas (1972) Ltd. IV-4
Identification of Impacts during Operational stage
The major activities at BMM Ispat Ltd site in the operational phase involves storage &
handling of ore, coal and other raw materials, processing of ore and coal for Steel
making, captive power generation and cement manufacturing. These activities may
affect the environment in varying degrees through natural resources depletion viz.
water consumption, release of particulates and gaseous emissions, contamination of
water body, run-off from waste storage area etc. During working life of plant, air,
water and noise may be affected due to material usage and processing for steel and
associated activities in general. The sources of pollution during operational is given in
Table 4.2.
Allied operations, e.g. transportation of materials, operations of workshop and garage,
canteen etc., may also affect air, water and noise environment.
Green belt development will have a positive impact not only on flora and fauna but
also on air quality, noise and soil characteristics.
Positive impacts on socio-economic environment are expected due to employment,
further infrastructure development and also due to socio-economic welfare
developmental activities to be taken up by BMMI.
Screening of identified Impacts
Some of the impacts identified in various phases are insignificant and do not warrant
much attention whereas some other are very important. The object is to identify those
impacts, which are significant and require a detailed analysis for decision making or
formulating adequate management measures.
Richardson & Cruddas (1972) Ltd. IV-5
Table- 4.2 Source & Types of Environmental Pollutants
released due to proposed project
Section /
Units Feed Materials & Fuels Operation Pollutants Recipient Form of
Pollution
Dust Air Air Pollution
Raw Material Handling
Low grade iron ore, imported coking coal, Non-coking coal, Limestone, Dolomite,
Storage Run off /Leachates Drain Water Pollution
Dust Air Air Pollution
Noise Workzone Workzone noise Pollution
Iron ore beneficiation Low grade Iron ore
wet grinding &
beneficiation Effluent Plant
drain/reuse Water Pollution
Sponge Iron Plants
Iron Ore, Coal, Dolomite
Reduction of Iron Ore Dust, SO2, NOx Air Air Pollution
Pelletization plant
Iron ore Concentrated
Heat hardening Dust Air Air Pollution
Heat, Dusts, SO2, NOx Air Air Pollution
Sinter Plant
Iron Ore concentrate, Limestone recycled fines, etc. as feed and coke and BF gas as fuel.
Sintering at an elevated temperature Noise Air Workzone noise
Pollution
Heat, Dusts, SO2, NOx Air Air Pollution Blast Furnace
plant
Coke, Iron Ore, Sinter, Fluxes and BF gas
Smelting of Iron oxide
Noise Workzone Workzone noise Pollution
Heat, Dusts Air Air Pollution
Steel Melting Shop
Hot Metal, Fluxes, Ferro Alloys
Steel Making, Refining and Continuous Casting of Slabs & billets
Particulate Dusts Laden
Water Plant Drain Water Pollution
Heat, SO2, NOx Air Air Pollution Noise Workzone Air Noise Pollution
Rolling mill Steel Slabs , billets and furnace oil
Hot Rolling of Slabs and
billets
Oil and Particulates Laden Mill Effluent
Concentrated/Treated in
thickener
Sludge to beneficiation
plant
Heat, SO2, NOx, Fly ash, Bottom ash
Air Air Pollution
Noise Work zone Air Noise Pollution
Captive Power Plant Flue gas & coal
Steam Raising and Power Generation
Wastewater of DM Plant
containing acids / alkalis
Guard pond Water Pollution
Richardson & Cruddas (1972) Ltd. IV-6
Section / Units
Feed Materials & Fuels Operation Pollutants Recipient Form of
Pollution Cooling Tower Guard pond Water Pollution
Dust Air Air Pollution Cement Plant BF Slag, Clinker,
Gypsum and Coal
Grinding, Screening and
packing Noise Work zone Air Noise Pollution
Coke Oven Plant Coal
Non-recovery type coke making
Flue gas Power plant Air Pollution
Richardson & Cruddas (1972) Ltd. IV-7
4.2 Prediction of Impacts
Impacts during Construction Phase
Impact on Ambient Air Quality
During the construction phase of the project, a considerable amount of civil work
activities like grading of land, excavation, back filling, storing, piling etc involving
movement and transportation of earth will take place. This will lead to generation of a
large emission of fugitive dust. The fugitive nature of dust will have local impacts in
the area where the activity will be carried out. Water spraying is proposed to be
carried out on the roads, which will be used for transportation of materials to suppress
fugitive dust. Further, the civil construction activities are temporary in nature and will
last for 18-24 months and will not have long term impact on the ambient air quality.
Impact on Noise Levels
Noise levels are also likely to increase due to increased movement of trucks and other
diesel powered material handling equipment. This will have an adverse impact in the
vicinity of the construction activities. However, movement of trucks and machinery
will be mainly during daytime to keep the impact of increased noise minimum.
Since the construction phase will be temporary, the impact on ambient noise levels
will be temporary and cease once the construction phase is over.
Impact on Water bodies
The water required for the construction purposes is around 800 cum per day and will
be met from down stream of TB dam/Almathi dam/ ground water. Debris, mud etc.
generated during construction in rainy seasons will contaminate the storm water run-
off with large amounts of suspended solids. This water will be channelized through
catch drain to a suitable size settling pond to trap the suspended solids.
Impact on Land use
During construction, a large amount of construction debris like surplus earth, scrap,
waste packing materials, cables etc will be generated. These will be stored in
identified areas, which can later be either used in the operational phase or sold to out
side parties for reuse.
Richardson & Cruddas (1972) Ltd. IV-8
Socio-Economic Impacts
The construction phase of the project involves large deployment of manpower, both
direct and indirect. This period has huge potential for employment, both direct and
indirect, which will affect the economy of the surrounding area. But these impacts will
be temporary in nature. The construction phases of the project will require different
skills of people at different times, involving large migration of labour force over short
periods. This will have adverse impact on the existing infrastructure unless adequate
precautions are taken in advance. However, over the years, a large number of
industries have been established in the surrounding area, as a result of which, the
availability of skilled manpower in the nearby area has improved considerably.
Further, the infrastructure in the surrounding area has developed in the intervening
period to accommodate the migrating population. As a result of which the impact
during construction will not be adverse at the project site.
Impacts during Operational Phase
During operation of the proposed steel plant, impacts are anticipated on ambient air
quality and noise levels, water, land-use, ecology and socio-economic environment.
Impact on Ambient Air Quality
The proposed Steel production of 2.0 Mt/YEAR, 1.4 Mt/YEAR cement production and
230 MW captive power plant will have impact on the air environment beyond the core
zone. While the impact of fugitive emissions will be within the core area. The effect of
emissions from the point sources is a major concern, as it will have an impact on the
ambient air quality in the surrounding area. It is also proposed to limit the design
emission norms well within the prescribed standards. The impact of pollution of the
steel production plant on the ambient air is assessed using mathematical modeling
(ISCST3). The data used in mathematical modeling are presented below.
Micro- meteorological data
The meteorological data recorded continuously during the winter season 2007-08 on
hourly basis on wind speed, wind direction and temperature have been processed to
obtain 24-hourly mean meteorological data as per guidelines of IMD for application of
ISCST 3 model. Stability classes computed for the mean hours are based on guidelines
issued by CPCB on modeling. Mixing heights representative of the region have been
taken from the available published literature. Table 4.3 provides information on
emission data.
Richardson & Cruddas (1972) Ltd. IV-8
Table 4.3 Source-wise Emission data
Emission (g/s) Sl. No Source No. of
Stacks Stack
height (m) Stack dia.
(m) Velocity
(m/s) Temp (oC) PM SO2 NOx
1. Pellet Plant Grate system 1 55 4.0 / 7.5 20 120 12.92 18.0 0.02 Proportioning bins 1 30 1.8/ 2.4 8.0 A 1.02 - - Cooler discharge area 1 30 1.8 / 2.4 9.8 A 1.247 - - Coal grinding system 1 30 1.5 / 2.0 7.6 A 0.67 - -
2 DRI Plants kiln 1 kiln2
1
90 4.1
16
130
5.22
7.93
8.99
kiln 3 kiln4
1
90 4.1
16
130
5.22
7.93
8.99
Day bins 1 30 1.8 11.2 A 0.792 - -
Coal preparation unit 1 30 1.5 /2.0 10.8 A 0.954 - -
Product Handling unit 1 30 1.8 /2.4 10.9 100 1.387 3 Coke Oven Plant Batteries 1 & 2 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 3 & 4 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 5 & 6 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 7 & 8 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 9 & 10 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 11 & 12 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 13& 14 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Batteries 15& 16 1 70 3.5 / 5 7.8 120 3.694 22.16 36.93 Coal preparation unit 2 30 2 / 2.5 7.8 A 1.225 - - Coke quenching 2 30 1.8 / 2.4 13.1 100 1.66 - - 4 Sinter Plant Sinter machine 1 1 45 3.2 /4.5 22.0 110.0 9.166 13.750 1.83 Sinter machine 2 1 45 3.2 /4.5 22.0 110.0 9.166 13.750 1.83 Flux crushing units 1 30 2.25 / 3 12.8 A 2.545 - - Coke crushing unit 1 30 2.5 / 3.25 8.5 60 2.086 - - Proportioning bins 1 30 1.8 / 2.5 9.5 40.0 1.208
Richardson & Cruddas (1972) Ltd. IV-9
Emission (g/s) Sl. No Source No. of
Stacks Stack
height (m) Stack dia.
(m) Velocity
(m/s) Temp (oC) PM SO2 NOx
Cooler discharge & Sinter screening unit 1 30 2.5 / 3.2 8.2 80-100 2.012
5 Blast Furnace BF 1 1 55 2.0 11.0 250 1.736 - 0.004 BF2 1 55 2.0 11.0 250 1.736 - 0.004 BF3 1 55 2.0 11.0 250 1.736 - 0.004 BF 4 1 55 2.0 11.0 250 1.736 - 0.004 Stock house 2 30 1.8 / 2.5 12.6 A 1.603 - - Coal Pulverizing system 1 30 1.5 / 2.25 9.5 A 0.84 - - Cast house 2 30 2 / 2.5 12.8 40 2.01 - - 6 EAF & Steel making shop 1 40 1.4 11.0 110 0.833 0.001 - 7 Rolling mill Reheating Furnace 1 1 80 1.54 15 150 2.77 41.55 68.4 Reheating Furnace 1 2 80 1.54 15 150 2.77 41.55 68.4 8 Calcination plant 1 1 30 1.26 8.0 110 0.5 - - Calcination plant 2 1 30 1.26 8.0 110 0.5 - -
9. Cement grinding unit Granulated slag drying system 1 40 3 13.5 180 5.0 14.5 Traces
Materials Transfer points dedusting system 2 30 1.8 11.2 A 0.80 - -
Cement mix grinding system 1 60 4 / 6 15 80 9.02 - -
10 Captive Power Plant Coal crushing and handling system 1 40 1.5 9.5 A 0.84 - - Coal Firing system 1 220 3.0 / 4.5 18.0 140 12.72 15.2 7.52
Richardson & Cruddas (1972) Ltd. IX-1
Mixing Heights
Knowledge of site specific mixing height (Convective stable boundary layer and inversion
height or nocturnal boundary layer) is crucial in realistic adoption of appropriate plume rise
and vertical dispersion parameters. IMD generate data on mixing depth at Bangalore using
radiosonde technique with two readings a day, which are available with IMD, Pune. The
following tables list out the mixing heights which have been considered in air quality
modeling.
Date Mix (M) Mix (E) Date Mix (M), m Mix (E), m 01.11.2001 311 1675.3 01.12.2001 720.8 700.8 02.11.2001 277.5 315.6 02.12.2001 595 752.3 03.11.2001 668.6 1141.9 03.12.2001 311 672.2 04.11.2001 291.5 623.6 04.12.2001 77.7 1182.2 05.11.2001 238.8 450.4 05.12.2001 232.4 646.8 06.11.2001 1102.8 1190 06.12.2001 179.1 582.9 07.11.2001 611.4 240.2 07.12.2001 331.6 843.9 08.11.2001 682.5 799.8 08.12.2001 307.3 843.4 09.11.2001 708.5 1232.1 09.12.2001 203.0 655.8 10.11.2001 613.7 718.3 10.12.2001 342.0 911.5 11.11.2001 247.9 401.5 11.12.2001 426.7 961.5 12.11.2001 338.7 688 12.12.2001 606.1 997.2 13.11.2001 598.4 624 13.12.2001 321.4 1200 14.11.2001 272.4 400.1 14.12.2001 274.5 1308.5 15.11.2001 397.6 601.5 15.12.2001 1191.9 1370.1 16.11.2001 336.2 643.7 16.12.2001 679.2 1372.7 17.11.2001 364.3 651.9 17.12.2001 349.9 1263.8 18.11.2001 632.5 186.6 18.12.2001 663.8 742.8 19.11.2001 314.2 582.2 19.12.2001 670.4 617.6 20.11.2001 361.2 696.6 22.12.2001 1639.6 1287.7 21.11.2001 664.3 1223.3 23.12.2001 737.3 213.8 22.11.2001 363.6 353.1 24.12.2001 657.1 642.7 23.11.2001 313.4 338.2 25.12.2001 610.5 674.9 24.11.2001 381.5 644.1 26.12.2001 725.5 828.9 25.11.2001 727.3 1789.1 27.12.2001 889.4 1720.9 26.11.2001 728.2 1771.3 28.12.2001 1169.5 1807.7 27.11.2001 626.6 1730.5 29.12.2001 654 1170 28.11.2001 343.8 675.6 30.12.2001 396.1 1247.4 29.11.2001 586.5 2199 31.12.2001 617.9 716.3 30.11.2001 243.4 546.8
MIX (M) – Morning mixing height in meter
MIX (E) – Evening mixing Height in meter
Richardson & Cruddas (1972) Ltd. IX-2
Mixing Heights (Contd.,)
Date Mix (M) Mix (E) Date Mix (M), m Mix (E), m 01.01.2002 395 623.8 01.02.2002 672.9 1367.2
02. 01.2002 652.1 1169.8 02. 02.2002 221.9 105.8
03. 01.2002 409.9 684.6 03. 02.2002 873.6 1037.6
04. 01.2002 363.5 1249.1 04. 02.2002 602.6 1250.6
05. 01.2002 1682.7 1781.6 05. 02.2002 267.6 765.4
06. 01.2002 682.9 1666.1 06. 02.2002 272.3 1712.1
07. 01.2002 705.0 1175.0 07. 02.2002 328 1223.4
08. 01.2002 1104.2 1224.6 08. 02.2002 643 934.4
09. 01.2002 1278.1 1327.8 09. 02.2002 359 714.5
10. 01.2002 672.7 805.2 10. 02.2002 334.4 1197.3
11. 01.2002 674.4 1188.3 11. 02.2002 300.9 1132.6
12. 01.2002 913.6 1618.1 12. 02.2002 449.6 1021.5
13. 01.2002 475.4 1650.2 13. 02.2002 340.1 1175.7
14. 01.2002 583.2 1613.5 14. 02.2002 649.4 2222
15. 01.2002 651.2 1696.8 15. 02.2002 298.2 1343
16. 01.2002 381.1 1119.0 16. 02.2002 217.2 2268.5
17. 01.2002 573.8 1081.8 17. 02.2002 717.3 2083.6
18. 01.2002 301.5 701.3 18. 02.2002 278.1 1944.2
19. 01.2002 803.7 1434.7 19. 02.2002 228 2287.6
20. 01.2002 440.4 787.3 20. 02.2002 261.1 2317.2
21. 01.2002 690.4 1101.9 21. 02.2002 160.6 1764.8
22. 01.2002 268.9 1277.7 22. 02.2002 161.5 1348.3
23. 01.2002 744.9 1699.1 23. 02.2002 652.6 2350
24. 01.2002 364.9 1744.8 24. 02.2002 315.3 1680.2
25. 01.2002 1142.3 1786.6 25. 02.2002 199.9 1855
26. 01.2002 592.2 1773.7 26. 02.2002 166.3 1865.4
27. 01.2002 296.0 620.7 27. 02.2002 302.2 2868.6
28. 01.2002 697.6 1203.2 28. 02.2002 268.1 2228.5
29. 01.2002 1181.7 1559
30. 01.2002 461.9 1188.8
31.01.2002 1191.3 1598.9
MIX (M) – Morning mixing height in meter
MIX(E) – Evening mixing Height in meter
Terrain characteristics
The core and buffer zone areas are fairly plain in nature except in North Eastern area which
is hilly. No tall buildings, are present and the area is rural in nature.
Richardson & Cruddas (1972) Ltd. IX-3
Application of ISCST 3 for prediction of ground level concentration
Prediction of cumulative ground level concentrations due to emissions from the integrated
steel plant and cement plant have been computed using ISCST3 model.
ISCST 3 model with the following options has been employed to predict the ground level
concentrations due to emissions from the various units of steel production.
• Area being rural, rural dispersion parameters are considered.
• Predictions have been carried out to estimate connection values over a radial
distance of 10 km around the source.
• A total of 1200 receptors with combination of polar and Cartesian receptor network
have been considered.
• Emission rates from all the sources are considered as constant discharge and
magnitude during the entire period.
• Ground level concentration computed is based on without any consideration of
decay coefficient.
• Calm winds recorded during the study period have also been taken into
consideration.
• 24 hourly (for 24 hour mean meteorological data as per guide lines of IMD and MoEF)
mean ground level concentration was estimated for Winter`2007-08.
• An option of creation of data file giving average ground level concentration for the
mean meteorological data of winter season has been used for post processing in
Surfer-6 graphic package.
Basic Input data requirements
The basic data inputs include the run stream set up file and the meteorological data file.
The run stream set up file contains the selected modeling options, source location and
parameter data receptor locations, meteorological data specifications and output options.
The meteorological data file contains the hourly data on wind speed, wind direction,
ambient temperature, atmospheric stability class and mixing height.
Output data
Richardson & Cruddas (1972) Ltd. IX-4
The output may be obtained for short term (hourly, daily or monthly) averages or long term
(annual) averages.
Predicted ground level concentrations
Air Environment in Core zone - Post project Scenario (µg/m3)
24 hourly concentrations Suspended Particulate
matter(SPM) (max)
Sulphur dioxide (SO2) (max)
Oxides of nitrogen (NOX) (max)
Baseline Scenario(max) 176 9 18
Predicted Ground level Concentration(max) 41.3 41.2 25.6
Resultant concentrations 217.3 50.2 43.6
NAAQ standards 500 120 120
Isopleths for SPM, SO2 and NOx are give fig. IV.2 -IV.4.
Air Environment in the study area - Post project Scenario (µg/m3)
Baseline scenario (max) Predicted values Post Project
scenario NAAQ standards S. No. Location name
SPM SO2 NOx SPM SO2 NOx SPM SO2 NOx SPM SO2 NOx
1 Existing Plant (A2) 186 16 30 24.5 31.6 28.2 210.5 47.6 58.2 500 120 120
2 Dhanapura (A3) 146 7 10 23.1 28.4 26.1 169.1 35.4 36.1 200 80 80
3 Marimanhalli (A4) 145 8 18 21.0 12.6 12.5 166.0 20.6 30.5 200 80 80
4 Nagalapura (A5) 132 7 12 9.2 21.2 11.8 141.2 28.2 23.8 200 80 80
5 Mugimavinahalli (A6) 146 8 18 3.8 6.8 1.2 149.8 14.8 19.2 200 80 80
6 Haravanahalli (A7) 115 7 10 4.8 8.9 1.8 119.8 15.9 11.8 200 80 80
7 Ramgad (A8) 132 8 16 3.9 2.1 0.8 135.9 10.1 16.8 200 80 80
8 Medarahalli (A9) 134 8 14 4.9 1.3 0.4 138.9 9.3 14.4 200 80 80
9 Vysankari (A10) 112 7 12 3.6 2.4 1.4 115.6 9.4 13.4 200 80 80
Richardson & Cruddas (1972) Ltd. IX-5
Fig. IV.2
Richardson & Cruddas (1972) Ltd. IX-6
FIG. IV.3
Richardson & Cruddas (1972) Ltd. IX-7
FIG. IV.4
Richardson & Cruddas (1972) Ltd. IX-8
Impact on Water
The total make-up water requirement for proposed steel plant complex will be met by
augmenting the water from the down stream of TB Dam/Almathi dam by a pipeline. It is
proposed to build a separate reservoir to meet the requirements of the various uses. The
proposed plant will also draw ground water for steel plant operations. Thus operation of the
plant will not affect ground water availability in the study area.
The effluents likely to be generated from the following sources:
1. Wastewater generated from hot rolling mills.
2. Waste water from the run-off from Raw Material Storage Yards
3. Waste water from the soft / DM plant
4. Sanitary wastewater from canteens and toilets.
5. Blow-downs from ICW and DCW circuits
6. Backwash from side stream pressure filters of cooling towers
EAC water from GCP`s : The wastewater collected from the individual GCPs are
treated in respective clarifiers, where the solids are removed by addition of water
treatment chemicals. The clarified water is recycled back into the system. The
slurry collected at the bottom of the clarifier is pumped to the pellet plant.
However, due to continuous and repeated use of recycled water, the solid
concentration in the recycled water will increase needing periodic blow down. The
blow down water will be led to an effluent storage pond for further treatment and
will be recirculated.
Rolling mills: The water used in hot steel cooling operations gets contaminated with scales
and oil. The metallic scales are separated from the re- circulating water in scale pits. The
solids free water is passed through pressure filters for removal of residual solids. The
treated water after the filters are recirculated in the process. The wastewater collected
from the backwash of the pressure filter is further treated in a thickener for recovery of
water, which is led back to the system. The slurry is led to the pellet plant. However, due
to continuous and repeated use of recycled water, the solid concentration in the recycled
water will increase needing periodic blow down. The blow down water will be led to an
effluent storage pond for further treatment.
Run-off from Raw Materials Storage Yards: The wastewater from the run off of the raw
material storage area contains solids, which are led to a settling pond located at the
individual yard. The decanted water is led to the effluent collection pond for further
Richardson & Cruddas (1972) Ltd. IX-9
treatment. The pond gets is dried during non-monsoon seasons and the sludge is used in the
beneficiation plant.
Soft / DM plant: The wastewater from the soft / DM water plant contains acids, alkali
which are treated by neutralization in a tank and the neutralized effluent is led to the
effluent collection pond.
Sanitary waste from canteens and toilets: The wastewater contains organic solids, which
is treated in a centralized sewage treatment plant using a conventional activated sludge
process. The treated water is led to the effluent collection pond.
Blow-downs from ICW and DCW circuits: The blow down from the ICW and DCW circuits
contain dissolved solids and to some extent suspended solids. These are led directly to the
guard pond.
Backwash from side stream filters: The backwash from the side stream filters contains
large amount of solids. The slurry collected from the backwash is fed to the nearby gas
cleaning pant circuits for separation of water and solids.
Effluent collection pond: As can be seen, the effluent collection pond collects partially
treated wastewater from all the above units. Seven days storage guard pond will be
provided to avoid excess water discharge during rainy season. The influent water contains
suspended solids and dissolved solids. The water is used for gardening and dust suppression.
The sources of discharge from the proposed steel plant and the control measures to be
adopted are given in Table 4.4.
Table – 4.4 List of Water Pollution Control Systems
Sl. No.
Source Pollutants Control system / Treatment
1. Raw material handling yard SS Catch pits followed
2 Raw Water Treatment plant
SS, Colloidal matter, Dissolved gases, micro-organism
Chemical coagulation with sedimentation and filtration
3. Beneficiation Plant Hydrocyclones, Thickneres, slim pond
4. Pellet Plant Collection sump, guard pond
5. Sponge Iron Plant Collection tank & Ash handling dust suppression
6 DM Plant pH Neutralization pit 7 Steel Melting shop SS Guard pond
8 CCM Suspended Solids, Oil & Grease
Settling Tanks fitted with Oil & Grease Trap
9 Calcination & Oxygen plant SS, Alkalinity Settling with Guard pond 10 Rolling Mills SS, Oil & Grease , Settling Tanks fitted with
Richardson & Cruddas (1972) Ltd. IX-10
Sl. No.
Source Pollutants Control system / Treatment
mill scale Oil & Grease Trap
12 Captive Power Plant Direct use in ash handling & excess to guard pond
Cooling Tower & Boiler bow down
Temperature, Dissolved Solids
Reused in the plant for dust suppression and slag
granulation
13 Sewage Treatment system BOD, Suspended Solids Sewage treatment plant
Impact on Noise Levels
During normal operations of the plant, ambient noise levels will increase significantly only
close to the compressors and blowers and other plant operations. But this will be confined
only within plant boundary. The noise level within the plant boundary will be confined
within shops. The level will be further minimized when the noise reaches the plant
boundary and the nearest residential areas beyond the plant boundary, as elaborate green
belt development is envisaged for attenuation of noise and fugitive emissions. The noise
production in various units of the steel production plant are as presented below.
Noise Levels in various units of the steel making Plant
S.No. Source Noise Level dB(A) 1 Sponge Iron Plant
In front of Rotary Kiln & Cooler 70-82 Near Crusher and Screen 75-78 Near Bag filters 79-80 Near Main gate 65-68
2 Mini Blast Furnace Plant 75-80 3 Sintering plant (Phase II) 70-75 4 Pelletization plant 70-75 5 EAF & LF Plant 75 –80 6 Billet Casting machine section 75-80 7 Rolling mill section 85 8 Material Handling 70 –75 9 Material charging and conveying 75-78 10 Compressors 80 11 Pumps 75-80 12 ID Fans 85
All the equipment in the blast furnace complex will be designed/operated in such away that
the noise level shall not exceed 80 dB (A).
Richardson & Cruddas (1972) Ltd. IX-11
However, if during operation, the noise level exceeds the above norms then the protective
measures given in Environmental Management Plan will be followed. Hence, no impact due
to proposed plant on ambient noise is anticipated.
Noise Dispersion Model
For the purpose of Noise modeling, the plant is considered as one source. Hence, total
Noise will be equal to 80 - 87 dB(A). The dispersion of this noise is computed by using the
model
LP2 = LP1 – 20 log10 (r2/ r1)
Where LP2 and LP1 are Sound Pressure Levels at points located at distances r2 and r1 from
the source. The combined effect of all the sources then can be determined at various
locations by the following equation.
LP (total) = 10 log (10Lp1/10 + 10 LP2/10 + 10 LP3/10 ---------)
Where LP1, LP2, LP3 etc. are Noise levels at a point due to different sources.
Based on the above equation, a user-friendly model has been developed. The details of the
model are as follows.
Noise level can be predicted at any distance specified from the source
Model is designed to take topography or flat terrain
Co-ordinates of the sources in meters
Output of the model in the form of isopleths and
Environmental attention factors and machine corrections are made for the
measured Leq. Levels
Input to the Model
Major noise sources as Cumulative noise source has been identified and monitored in similar
type of proposed plants. The input to the model has been taken as the cumulative noise of
12 major noise generating sources in the plant. The resulting noise from the cumulative
source is taken as 87.8 dB(A).
Richardson & Cruddas (1972) Ltd. IX-12
Noise Impact analysis on surrounding community
There will not be any noise impact on surrounding village residents by the proposed Steel
production plant.
Impact on traffic density
To quantify the impact of the proposed steel plant at Danapura and its allied activities on
traffic, it is necessary at first to evaluate the existing load of heavy vehicular traffic at the
site. Proposed site is connected with a bitumen road of two lane from the highway (Hospet,
Bellary) at a distance of 2.6 km. As the site has quite significant traffic density, monitoring
was carried out in January 2008 for 4 days indicate that the traffic density in the Highway
range 300 to 350 vehicles per hour.
The mode of transportation of Raw Material required and Products and Byproduct generated
by rail and road due to the proposed project is given in the below table:
Quantity transported, t/yr Material By rail By road
Raw materials
Low grade iron ore fines 4,400,000 ---
Bentonite --- 8,400
Non coking coal 1,243,000 ---
Coking coal 924,000 ---
Limestone 526,000 ---
Dolomite 342,000 ---
Quartzite 125,000 ---
Clinker 726,000 ---
Gypsum --- 42,000
Rolled products 1,600,000 400,000
Portland slag cement 1,000,000 400,000
Cold pig iron --- 14,000
DRI --- 74,000
Coke breeze --- 22,000
TOTAL (Raw material & Products) 10886000
(~ 92%) 960400 (~ 8%)
From the above table, it is understood that the traffic density by road is insignificant as
major transportation of raw material and products is by rail. The construction and
operational Phases of the proposed plants is likely to increase the traffic density on
Highway and on the road leading to the plant from Highway.
Richardson & Cruddas (1972) Ltd. IX-13
The railway loading/unloading station is very nearer to the project site and the major
commodities of raw materials and finished products are planned to be transported by rail.
The transportation by rail is having more economical and environmental benefits and hence
no alternative method of transportation is planned.
Impact on Ecology
Ecological Impact of the proposed industry in the area is discussed under following sub
heads.
Aquatic
The important perennial water body is TB dam 5.0 Km away. As the plant is being designed
for maximum recirculation, with “zero discharge” concept no effluent will be discharged
outside.
The domestic and plant sanitary water is also proposed to be treated and used for
gardening purposes. Hence no adverse impact on aquatic bodies are anticipated.
Terrestrial
Air pollutants released by the steel making plant found to be well within the prescribed
standards and no significant impact on terrestrial flora is expected.
Solid Waste Generation
The major solid waste expected to be generated from the various facilities of integrated
steel plant are given in Table 4.5.
Table 4.5 Quantity of Solid Waste Generated and re-used in the Steel Plant
Sl. No. Solid Waste Nature of
Solid Waste Quantity
(tonnes/day) Probable Reuse
PELLET PLANT
1. Dust from ESP Dust 220.0 sintering plant
DRI PLANT
1. Dust Settling Chamber Sludge 20.0 Sintering plant
2. De-dusting System Dust 48.0 cement plant
4. Product Separator System (Char) Fines 684.0 captive power
plant
5. Heat Exchanger and ESP Dust with fly ash 215.0 cement plant
Richardson & Cruddas (1972) Ltd. IX-14
SINTERING PLANT
1. Sinter Dust Solid 113.0 Sintering plant
BLAST FURNACE
1. Sinter BF return Sinter 178.0 sinter plant 2. BF Slag Slag 1766.0 cement plant
STEEL MELTING SHOP
1. Slag Slag 732.0 control landfill
2. Flume dust from bagfilter dust 415.0 sintering plant
COTINUOUS CASTING MACHINE 1. Scale & Muck Scales 110.0 sintering plant
2. Scrap - 266.0 within the steel plant
ROLLING MILLS
1. Scrap Scrap 211.0 within the steel plant
2. Scale & Muck Scale 211.0 sintering plant
3. Oil and Grease Traps Oil and Grease 0.3
sold to authorised
vendors
4. Reheat Furnace Broken Refractories - Land filling
COKE OVEN PLANT 1. Coke breeze Dust 465 coke oven plant 3. Dust from bag filters Dust 31.0 cement plant
CAPTIVE POWER PLANT
1. Ash including fly ash Dust 316.0
2. Bottom ash Dust 80.0
cement mfg brick mfg/ road
construction
CEMENT PLANT
1. Dust from EAP Dust 38.0 Cement plant
Oil Soaked cotton waste, organic wastes Incinereated and control landfilling
Lead acid batteries sold to authorised vendors
Richardson & Cruddas (1972) Ltd. IX-15
Socio– Economic Impact
• The project is not going to cause significant damage to the existing agricultural
situation. Instead, it is likely to provide the farmers with supplementary income.
• The project has very strong positive employment and income effects.
• There is a great possibility of industrialization in the vicinity of the proposed steel
plant. This is likely to bring dramatic changes by transforming this backward area
into an industrially developed one.
• The project has very strong positive impact, which is likely to result in the
improvement of economic situation of Hospet
• Overall peoples’ perception on the expansion project is a mix of advantages and
disadvantages. On one hand, they expect job opportunities, market expansion etc.
as advantages and on the other hand they are worried about the damage to
agriculture.
• As an impact of identification of the project, small-scale industrial economy is likely
to flourish in the surrounding area. The small-scale industrial units are expected to
get financial supports from the financial institutions and banks. In this way, an
overall development may take place in this area.
• The process of development will have maximum impact on the lifestyle of the local
people. The project and the consequent peripheral industrial economy will generate
income to the local and migrated people which will increase the aggregate demand.
This demand will get realized in the market and finally, lead to the market
expansion in the locality of the project. Market expansion supported by expected
infrastructural developments like roads, electricity, water supply etc. will result in
improving the economic development in the entire region.
Richardson & Cruddas (1972) Ltd. IX-16
CHAPTER V
ENVIRONMENTAL MONITORING PROGRAMME
5.1 Preamble
Several measures have been suggested in the Environment Management Plan (EMP) for mitigation of identified adverse environmental impacts. These have to be implemented to ensure compliance with the environmental regulation and also to maintain a healthy environmental conditions in and around the steel plant.
A monitoring strategy is required to ensure that all environmental resources which may
be subject to contamination are kept under review and hence monitoring of the
individual elements of the environment is necessary. The Environment Management
Department (EMD) of BMM will be entrusted with this responsibility. The officers of EMD
will assess the progress and analyze the data periodically.
In addition to the above, the unit will take all necessary steps to implement the
measures suggested in the Charter on Corporate Responsibility for Environmental
Protection (CREP) for Integrated Iron and Steel Industry. Some of the measures have
already been included in the plant design. The others will include:
• Direct injection of reducing agents for examples, pulverized coal into the Blast
Furnaces.
• 100% utilisation of Blast Furnace and Steel Melting Slag.
• Hazardous wastes to be handled and disposed of strictly in accordance with the
Hazardous Wastes (Management and Handling) Rules, 2003.
• Specific water consumption to be brought down to less than 8 m3/ton of crude
steel.
• Promotion of Energy Optimization Technology including periodic energy audits.
Richardson & Cruddas (1972) Ltd. IX-17
5.2 Meteorological Station
It is necessary to monitor the meteorological parameters regularly for assessment and
interpretation of air quality data. The continuous monitoring will also help in
emergency planning and disaster management. BMM will install a designated weather
station for this purpose and the following data will be recorded and archived.
• Wind speed and direction
• Rainfall
• Temperature and humidity
5.3 Emissions and Air Quality
On-line continuous monitoring system will be installed in major stacks to monitor
particulate matter and gaseous emission. In case emissions are found to exceed the
norms, the on duty personnel will check the relevant process parameters and take
appropriate corrective action.
BMM ISPAT Ltd will monitor the ambient air quality regularly in 5 locations in and around the plant (downwind direction and where Max. GLC of SPM, SO2 & NOx) to ascertain the effect of process emissions on the ambient air quality. BMM will establish 2 continuous particulate matter monitoring stations. The locations will be identified in consultation with KSPCB. The equipment will have facilities to monitor both SPM, RPM, SO2 and NOx.
5.4 Water Quality
Surface and ground water will be sampled regularly once in a season from various locations in and around proposed plant to ascertain the trend of variation in the water quality, if any. Treated process wastewater quantity will also be monitored for pH, TSS, COD and Oil & Grease regularly. The metallic constituents in the untreated effluent will be ascertained once a month through recognized laboratory of KSPCB/CPCB .
5.5 Drainage System
The effectiveness of the drainage system depends on proper maintenance of all
drainage pipes/channels. Regular cleaning of drains will be done to remove
accumulated sludge/sediments. The catch-pits linked to the storm water drainage
system from the raw material handling areas will also be regularly cleaned to ensure
their effectiveness. This exercise will be carried out during the pre monsoon and at
regular intervals.
5.6 Noise Levels
Richardson & Cruddas (1972) Ltd. IX-18
Noise levels will be measured at the source of generation on quarterly basis- It is
desirable that the noise attenuation measures are taken at the design stage of the plant
itself. However, in case of high noise generating equipment which are not frequented
by the plant personnel, the area may be cleanly marked as `High Noise" area and the
employees be provided with personal protective equipment like ear plugs/ear muffs.
5.7 Occupational Health
Occupational health surveillance of the workers will be done on regular basis especially
for those to be engaged in handling hazardous substances and high noise generating
equipment and process area.
5.8 Biological Monitoring
A massive tree plantation will be taken up along the boundary of the plant leading to a
favorable impact on the surrounding environment. BMM will continue to improve the
green cover in the area by planting trees in the open area. Trees survival rate will be
monitored in the plantation areas and will be maintained at about 80% by replacement
of dead trees.
5.9 Socio-Economic Development
BMM ISPAT Ltd. will undertake various social welfare programmes for upliftment of
surrounding villages. The community which is benefited by BMM ISPAT Ltd. are thus one
of the key stake holders for steel plant. The BMM ISPAT Ltd. will have structured
interactions with the plant surrounding villages people to disseminate the measures
taken by the BMM ISPAT Ltd and also to elicit suggestions for overall improvement of
the surrounding villages.
5.10 Housekeeping
The EMD shall be keeping a very close monitoring of house keeping activities and
organizing regular meetings of joint forum at the shop level (monthly), zonal level
(once in two months) and apex level (quarterly). The CED (Civil Engineering
Department) shall take care for the house keeping of shops.
5.11 Interaction with State Pollution Control Board (SPCB)
Richardson & Cruddas (1972) Ltd. IX-19
EMD shall be in regular touch with KSPCB & MoEF and send them quarterly progress
report on EMP. Any new regulations considered by State/Central Pollution Control
Board for the Industry will be taken care of.
5.10 Laboratory facilities
It is imperative to BMM to have a well-equipped environmental control laboratory inside
the plant premises. The Environmental control laboratory shall apply for recognition as
per EP Act 1986 and notified in Government of India Gazette. The laboratory shall be
running continuously 24 hours in three-shift operation and will be carrying out all
monitoring as specified in their Consent and EC condition.
All the personnel deployed in the laboratory will be given training by external experts
so as to carry out necessary environmental monitoring as well as analysis. The
equipment to be made available for carrying out environmental monitoring is given in
Table 5.1.
Richardson & Cruddas (1972) Ltd. IX-20
Table 5.1 List of Monitoring / Analytical Equipments
Sl. No. Item Quantity
1 Respirable Dust Sampler 4
2 Stack Monitoring Kit 2
3 HVS Flow Calibrator 2
4 PM-10 HVS 2
5 Dry Gas Meter 2
6 Analytical Balance 1
7 Digital Balance 1
8 Personal Sampler 1
9 Nephelo Turbidity meter 2
10 DR-2000 Spectrophoto Meter 2
11 COD Reactor 2
12 Portable Dissolved Oxygen Meter 2
13 PDV-2000 Digital Voltameter 1
14 Selective Ion Meter 1
15 Composite Sampler 2
16 Visible Spectro Meter 1
17 BOD Analyser 1
18 BOD Incubator 1
19 Ultrasonic Flow Meter 4
20 Vaccum Pump 1
21 Drying Oven 2
22 Ultrasonic Cleaner 1
23 Adjustable Digital Pipettes 1
24 Spectrophotometer 1
25 Digital Multimeter 1
26 D.O Meter 1
27 Hot Plate 1
28 Muffle Furnace 1
29 Digital Conductivity meter 1
30 Sound Level Meter with calibrator & Octave Pilter Set 1
31 Electronic Balance 1
32 On-line ambient air monitoring station 2
33 On-line stack monitoring of major stack 10
34 weather monitoring station 1
Richardson & Cruddas (1972) Ltd. IX-21
5.11 Frequency of monitoring of pollution sources
Regular monitoring in a systematic and standardized manner helps in assessment of
current environment and provides information on operational performance of installed
pollution control facility.
Sl. No. Place of Monitoring Parameters of Pollution Frequency of Monitors
1. Stack emission Temperature, Velocity, Gas discharge, SPM, NOx and SO2
To be carried once in a month
2. Ambient air quality at plant boundary and nearby habitation
SPM, NOx, SO2 and RSPM Weekly twice at 6 locations and continuously at 2 locations
3.
Monitoring of Surface and ground water quality surrounding areas of dumping site
As per IS:10500 norms To be carried once in 3 months ( Seasonal )
4.
Noise monitoring near kilns, product house, raw material yard power plant and plant boundary
Leq dB(A)
Workzone noise levels once in a month Ambient noise levels once in 3 months
5. Effluent outlets pH, SS, Phenol, COD, BOD, DO, NH3-N, Temperature, Oil and grease
once in a week
Note : The monitoring will be carried out as per EC & Consent conditions and in consultation with KSPB
5.12 Cost Profiles of Pollution Control Measures
Cost of Project
Particulars Amount (Rs. in Lakhs)
Land & Site Development 200.0
Buildings 326.9
Plant & Machinery 3269.0
Engineernig Services 326.9
Preliminary and Preoperative expenses including interest during construction 375.8
Contingency 610.5
Margin money for working capital 206.9
Power Plant` 85.3
Total Project Cost 6151.3
Mode of Finance Rate of interest
Richardson & Cruddas (1972) Ltd. IX-22
Borrowing for working capital 14%
Term Loan 13%
5.13 Cost of Pollution Control/ Environmental protection Measures
Area of Expenditure Recurring cost per
annum (Rs. in Crores)
Capital Cost (Rs. in Crores)
Air Pollution Control 10.0 200.0
Water Treatment System 10.0 50.0
Waste Water Treatment System 3.0 30.0
Solid Waste Management System 5.0 50.0
Noise Pollution Control 0.50 2.0
Environmental Monitoring and Management
2.50 10.0
Social corporate responsibilities 2.0 10.0
Road diversion/development/Modification
2.0 15.0
Occupational Health 1.50 3.0
Greenbelt Development 5.0 25.0
Others 0.25 2.0
Total 41.75 397.00
Percent of recurring cost in terms of Capital Cost for pollution control measures
10.52 % -
Percent of capital cost of pollution control measures in terms of total project cost
- 6.45 %
CHAPTER VI
Richardson & Cruddas (1972) Ltd. IX-23
ADDITIONAL STUDIES
6.1 Risk Assessment, On-Site Emergency Preparedness & Disaster Management Plan
It is presumed that the proposed facilities in the 2.0 MT/Yr steel bars & rods, 230 MW captive
power generation and 1.4 MT/Yr cement manufacturing at BMM Ispat Ltd. Will be designed and
engineered with all possible safety measures and standard code of practices of engineering. In
spite of this, there may be some design deficiency or due to operation and maintenance faults,
which may lead to accidental events causing damage to life and or property. This Chapter
presents an overview of environmental risks associated with various production facilities,
suggested remedial measures and an outline of the emergency preparedness plan.
Risk Assessment
The objectives of environmental risk assessment are governed by the following, which
excludes natural calamities:
a) To identify the potential hazardous areas so that necessary design safety measures can
be adopted to minimize the probability of accidental events.
b) To identify the potential areas of environmental disaster which can be prevented by
proper design of the installations and its controlled operation.
c) To manage the emergency situation or a disastrous event, if any, from the plant
operation.
Managing a disastrous event will obviously require prompt action by the operators and the
crisis management personnel using all their available resources like alerting the people and
other plant personnel remaining inside, deployment of fire fighting equipment, operation of
emergency shut off valves, opening of the escape doors, rescue etc.
Minimizing the immediate consequences of a hazardous event include cordoning off,
evacuation, medical assistance and giving correct information to the families of the
affected persons and local public for avoiding rumors and panic.
Lastly, an expert committee is required to probe the cause of such events and the losses
encountered, and suggest remedial measures for implementation, so that in future such
events or similar events do not reoccur.
Richardson & Cruddas (1972) Ltd. IX-24
Identification of hazards
The hazards are attributable due to processing of raw materials and chemicals used in
steelmaking and the other plant operations. A list of major raw materials used in the Plant
and the process units with their hazard potential is presented below;
Hazard Identification of the proposed steel plant facilities
Group Item Hazard potential Remarks
Iron ore None -
Coal Moderate Fire
Other fluxing minerals None -
Product steel None -
Acids/Alkalis Major Bio corrosive
Raw materials & Products
Lube oil Moderate Flammable
Iron Ore beneficiation
Iron ore dust Moderate Environmental Pollution
Processing
Sintering/ Pelletization
Dusts Moderate Environmental Pollution
BF gas Major Flammable and CO pollution
Hot Metal Major Personnel injury & fire
Iron making in BFs
Molten Slag Major Personnel injury & fire
EAF / LD gas Major Flammable and CO pollution
Liquid steel Major Personnel injury & fire
Steelmaking in EAF`s
Molten Slag Major Personnel injury & fire
Rolling Mills Gas firing/LDO firing Moderate Fire
Utilities
Liquid Propane Leaks/ vapour cloud Major Fire/explosion
Fuel gas Distribution Gas leaks Major Fire and CO pollution
Electric power Supply
Short circuit Major Fire
Richardson & Cruddas (1972) Ltd. IX-25
Group Item Hazard potential Remarks
Transformer Small Explosion & Fire
Power Plant
Steam turbine
generator
building
Moderate
Fires in Lube oil system, Short circuit in control room / switch gear, cable galleries & oil drum storage
Boilers Moderate Fire / steam explosion
Coal Handling
plant
Moderate
Fire or dust explosion
Coal Storage Moderate Spontaneous combustion
FO/ LDO tank
farms
Major
Fire
Cement Plant Dust Moderate Environmental Pollution
From the above Table, it may be observed that major on-site emergency situation may
occur from the organic coal chemicals storage and handling, fuel gas handling, molten
metal and slag handling, acids and alkali storage / handling and electrical short-circuits.
The off-site environmental disaster may occur if large-scale fire and explosion occurs, the
effect of which extends beyond the plant boundary. The off-site environmental disaster
may occur due to significant environmental degradation prolonged for a sustained period.
HAZOP Study
It is suggested to have HAZOP Study for the fuel gas distribution network handling facilities
prior to commissioning, for last minute corrections in the design of the systems from fail
safe angle. The HAZOP analysis for the gasholder has been carried out for safe operations.
The degree of Hazard is identified based on FEI and TI range as per the criteria given below.
FEI Range Degree of Hazard
0-60 Light
61-96 Moderate
97-127 Moderately High
128-158 Heavy
159 & above Severe
Richardson & Cruddas (1972) Ltd. IX-26
TI Range Degree of Hazard
0 –5 Light
5 –10 Moderate
>10 Severe
Fire and explosion are the likely hazards which may occur due to the fuel storage. Hence F
& EI has been calculated for storage capacities of fuels in the plant and are shown in table
below.
Fire & Explosion and Toxicity Index for storage facilities
Fuel Total quantity of Storage F & EI Category TI Category
FO/ LDO 2x360 m3 8.5 Severe - -
Electrical safety: Adequately rated and quick response circuit breakers, aided by reliable
and selective digital or microprocessor based electro-magnetic protective relays will be
incorporated in the electrical system design for the proposed project. The metering and
instruments will be of proper accuracy class and scale dimensions.
Risk management measures
The risk management measures for the proposed project activities require adoption of best
safety practice at the respective construction zones within the works boundary. In
addition, the design and engineering of the proposed facilities will take into consideration
of the proposed protection measures for air and water environment as outlined in earlier
Chapter. The detailed risk management measures are listed below;
Coal Handling Plant
Coal dust when dispersed in air and ignited will explode. Crusher house and conveyor are
most susceptible to this hazard. The minimum of explosive concentration of coal dust (33%
volatiles) is 50 grams /m3. Failure of dust extraction & suppression systems may lead to
abnormal conditions and increasing the concentration of coal dust to the explosive limits.
The sources of ignition are incandescent bulbs, electric equipment & cables, friction &
spontaneous combustion in accumulated dust. Dust explosion may occur without warning
with maximum explosion pressure upto 6.4 bars. Another dangerous characteristics of dust
explosions is that it sets off secondary after of initial dust explosion. Stack pile area shall
be provided with automatic garden type sprinklers as well as to reduce spontaneous ignition
of coal stocks piles, necessary water distribution net work will be provided for distributing
water at all transfer pints, crusher houses, control room, etc.
Richardson & Cruddas (1972) Ltd. IX-27
A centralized control room with micro-processor based control system has been envisaged
for operation of the coal handling plant. Except locally controlled equipment like traveling
tripper, dust extraction / dust suppression / ventilation equipment, sump pumps, water
distribution / ventilation equipment, sump pumps water distribution system all other in line
equipment will be provided for safe and reliable operation of the coal handling plant.
Control measures for coal yard
The entire quantity of coal will be stored in separate stack piles, with proper drains around
to collect washouts during the monsoon. Water sprinkling system will be installed on stocks
of pile to prevent spontaneous heating combustion and consequent fire hazards. The stack
geometry will be adopted to maintain minimum exposure of stock pile areas towards
predominant wind direction temperature will be monitored in the stock piles regularly to
detect any abnormal rise in temperature inside the stock pile to be enable to control the
same.
Blast Furnace
Preventive Measures
If any job is to be undertaken in BF areas where the BF gas is toxic, the following procedure
has to be laid down to ensure safety of men and the equipment.
a) Gas Safety man will accompany the team and will test the atmosphere for the presence
of CO, before starting the work.
b) If `CO' concentration is found exceeding the safe limit, the job will be undertaken using
necessary safety appliances viz., Oxygen Breathing Apparatus/ Blower type Gas mask.
c) Any gas cutting/welding job will be undertaken with the clearance from Gas Safety
man.
Gas Explosion, Prevention & Preventive Measures
The following actions will be taken to prevent any gas explosions in case of gas leakage.
1. For jobs on gas lines/equipment, non-sparking copper tools will used. If such tools are
not available, grease coated steel tools will be used. Electrical drill & other electrical
equipment will not be used as these can give rise to sparks.
2. The gas line will be thoroughly purged with steam before undertaking the job on the
same.
Richardson & Cruddas (1972) Ltd. IX-28
3. Naked lights will not be used near any de-pressurized gas main or equipment unless the
same has been thoroughly purged.
4. In case of profuse leakage of gas, action will be taken for water sealing and isolating
that portion.
5. The approach road to the gas line complex will be kept free from any obstructions.
6. If gas catches fire due to some leakage, it will be extinguished with plastic clay, steam
or water. The portion of gas main affected will be cooled down with water. The valve
will not be closed when fire is still there and the pressure in the main will be
maintained at minimum 100 mm (WC).
7. Gas tapping points of flow or pressure measurement will be cleaned with wooden stick
or grease coated wire.
8. If lighting is necessary near gas line, portable spark proof electric lamps of low voltage
or explosion proof torchlight will be used for enclosed areas.
Hot Metal & Slag
Sudden break out of molten metal & slag may result in heavy explosions, due to their
coming in contact with water, thereby causing serious burn injuries to persons and damage
to equipment. These breakouts may take place from weak portions of the Hearth, Tuyeres
& monkeys.
Preventive Measures
1. Any accumulation of water will be prevented in such vulnerable areas.
2. In case of minor leakages, the flow of molten metal & slag will be controlled.
3. If there is major breakout, the area will be cut off and cordoned.
4. Vital connections e.g. water, gas, compressed air, oxygen etc. will be cut off or
regulated, as per requirement.
Steel Melting Shop
The main hazards arise out of the use of hot metal and oxygen at the Arc Furnace. The
spillage of hot metal/slag can cause serious burn injuries and fires. Severe explosions are
also caused due to hot metal/slag falling over a pool of water, resulting in injuries to
Richardson & Cruddas (1972) Ltd. IX-29
persons, fire and damage to equipment due to flying of hot splinters & splashing of liquid
metal/slag.
Preventive Measures
1. Any accumulation of water will be prevented in such vulnerable areas.
2. In case of minor leakages, the flow of molten metal & slag will be controlled.
3. If there is major breakout, the area will be cut - off and cordoned.
4. Vital connections e.g. water, gas, compressed air, oxygen etc., will be cut-off or
regulated, as per requirement.
Oxygen plant
The oxygen though not itself flammable, supports combustion and is, therefore hazardous
as any combustible material burns internally in its presence. Any oxygen leakage can also
cause severe burn injuries if it comes in contact with human body. Similarly, the liquid
oxygen, frequently referred to as LOX is liquid at about – 147°C. It is pale blue in color and
is slightly heavier than water. It is classified as a non-flammable gas. However, since it
supports combustion, any organic or inorganic combustible material burns with enhanced
intensity in its presence. Apart from this hazard, liquid oxygen due to low boiling point
when exposed to atmosphere takes away heat from the surrounding to get evaporated. This
results in instant freezing if any contact is made between the human body and this
material.
The protective material worn for fighting emergencies related to liquid oxygen will not be
used near any sources of ignition, as the large volume of gas produced from small amount of
liquid will create an oxygen rich atmosphere.
The part of human body coming in contact with liquid oxygen should be sprayed with
ordinary water and later treated in a similar way to frostbite treatment. For Fire fighting
involving LOX, water is the best extinguishing agent. Water will be sprayed to prevent rapid
boiling and splattering of liquid that may be caused by a straight stream.
Care will also be taken not to direct the water spray on to mechanical relief devices which
will result in freezing of water, rendering the devices in-operative.
Fuel oil Storage & Pipe lines
The fuel oils stored in bulk are L.D.O. & LPG. Main hazard in the storage areas and pipelines
is due to any leakages which may result in serious fire.
Richardson & Cruddas (1972) Ltd. IX-30
Preventive Measures
The storage tanks are constructed and maintained as per the guidelines laid down in the
Petroleum & Carbide Act.
Cable galleries
For container of fire and preventing it from spreading in the cable galleries, unit -wise fire
barriers with self –closing fire resistant doors with minimum fire rating of approximately 90
minutes are planned. The ventilation system provided in the cable galleries will be interlocked
with the fire alarm system so that, in the event of a fire alarm, the ventilation system is
automatically switched off. Also, to avid spreading of fire, all cable entries / opening in cable
galleries, channels, barriers etc., will be sealed with non-flammable / fire resistant sealing
material. Instrument cables will be fire resistant low smoke type.
Transformer Section
This section includes generator transformer, station reserve transformer, unit auxiliary
transformer and switch-gear bays. Temperature rise detectors will be used for detection of
fire for transformers and the lube oil storage area, while automatic type High velocity
Sprinkler Protection System is planned to put out the fires.
On-site Emergency Preparedness Plan
The On-site Emergency Plan relates to the laid-down and well-practiced procedure after
taking care of all design based precautionary measures for risk control. This plan is aimed
for tackling any emergency situation, if arises.
Objective of the Plan
The emergency plan has been prepared to ensure the smooth working of the steel plant
complex. The main objectives of the plan are to take immediate actions to meet any
emergency situation making maximum use of combined in-plant and allied resources for the
most effective, speedy and efficient rescue and relief operations. These are briefly
enumerated below:
1. Cordon and isolate the affected area for smooth rescue operation
2. Rescue and treat casualties and safeguard the rest
3. Minimize damage to persons, property and surroundings
4. Contain and ultimately bring the situation under control
5. Secure and safe rehabilitation of the affected area
Richardson & Cruddas (1972) Ltd. IX-31
6. Provide necessary information to statutory agencies
7. Provide authoritative information to the news media.
8. Ward off unsocial elements and prying onlookers.
9. Counter rumor mongering and panic by relevant accurate information.
Methodology
Keeping in mind the detailed information on the proposed steel plant, the plan is formed on
the following basis:
- Identification of possible hazards in various units and their impact on the surroundings
- Detailed information on the available resources and control measures.Industrial Safety
and Fire Fighting
As detailed above, many working premises of the plant have hazardous and fire-prone
environment. To protect the working personnel and equipment from any damage or loss and
to ensure uninterrupted production, adequate safety and fire fighting measures have been
proposed for the project.
Consequence analysis (Petroleum Class C)
Major Hazard scenario at the tank premises spillage of FO and LDO from pump discharge
nozzles side failure. The main hazard is of forming a pool of fire and toxic effect due to
release of above fuels.
Various scenarios of toxic and thermal radiations impact consequence have been estimated
and summarized based on the models presented in Gele Book or Yellow book published by
TNO, The Netherlands and other Tests.
Above Ground Tank Farm
Pool fire impact distances (m)
4 12.5 37.5
Sl.No Scenario
Stability class
and wind speed
Realease Rate (Kg/s)
Release duration (Sec)
Pool
dia. (m)
IDLH distance (m)
KWm2 KWm2 KWm2
Flash fire
impact distance
(m)
F,1 3.44 2353 37 - 44 23 5 23
1
FO storage tank bottom nozzle failure B,2 3.44 2353 37 - 44 22 5 23
2 LDO pump discharge F,1 3.1 500 - - 34 18 5 5
Richardson & Cruddas (1972) Ltd. IX-32
nozzle failure B,2 3.1 500 - - 42 20 5 5
Fire fighting arrangements
Types of fire extinguishers, its capacity and total numbers proposed in the Integrated Steel
plant of BMM Ispat Ltd are as follows.
S.No. Types of extinguishers Capacity Quantity
1 Dry Chemical Powder 10 Kg each 22.5 Kg each
264 Nos 72 Nos.
2 CO2 extinguisher 9 Kg each 2 Kg each
96 168
3 Water with CO2 catridge 9 litre 48
4 Foam type 50 litre 9 liters
48 72
5 ABC type extinguisher 2 Kgs 2.5 Kgs
24 24
Fire Hydrant system The list of hydrants proposed in the Integrated Steel plant are as follows.
S.No. Items Quantity
1 Hydrants 30 Nos
2 Hydrant Hoses 30 Nos.
3 Hose reel 4 Nos.
4 Fire suit 8 Nos.
5 Fire Pumps 4 Nos.
6 Water monitor 2 No.
7 Foam monitor 2 No.
8 Hose boxes 30 Nos.
9 Fix hose branches 30 Nos
10 Foam making compound 40 litres
11 Siren 2 No.
12 Emergency Stretcher 2 No.
Richardson & Cruddas (1972) Ltd. IX-33
13 Asbestos blanket 2 No.
14 Fire Engines 2 No.
Fire reservoir
Sources of firewater will be from the main water supply line connected to the fresh water
reservoirs.
Safety Plan during Construction & Erection phase
A highly qualified and experienced Safety Officer will be appointed. The responsibilities of the
safety officers include identification of the hazardous conditions and unsafe acts of workers
and advice on corrective actions, conduct safety audit, organize training programmes and
provide professional expert advice on various issues related to occupational safety and health.
In addition to employment of safety officer, every contractor, who employees more than
250 workers, should also employ one safety officer to ensure safety of the workers in
accordance with the conditions of the contract.
Safety of Personnel
All workmen employed in hazardous working conditions will be provided with adequate
personal safety appliance as applicable to the work like;
- Industrial safety boots
- Industrial helmets
- Hand gloves
- Ear muffs
- Welder’s screens and aprons
- Gas masks
- Respirators
- Resuscitators
Fire Protection facilities
Keeping in view the nature of fire and vulnerability of the equipment and the premises, the
following fire protection facilities have been proposed for the plant.
Richardson & Cruddas (1972) Ltd. IX-34
Portable Fire Extinguishers
All plant units, office buildings, stores, laboratories, MCCs etc. will be provided with
adequate number of portable fire extinguishers. The distribution and selection of
extinguishers will be done in accordance with the requirement of fire protection manual of
the Tariff Advisory Committee (TAC).
Hydrant System
Hydrants will be provided in the coal handling plants at suitable locations and in different
levels inside the plant buildings. Yard hydrants will be provided in the vicinity to meet the
additional requirement of water to extinguish fire.
Automatic Fire Detection System
Unattended vulnerable premises like electrical control rooms, cable tunnels, MCC, oil
cellars, etc. will be provided with automatic fire detection and alarm systems.
Manual Call Point Systems
All major units and welfare/administrative building will be provided with manual call points
for summoning the fire fighting crew from the fire station for necessary assistance.
Fire Station
BMM ISPAT LTD is going to provide elaborate arrangements for managing any incidents of
fire. The Fire station is centrally located with adequate communication facilities and
trained manpower. These are adequate for meeting the requirements of the proposed plant
facilities in the 10 MT/Yr stage also. There will be one central fire station with fire tenders
to extend the necessary assistance required for fighting fire in any of the plant units and
associate premises with requisite augmentation. The following equipment will be provided
in fire station/fire posts.
- Water tender
- Foam tender
- Portable pump
- Wireless set
Richardson & Cruddas (1972) Ltd. IX-35
- Hoses
- Hot line telephone, etc.
Plant Disaster Control
The On Site Emergency Plan is prepared considering all the different units of the proposed
steel plant complex.
Organization
A Central Disaster Control Cell will be set up under the direct charge of the Chief Executive
of the project. He will be the person nominated to declare any major emergency and will
be in-charge of all operations in such situations. In his absence, Sr. Vice President (Works)
will be the in-charge. He will be supported by the other nominated members of cell, e.g.,
Senior Manager for Plant operations and service agencies – BF, Coke Oven and by product
plant, SMS & Mill, Personnel, Security, Fire and safety, Administration and Medical Officer.
In case of any major emergency, the Disaster Control Cell would operate from Disaster
Control Room. At the shop level, Senior Managers, have been nominated as Controllers who
will be assisted by Manager, Shift-in-charges and trained key workers to deal with any minor
emergencies arising at the shop.
Information Flow
The following guidelines will be observed by any person after noticing a gas leak, fire, etc.
till help is made available from the Central Disaster Control Cell or Shop level Disaster
Control Cell.
- Raise alarm
- Communicate to the control room about the incident/emergency.
- Communicate to fire station for relief in case telephone is available otherwise try to
attract attention by any available means.
- Attempts to close doors, windows or ventilators of the room to prevent any
contaminated air getting in.
Central Disaster Control Room
Upon receiving information from any site regarding emergency, the person operating from
the Disaster Control room will :
Richardson & Cruddas (1972) Ltd. IX-36
- Depute a person to rush to site and assess the situation.
- Inform fire, transport, safety, medical and concerned control room.
- Organize operating personnel and arrange for control over the situation.
- Keep the management informed about the gravity of the situation from time to time.
- On receiving the call, the Disaster Control room will immediately direct the different
supporting service agencies as enumerated below :
- Security and Administration services : responsible for safety of the plant against
trespassers, saboteurs, any crowd, information to Government authorities and in the
neighborhood (if required), provision of transport facilities, telecommunication facilities
and fire service facilities.
- Safety service: responsible for implementation of safety measures at work place and
occupational safety.
- Medical service: responsible for providing medical care to the injured or the affected in
an event of emergency.
- Stores: responsible for providing adequate number of tools, tackles and accessories for
proper emergency control.
- Preservation of evidence and taking of photographs, if necessary, for future enquiries to
determine the cause and taking further preventive actions.-
- Welfare: Provide food, clothes, shelter etc., as per requirements.
- Power and water supply : To ensure supply of fire fighting water requirement and
provisions of power supply.
Shop Level Disaster Control Cell
The Controller at the shop level will take immediate charge of any emergent situation and
will assume full responsibility regarding mobilisation of resources, guide and help service
agencies in properly carrying out their assigned duties. Being from the operations side of
the plant, he has full knowledge of the process aspects and he will decide whether to stop
the plant/process. He will be responsible for overall co-ordination. In his absence, his
Deputy will be Controller of the operations. The duties of the Shop level Controller are
enumerated below:
Richardson & Cruddas (1972) Ltd. IX-37
- Assess the magnitude of emergency and decide, if any possibility of major emergency
exists and inform the Central Control Room, if necessary.
- Direct Safe close down of plant or any operation, if necessary.
- Direct evacuation of areas in the vicinity, which may be endangered.
- Ensure key personnel are called in immediately and they start carrying out their
assigned duties.
- Direct rescue and fire fighting operations from safe operation point of view.
- Direct the shop personnel to the designated places for safe assembly.
- Control rehabilitation of affected areas and any victim on emergency.
- Ensure complete safety before restarting the plant/ operation.
At Shop floor, teams of workers will be trained, who will be present at the incident site for
doing the needful. They will assist and extend help to the following :
- Fire brigade team in controlling fire.
- Operational staff in shutting down plant to make it safe.
- Search, evacuation, rescue team.
- Movement of vehicles for emergency control.
- Plant pollution monitoring staff for carrying out atmospheric tests.
- Medical team for providing necessary help.
- Any other special operation.
Contingency Plan
It is based on the following considerations:
- The plant general layout.
- The available resources.
- The analysis of hazards.
It is aimed at the
Richardson & Cruddas (1972) Ltd. IX-38
- Pre-emergency activities.
- Emergency time activities.
- Post-emergency activities.
In the event of an emergency, the people from affected pockets will be directed to move to
safe assembly places nearby the units.
The following facilities will be provided.
- Security service
- Fire fighting service
- Medical service
- Pollution control service
- Public relation service
- Telecommunication service
- Transport service
- Evacuation service
- Welfare service
An alarm system will be provided with a wailing type siren at a centralized place and
actuators at the strategic locations in the plant. Adequate number of telephones will be
provided in each unit at Shop floor so that a person can either directly raise the alarm or
ring up disaster control room from where the alarm can be raised directly. The wailing siren
will mark the beginning of the emergency while a continuous note will mark the end
meaning all clear signal.
All fire fighting equipment like valves, fire hydrants, pumps, monitors, etc., will be checked
periodically to detect defective parts and such parts would be immediately replaced. Mock
drills will be conducted for training the persons and to check the performance of men and
equipment and also to keep them fit for any emergency. The plant will be equipped with a
separate Medical Centre with necessary instrument/appliances, medicines and trained
manpower. The Medical Officer will maintain close liaison with different hospital in the
nearby city.
Rescue and Repair Services
The responsibility of effective working of Rescue and Repair Services will be with the
incident controller.
Richardson & Cruddas (1972) Ltd. IX-39
Rescue Services
- To extricate persons from the debris of collapsed building/structure and safe human
lives.
- To hand over the extricated persons to first aid parties.
- To take immediate steps as may be necessary for the temporary supports or demolition
of buildings and structures, the collapse of which is likely to endanger life or obstruct
traffic.
- To cut off supplies of water, gas, electricity to damaged buildings.
Trained Rescue parties will be formed at the Shop levels, who will be provided with the
following equipment:
1. Self contained oxygen breathing apparatus
2. Blower type gas mask
3. Resuscitators
4. Petromax lamp / Torches
5. Axe/hand saw
6. Bamboo ladder
7. Necessary Safety appliances
8. First aid box
9. Blankets
On-site emergency planning rehearsals need to be carried out from time to time. It requires
monitoring by experienced persons from other similar factories or by senior officials from
the State Inspectorate of Factories and/or the Directorate of Fire Services, who can help in
updating the emergency plan procedure.
Off-site emergency planning
Off-site emergency planning is normally under the jurisdiction of the district administration.
The designated official of the Steel Plant is required to have co-ordination with the District
administration for responsive action in off-site emergency planning.
Richardson & Cruddas (1972) Ltd. IX-40
Fire Fighting Organization and Procedure
There will be trained fire fighting personnel and a Fire Officer under the Fire & Safety
Department. The following important instructions will be given for fire prevention and
tackling of any fire in the plant.
- Overall control of the Fire fighting operations will rest with the senior most officer
present at the scene of fire, who will be assisted by the operational and fire staff. Close
co-ordination and planning for fire protection will be done between Plant Operations
and Fire Service.
- While turning out for fire calls, the fire staff will be guided to the correct location
immediately on their arrival.
- In-charge of the section at Shop floor will explain special risks involved and guide the
In-charge of the Fire fighting crew. He will, however, not interfere in the method of fire
fighting operations.
- No one will tamper with the sources of water supply/ fire hydrants or misuse them in
any manner. The passages/approach to/from fire hydrants to the fire appliances will
always be kept clear.
Fire drills will be held in each, zone periodically under the direction of the Fire Officer.
Richardson & Cruddas (1972) Ltd. IX-41
The organization and brief procedure for fighting small, major and simultaneous fire is
given below :
Degree of fire emergency Fire chief Siren code Persons attending
Small fire
Major fire
Simultaneous fire
Functional head in charge of affected area
Head of the production department
In-charge of affected area
No siren
Wailings two minutes
No siren except for major fire
First and second line fire-fighting teams
First, second and third fire-fighting teams
Persons already present at the scene of fire, operators
Definitions :
Small fire : A fire in its incipient stage which is controlled by the first line fire
fighting team.
Major fire : The fire is spreading to other equipment or areas and which
threatens to go beyond the control of first line and second line fire
fighting teams.
Simultaneous fire : More than one fire occurring at the same time.
Fire Control Office: The Fire Control Officer will be in-charge at the scene of fire. In case of
small fire, Section Head / Functional Head of affected area will be
fire Officer.
In major fire, the Head of Production Department will be the Fire Control Officer.
In simultaneous fires, in-charges of the respective affected areas will be the Fire Control
Officers.
Fire call: Fire call will be received at the fire station regarding occurrence of fire and its
location. The message will be conveyed either by telephone or fire alarm or in person.
While giving Fire call message on telephone, the person will
- Give his name, Section & Department.
- Exact location of Fire and if possible, nature of fire.
Richardson & Cruddas (1972) Ltd. IX-42
- Confirm that the Fire call message is repeated by the Control room attendant.
When the call message is given by the Fire alarm, the person will stand rear the Fire alarm
to guide the Fire fighting team to the location of the fire.
Fire Siren Code :
For small fire : No siren will be sounded.
For major fire : Wailing type continuously for two minutes.
For all clear : Straight sound for two signal minutes.
Testing of the Fire Sirens
Fire sirens may be tested by sounding straight for one minute on Wednesday at 9 AM for
cogeneration power plant.
Fire Fighting for Small Fire
The small fire will be tackled by the first line team which will comprise the persons already
present at the scene of fire. However, the second line fire fighting team whose composition
is given below will also report at the scene of fire immediately after receiving the Fire Call
of affected area at the time of fire. The team will consist of the following:
Fire Control Officer
First line Fire Fighting team:
Operational / maintenance staff and/or other plant personnel working in the area.
Second line Fire Fighting team :
- Fire station shift-in-charge and trained fire fighting personnel.
- Ambulance driver with ambulance.
- Functional head of affected area.
- Shift Officer production.
- Security personnel.
Third line Fire Fighting team :
- Fire Officer & Auxiliary Fire Fighting personnel.
- All Departmental & Functional Heads.
- Local Fire Brigade from Govt., if necessary.
Richardson & Cruddas (1972) Ltd. IX-43
Fire Fighting for Major Fire
The major fire will be tackled by the first line, second line and the third line fire fighting
teams. The fire chief in this case is the Head of the Production Department. The fire chief
for small fire will judge the nature of fire and in case of major fire, he will inform Fire
Officer (either himself or through responsible persons) to sound the fire sirens (wailing
type) continuously for two minutes. The team will consist of the following who will
immediately report at the scene of the fire.
1. Fire Officer
2. First, Second and third line Fire Fighting team.
3. Auxiliary Fire Fighting personal
All the members of the auxiliary fire fighting crew will have thorough training on the job.
Responsibilities of Fire Control Room Operator
During fire Call :
- To take correct message regarding location, type of fire etc., from the caller.
- To repeat the message.
- To inform fire fighting personnel on duty immediately for turn out by hearing the bell.
- To ask the pump house operator to maintain adequate head in the fire water line.
- To inform Telephone Exchange.
- To inform first aid centre.
Responsibilities of Fire Fighting Personnel :
- To report immediately at the scene of fire.
- To take instructions from Fire Officer.
Responsibilities of Fire Officer:
- To direct the deployment of Fire fighting personnel and fire fighting appliances.
Richardson & Cruddas (1972) Ltd. IX-44
- To organize additional fire fighting crew, if required, depending upon gravity of the
situation.
- To guide plant employees in fire fighting.
- To co-ordinate between different groups of fire fighting personnel & team of trained
workers from the department.
- To control the spread of fire and rescue operation, if necessary.
- To extinguish the fire.
- To replenish the required fire fighting material/equipment.
- To arrange relievers wherever necessary.
- To assess the situation and arrange additional help if necessary in co-ordination with
Disaster Control room.
- To advice for all clear siren to be blown after the major fire emergency is over.
Responsibilities of Ambulance Driver :
- To report to the scene of fire with ambulance immediately.
- To carry the casualties, if any, to the medical centre as directed by Medical Officer/Fire
Officer at the earliest.
- To park the ambulance without obstructing the fire fighting operations and traffic.
Responsibilities of Security personnel at the manned gate :
- To prevent entry of unauthorized persons.
- To keep the gate open for emergency vehicles and officers and staff concerned with fire
fighting and allied operations.
Responsibilities of Telephone Operator :
- To receive fire call messages.
- To inform Shift Officer for all fires.
Responsibilities of Medical Officer during major fire :
- To be available at the first aid centre for necessary medical advice.
Richardson & Cruddas (1972) Ltd. IX-45
- To depute one of the medical staff to the scene of fire to render any medical assistance, required at site.
Richardson & Cruddas (1972) Ltd. IX-46
Responsibilities of Head of the Personnel and Welfare Department during major fire :
- To arrange the transport of the fire fighting personnel with minimum loss of time in consultation with the Fire Control/Fire Officer.
- To make arrangements for the refreshment/meals for persons engaged in fire fighting.
- To inform the Fire Officer regarding the actions taken.
Responsibilities of Head of the Maintenance Department during major fire:
- To report to the Fire Chief and render all help that may be required from Maintenance
Department.
Responsibilities of Head of the Electrical Maintenance Department during major fire :
- To report to Fire Officer and render assistance to be required from Electrical
Department such as installation of equipment, provision of temporary lighting etc.
Responsibilities of Head of the Materials Procurement Department during major fire :
- To arrange to man the stores for emergency issue of materials. If the materials are not
available in the stores or are likely to be exhausted during fire fighting operations, he will
arrange for the same from other sources.
Cloud Burst / Lighting
Cloud burst/lighting may at times lead to minor to major emergency. In such an emergency,
actions indicated under fire and explosion will be undertaken.
Food Poisoning
In case of food poisoning in plant canteens, the following will be done :
- Disaster Controller will inform the Medical Officer for immediate first aid.
- Medical Officer will contact other hospitals and seek their help, if necessary.
- Security will help in evacuating the affected people to various hospitals, in
co-ordination with the Medical Officer.
Mutual-aid System
At times the possibility of a major emergency (a situation out of control of plant authority)
cannot be ruled out. In such a case, the plant authority will declare it to be a major
emergency and total control will be transferred to the district level office of contingency
plan committee.
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Necessary help will also be sought from the concerned Government agencies having
necessary infrastructure for dealing with disaster.
6.2 Resettlement & Rehabilitation Plan Land use and Land required for the proposed Industry The State Government in its order No.CI/312/SPI/2008 dated 21.10.2008 has permitted the
industry to acquire 1429 hectares of land (3530.70 acres) coming in the jurisdiction of the
following five villages. Out of this land 785.54 hectares are patta land and the balance
643.35 hectares are Government lands. The details are as follows.
Gov. Land Patta Land (Private Land) Total Extent Sl.
No Name of the Village Hectares Hectares Hectares
1 Danapura 38.82 203.72 242.54 2 DN Kere 68.73 212.36 281.09 3 Nagalapura 243.58 25.73 269.31 4 Bylakundi 172.40 6.59 178.99 5 Garaga 119.83 337.13 456.96 Total 643.35 785.54 1428.89
As per the information gathered from Revenue Records the farmers from whom the land will
be purchased on “Consent Basis” have been classified based on their land holdings and
information is summarized in the table given below
Danapura
Nagalapura D.N.Kere Garaga Byalakundi
Area In Acres
Ranges Extent of land Acres
No of land loser
Extent of land Acres
No of land loser
Extent of land Acres
No of land loser
Extent of land Acres
No of land loser
Extent of land Acres
No of land loser
0-1 100.57 218 0.66 1 11.63 20 10.77 31 0 0
1-2 91.51 63 3.40 2 48.86 35 50.99 43 1.8 1
2-3 106.98 44 9.15 4 74.46 32 123.21 51 0 0
3-4 52.74 16 23.74 7 66.96 20 135.98 48 10.04 17
4-5 63.82 14 14.84 3 110.47 25 329.91 83 4.45 2
5-10 84.94 14 11.80 7 37.31 7 69.53 14 0 0
Above 10 0 0 00 00 57.77 1 112.65 12 0 0
TOTAL 500.56 369 63.59 24 407.35 140 833.04 282 16.29 20
TOTAL LAND LOOSERS : 835
Richardson & Cruddas (1972) Ltd. IX-48
It is intended that only dry agriculture land will be purchased from the farmers. No “Village
Tana land” will be purchased. There will not be any displacement of people from their
house hold. There will not be any displacement of people from their respective villages.
Therefore, there will not be any Rehabilitation and Resettlement of any Agriculturist or
Landless laborers.
Recruitment in the Existing Industry.
BMM Ispat Pvt Ltd and its sister concern M/s HKT Mining Pvt Ltd., are the two existing units
in operation at Danapura. The company is always willing to honour the Government
Direction to comply with the Saroojini Mahishi report regarding providing jobs for the local
people. Right from the beginning the policy followed by the company is to give preference
to Kannadigas in general and local people in particular. These two companies have
presently recruited above 882 people in all caders and out of this, 660 people are from
Karnataka which works out to 75% of the total employment. It is further to be observed that
57% of staff about 506 people are from Bellary District and balance 18% are from Karnataka
State. Only 222 people which is 25% of the total strength are from out side the State.
It is further to be noted that the company has been providing jobs to persons who have sold
their land for the industry. We have recruited 147 persons who have sold their lands to the
company. This is one of the requirements of Dr. Saroojini Mahishi committee report and we
have been honouring the said requirement.
It will be our endeavor to follow the Dr. Sarojini Mahishi report to the maximum extent
regarding recruiting kannadigas and giving employment to one member of the family who
sell the land to the company for our proposed 2 MT/Yr Integrated Steel Plant.
Diversion of inter connecting village roads passing through the Project area
Following village connecting roads are passing through the proposed project area.
1. Danapur – Garaga Tanda
2. DN Kerre – Garaga Tanda
3. Mariammanahalli – Garaga Tanda
4. Nagalapura – Garaga village
The above village roads need to be diverted to provide connectivity to the road users. The
project proponent is willing to undertake diversion of these roads at his cost in consultation
with concerned village elected representatives. The project proponent is making adequate
budget provision for diversion of these roads.
Richardson & Cruddas (1972) Ltd. IX-49
Main features of R&R Policy
With the main object of establishing harmonious and continued relationships with Land
owners, the project proponents will be offering a lucrative package with a human face to
all such farmers who will be willing to offer their land for sale on “Consent Basis”.
The project proponents will ensure that special care is taken for protecting the Rights of
weaker section of society especially members of Schedule Caste and Schedule Tribes.
Though there is no displacement of any farmer or landless laborer from their Habitation
and yet the proponent is willing to adopt a benevolent farmer friendly
Rehabilitation and Resettlement Policy and is willing to discharge its social
responsibility to benefit the surrounding villages. The features of such a policy may
include the following.
1. The recommendations of Sarojini Mahishi committee report will be adopted in the
recruitment of staffs.
2. As far as possible the recommendations of the National Rehabilitation and Resettlement
policy 2007 pronounced by Government of India will be adopted.
3. The Proponent is willing to provide one job either to the Khatedar who has
sold the land to the company or to one member of his family to be identified by
the Khatedar, commensurate with his or her education qualification, age and
suitability for the job.
If needed, the proponent is willing to deploy to the extent of man power
required for the development of the green belt each year, the services of
landless labourers and farmers belonging to the above 5 villages in this program.
In addition to a benevolent rehabilitation policy, the proponent is likely to carry out the
following social responsibilities.
i. The company may adopt few villages located in the Study Area.
ii. The company will improve the drinking water supply, street light and maintain
them.
iii. The company will provide adequate drainage & sanitation facility to these villages
and plant trees in the village limits & develop green belt around the villages.
Richardson & Cruddas (1972) Ltd. IX-50
iv. The company will build additional rooms to the existing schools wherever it is
needed, provide drinking water and adequate sanitation facilities in these schools.
v. The company will extend financial help in providing Mid-day meal to school going
children.
vi. The company through their hospital will extend medical facilities to such villages.
vii. Widows and unmarried daughters of the land loosers from these villages will be
trained in tailoring and sewing machines will be supplied to each one of them.
viii. If the village authorities desire, the company will be willing to take up maintenance
of the water body (Tank) of these villages.
Financial Outlay
To meet the above social obligations, the proponent is willing to make the required
budget provision for capital as well as Operation & Maintenance expenses every year. The
total capital cost allotted for the socio economic development is 25.00 crores and
recurring cost assumed to be 4.0 crores per annum.
CHAPTER VII
PROJECT BENEFITS
7.1 Following aspects of State Industrial & Mining Policy favours the
establishment of the proposed project
• Government accords highest priority to the objectives of dispersal of
industrial investments in various backward regions / districts of the State so
that the fruits of economic development and employment opportunities are
Richardson & Cruddas (1972) Ltd. IX-51
shared by all segments of society and in all parts of the state in as equitable
manner as possible.
• To focus on strengthening of the manufacturing industry in the state and to
increase its percentage share in the GSDP from the present average of
16.70% to over 20% by the end of the policy period.
• Special incentives for entrepreneurs setting up units in backward areas.
Additional incentives for units promoted by entrepreneurs from the category
of SC/ST, Minority, Women, Physically challenged & Ex-servicemen.
• Industrial Corridor / Cluster development would be taken up in potential
locations viz. (i) Bangalore – Mysore (ii) Hospet – Bellary (iii) Mangalore –
Upipi (vi) Bhadravathi – Shimoga (vii) Nelamangala – Kunigal (viii) Davanagere
– Harihar (ix) Kolar – KGF etc.
• Bulk of Iron Ore Resources are in Bellary/Hospet area.
• State has declared Bellary – Koppal area as “Steel Belt”.
• To maximize value addition to the mineral extracted, the state is
encouraging maximum investments in down stream industries.
• Priority will be given to the entrepreneurs who propose establishment of
industries for value addition with in the vicinity of the mineral bearing areas.
• To promote indigenous utilisation of Iron Ore fines and Beneficiation of low
grade ore.
• Encourages existing / new industries to set up facilities to use available raw
material & enhance quality up to the required specifications by the
processes like. Beneficiation, Pelletization and Sintering.
• Stand alone industry is to be encouraged as it provides large scale
employments. Such industries enhance value to the raw material by
converting a resource into a product and spawn auxiliary industries.
7.2 Employment and income effects
Richardson & Cruddas (1972) Ltd. IX-52
Employment and income generation are the most important aspects that need
detailed investigation in case of any industrial project. The present project has
some positive employment and income effect. A sizable number of local persons
are likely to be involved in different activities of the plant. For execution of the
project, a large number of people will be required directly and indirectly. This
will create a huge employment and income effect on the socio-economy of the
study area. So far indirect employment is concerned, the effect is very strong
and widespread. The project is expected to generate indirect employment and
income which is 4-5 times higher than the direct employment.
In view of this, it can be justifiably concluded that the present project will have
tremendous positive employment and income effects. The manpower required
for the proposed integrated steel plant, cement plant and Captive power plant
are indicated below
S.No Category Nos.
1 Managerial 340
2 Supervisory 1070
3 Skilled 2680
4 Unskilled 510
Total 4600
In addition to the above, the operation of the steel plant, itself will generate
revenues to the State and Central governments. Some of the potential economic
benefits likely to be accrued from the project are as follows:
• Earnings by the Govt. by way of taxes levies and duties like ED, IT, VAT,
TDS etc
• Business opportunities for the local entrepreneurs to set up small and
medium scale industries
• Business opportunities for the local entrepreneurs serving as service
providers, suppliers, contractors
• Investment opportunity for local infrastructure development
Richardson & Cruddas (1972) Ltd. IX-53
Thus, the steel plant will facilitate in catalyzing the development of
infrastructure, health care, upliftment of civic amenities, education for
economic upliftment of the locals and improvement in their living standards.
7.3 Industrialization around the steel plant
Steel plants by nature serve as the nuclei for development of small-scale
industries in the areas around them. These small-scale units usually have
input-output linkages with the steel plants. The demand for spares, assemblies
and sub-assemblies by steel plants are generally met through the supply (of
these items) from small-scale units located nearly. The small-scale units, in
turn, get necessary steel products from the steel plants. In the vicinity of major
Indian steel plants e.g. Rourkela Steel Plant, TISCO, Bhilai Steel Plant etc.
similar type of small-scale industries are visible. This brings forth mutual
advantages with one acting as complementary to another. The advantages to
steel plants as well as small scale units are listed below :
Richardson & Cruddas (1972) Ltd. IX-54
Advantages to steel plant
i) Assurance of a reliable source of supply of spares and consumables;
ii) Supply on short-delivery schedules enabling maintenance of lower inventory;
iii) Saving foreign exchange through import substitution;
iv) Lower freight element in comparison to materials supplied by firm located far away;
v) Better service facilities
Advantages to small scale units
i) Availability of ready market;
ii) Availability of raw material source for steel / by-product consuming industries;
iii) Getting price preference over distant suppliers;
iv) Availability of facilities from government;
v) Availability of infrastructure support from the steel plant
Proper utilization of these mutual advantages is expected to play a catalytic
role in the development of the region where the present project is proposed to
be implemented.
The small scale industries that are likely to come up in the vicinity of the steel
plant can be grouped into two i.e - spares, metal based. These will be
complemented by the service units.
The proposed project is expected to serve as centre of significant small-scale
industrial economy around it complemented by the services sector. This is
expected to play a major role in the future economic and social development of
this area.
Richardson & Cruddas (1972) Ltd. IX-55
7.2 Improvement In The Physical Infrastructure
Road
Improvement and extension of the existing network is, essential to
develop remote areas, better connection between the economic centers of
state, and also cross-border transport and for personal mobility of the masses.
Rail Network
Railways provided an important mode of transportation in the public
sector spreading over the entire country. It contributes to the country’s
economic development by catering to the needs of large-scale movement of
freight as well as passenger traffic and is a major source of promoting
integration among the masses. Railway provides transport facility to people and
handles freight above 600 million tons annually. The Indian railway is intended
to modernize the vast railway network, keeping both the economic and social
dimensions in mind.
Other Tangible Benefits
The other tangible benefits will be in the form of plant township hospital and
schooling facilities which will also help local population to enjoy the fruit of
better facilities in nearby. BMM Ispat Ltd also will undertake various community
welfare measures for up liftment of plant surrounding villages. These measures
include:
• Encouraging female education
• Encouraging entrepreneurship among locals Vocational training
• Upgrading one/ two primary school buildings and play grounds.
• Adoption of few villages for infrastructure development (Sanitation,
water supply, education, primary health)
• Construction of bus shelters.
• Health camps and eye camps.
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• Improvement of road network in the nearby villages
• Traffic islands, wherever required in Bellary / project surroundings
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CHAPTER VIII ENVIRONMENTAL IMPACT STATEMENT After collection of base line data, subsequent identification, prediction and
evaluation of impacts, EIS has been delineated for five basic environmental
components that are likely to be affected or benefited due to the proposed 2
MT/Yr steel plant, 1.4 MT/Yr and 230 MW captive power plant and its allied
activities near Danapura village, Bellary District, Karnataka state. For proper
assessment of environmental changes in the coming years, impacts predicted
due to proposed industry are presented for each environmental parameter in
table 8.1. Impact check list for plant construction and operation phases are
presented in table 8.2 and 8.3. The environmental impact matrix is presented in
table 8.4. which classifies the environmental parameters listed under impact
statement and check lists into different heads. Likely beneficial impact is
indicated by positive sign, likely harmful impact is indicated by negative sign.
EIS has been furnished for the following;
I. Air Environment
II. Water Environment
III. Noise Environment
IV. Land and Biological Environment
V. Socio Economic Environment
Richardson & Cruddas (1972) Ltd. IX-58
TABLE 8.1 COMPARATIVE CHART OF VARIOUS IMPACTS
Component Impact Due to Plant
I. Air Environment
1. Air Quality Impact scenario of air component due to the proposed plant emissions is significant. However the predicted concentrations are well within the standards as prescribed by CPCB.
2. Meteorology The meteorological data collected confirmed that the climatic status of the study area is consistent with regional meteorology. The industrial activity that is coming up has very negligible influence on the meteorology of the region. As such, the same pattern may continue.
II. Water Environment
3. Water Surface water quality will not get affected as entire quantity of effluent generated from sanitary uses will be treated within the plant site. Similarly, the process effluent from the Steel manufacturing units, boiler blow downs and cooling water discharges will be taken in to a large guard pond. The outlet of the guard pond is treated and treated by physico-chemical treatment process and treated water is utilized for green belt development. The storm water during season is harvested from roof tops, vacant plots, landscaping and paved roads. The harvested water is infiltrated and percolated into the ground water table.
4. Water Supply The water used for the industrial purpose is very significant. Water will be drawn from down stream of TB dam/Almathi dam/ ground water to an extent 3880 m3/hr. The impact on the water resources in and around the industry is significant. Water conservation practices, especially Rainwater harvesting and subsequent recharge into ground water table would likely improves the groundwater potential on a local basis.
III. Noise Environment
Richardson & Cruddas (1972) Ltd. IX-59
5. Noise There may be slight increase in noise levels due to the steel plant operations such as compressors, ID fans, pumps, material handling systems etc., There is no direct or indirect impact on nearby residence due to the noise produced in the plant. The noise level beyond one kilometer from the industry is insignificant.
IV. Land and Biological Environment
6. Forests No impact on forests and endangered plant species.
7. Flora and Fauna Greenbelt has a positive impact on flora. Slight dislocation of fauna due to increased human activity.
8. Land use Plant site, which is about 1429 Ha (3530 acre) is utilized for various establishments. As human activities increases around the plant site, land prices may likely to increase
9. Landscape Plant erection and rich plantation improve the visual effect.
10. Livestock Positive impact due to demand for milk, eggs and meat.
11. Solid waste Solid waste generated, which are not usable for any purpose will be disposed in control land filling in plant premises. Other solid waste will be reused in the plant itself. Fly ash will be utilized in cement manufacturing.
Richardson & Cruddas (1972) Ltd. IX-60
V. Socio Economic Environment
13. Educational Facilities No significant impact is anticipated immediately.
14. Medical Industry will provide medical facilities at factory premises at initial stage itself.
15. Occupational Facilities Some of the employees will find direct employment and many others indirect employment.
16. Transportation Slight impact due to increase in vehicular traffic.
17. Power supply Power will be drawn from the captive power plant established by BMM Ispat as auxiliary units.
18. Housing Some increase in house construction activity.
19. Economic aspects Local economy may improve through employment and rise in commercial activity.
TABLE - 8.2 IMPACT CHECKLIST FOR PLANT CONSTRUCTION
Environmental
Parameters Activities
Land use
Water Quality
Air Quality Noise Solid
Waste Housing Infra structure Services
Site clearing T T T T P
Road laying P T T T P
Foundation Works P T T T T P
Concrete Works P T T T P
Mechanical Erection T P
Material Storage T
Material Handling T T
Transportation T T
Water Requirement T
Temporary Constructions T T T
Temporary Services T T T
Hazardous Materials T T
Social Services T
T – Temporary Impact
P – Permanent Impact
Richardson & Cruddas (1972) Ltd. IX-61
TABLE - 8.3 IMPACT CHECKLIST FOR PLANT OPERATION PHASE
Environmental Parameters
Activities
Land use Water Water
Quality Air
Quality Noise Solid Waste Housing Infra
structure Services
Plant Commissioning Y Y Y Y Y
Water Requirement Y
Gaseous Emissions Y
Raw Material Handling Y Y Y
Product Handling Y Y Y
Spill/Leakages Y Y Y
Startup/Shutdown Y Y Y Y Y
Equipment Failure Y Y Y Y Y
Transportation Y Y
Housing Y Y Y Y
Education Y Y
Health and Recreation Y Y
Note: Y – Indicates Possible Impact
Richardson & Cruddas (1972) Ltd. IX-62
TABLE 8.4 IMPACT STATEMENT MATRIX
Environmental Parameters
Activities
Land use Water Water
Quality Air
Quality Noise Solid Waste
Infra structure Services Socio
Economy Ecology
Construction N N N N N P P P N
Plant Operation N N N N N P P N
Water Requirement N N N
Gaseous Emissions N N
Spills/Leaks/
Equipment Failure
N N N N
Material Handling N N P P N
Transportation N N P P N
Social Activities P P
Note: N – Indicates Negative Impact P – Positive Impact
CHAPTER - IX
Richardson & Cruddas (1972) Ltd. IX-63
ENVIRONMENTAL MANAGEMENT PLAN
9.1 General
This chapter discusses the environmental management plan (EMP) to minimize the adverse impact of the proposed project of 2.0 Mt/Yr steel production, 1.4 Mt/Yr cement manufacturing and 230 MW captive power production. Environment Management Plans are a useful vehicle for integrating and implementing the environmental management commitments, conditions, and statutory requirements. Environmental Management Plans and statutory requirements that are developed by proponents / his consultant during a proposal’s planning and design stages are presented in this chapter.
9.2 Objectives of EMP
The objectives of the proposed EMP are aimed for meeting five basic requirements,
namely
i) To integrate comprehensive monitoring and control of impacts.
ii) To comply with the environment protection regulations.
iii) To ensure that adverse environmental impacts on the core and buffer zone are
minimized, and
iv) To fulfill the Corporate Responsibility on Environment Protection (CREP)
v) To plan for ecologically sustainable development (ESD) within the frame work of
existing legislation and environmental management policies.
Richardson & Cruddas (1972) Ltd. IX-64
9.3 Applicable regulations
Following regulations on environment protection have been considered in formulating
this EMP:
• Section 21 of the Air (prevention and Control of Pollution) Act, 1981
• Section 25 and 26 of the Water (Prevention and Control of Pollution) Act, 1974
• The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989
• The Hazardous Wastes Management Handling Rules, 2000
• The noise pollution (Regulations and Control) Rules, 2000
• The Environment (protection) Rules, 1986.
9.4 Scope of EMP
In order to meet the above stated objectives, the proposed EMP would be an integral part
of the project from the design stage itself. This EMP is not conclusive and may require
further improvement as and when the situation demands.
The EMP is prepared in three stages, viz.,
• EMP at design stage
• EMP at construction stage and
• EMP at operational stage
9.4.1 Environmental Management Plan at Design Stage
Technological improvement
At the design stage of the proposed production facilities, the basic process route of
steel & Cement productions, and captive power generation, latest technologies
available to minimize pollution generation and reduction of water and power
consumption, wastewater recycling, solid waste recycling, waste heat recovery and
energy savings which are required to be looked into while selecting the process route of
each of the major production units. Following are the key areas where technological
improvements are suggested for arresting environmental pollution.
Richardson & Cruddas (1972) Ltd. IX-65
Conservation of Air ,Water and Energy recovery
• Fugitive dust emission control by dry fogging and dust extraction system.
• Fugitive emission control at raw materials storage and handling by land based
fume suppression system by sprinkling water.
• Fugitive emissions control at Sinter Plant and pelletization plants through feed
material controls and enclosures
• Extraction of electric power from BF top gas.
• Heat recovery in BF stoves.
• Arresting fugitive dust emissions in MBF shop.
• Reuse/recycling of treated wastewater.
Instrumentation & Controls
1. Blast Furnace Instrumentation
Cooling water flow / temperature metering
Humidity control / water injection
Hot blast / dome temperature control Fuel / Air ratio control
Oxygen enrichment control
2. Electric Arc Furnace (EAF)
Cooling water flow, temperature and pH metering
Gas flow metering
3. Converter
Cooling water flow, temperature metering
Gas mixing stations
VD/VAD/VOD instrumentation
4. Ladle Furnace
Cooling water flow, temperature metering
Argon rinsing station
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5. Con-cast continuous casting of steel
Mould cooling water Flow control
Pressure control
Temperature monitoring
Secondary cooling system
Flow control
Temperature monitoring
6. Rolling mill Instrumentation
Furnace Pressure control
Furnace temperature control
Fuel / Air ratio control
Temp core system
7. Sintering Plant
Damper settings controls
Pressure drop controls
Strand speed controls
Feed material controls
Sectional re-circulation of gases controls
8. Pelletisation Plant
Feed material controls
Pressure drop controls
Damper controls
9. Power Plant
Automatic blow down control
Foot traps with trap monitoring, strainers, disk check valves
Direct acting temperature regulations
Richardson & Cruddas (1972) Ltd. IX-67
Land environment management
It is necessary that at the plant layout design stage, optimum land area should be
considered, with requirements for material movement logistics so as to have more free
space for future retrofitting measures and beautification of the landscape. There is a
scope for beautification of the land area within the steel plant and township by
planting trees, flower gardens, grass lawns and fountains to improve the aesthetic
quality of the steel plant, as has been done in the existing steel plant.
Green Belt Development
Green belt is an important sink for air pollutants. Trees also absorb noise and by
enhancing the green cover, improve the ecology and aesthetics and affect the local
micrometeorology. Trees also have major long-term impacts on soil quality and the
ground water table. By using suitable plant species, green belts can be developed in
strategic zones to provide protection from emitted pollutants and noise.
In the proposed plant, green belt will be developed in vacant areas, around office
buildings, around stores, along the side of roads, along the plant’s boundaries and
around the waste dump area. Plant species suitable for green belts should not only be
able to flourish in the area but must also have rapid growth rate, evergreen habit, large
crown volume and small / pendulous leaves with smooth surfaces. All these traits are
difficult to get in a single species. Therefore a combination of these is sought while
selecting trees for green belt. The green belt should be planted close to the source or
to the area to be protected to optimize the attenuation within physical limitations. A
total of approximately 33% of total area will be developed as green belt or green cover.
The following species are suitable for planting in the area as recommended by Central
Pollution Control Board in their publication “Guidelines for Developing Greenbelts”
(PROBES/75/1999-2000): A very elaborate green belt development plan has been drawn
for the proposed plant. The areas, which need special attention regarding green belt
development in the industrial area, are:
- Along Plant Boundary
- Along Road Side
- Around Various Shops
- Around Office and Other Buildings
- Stretch of Open Land
- In and Around Township
Richardson & Cruddas (1972) Ltd. IX-68
Selection of Species The species for plantation have been selected on the basis of soil quality, place of
plantation, chances of survival, commercial value (timber value, ornamental value,
etc.), etc. It is to be noted that only indigenous species will be planted. Exotic species
such as Eucalyptus and Australian Acacia will not be planted. The Species will be
selected in consultation with State Soil Conservation Department.
Mixed plantations will be done keeping optimum spacing between the saplings.
Along Plant Boundary The row of plants facing plant should be smaller species and those facing outside should
be taller species. The species suggested for plantation is:
Small Species
• Kaneer (Nerium sp.) • Prosopis (Prosopis juliflora) • Bougainvellea (Bougainvillea spp.) • Ber (Zizyphus spp.) • Gulmohar (Delonix regia) • Duranta (Duranta sp.) • Kamayani (Murriya exocitica) • Bilayati Babool (Prosopis juliffera) • Babool (Acacia arabica) • Tall Species • Amaltas (Cassia fistula) • Siris (Albizzia lebbeck) • Neem (Azadirachta indica) • Druping Ashok (Polyalthia longifoila) • Mango (Mangifera indica) • Peepal (Ficus religiosa) • Arjun (Terminalia arjuna) • Jackfruit (Artocarpus heterophylla) • Palash (Butea spp) • Cassia (Cassia siamea) • Bottle brush (Callistemon lanceolatus) • Road Side Plantation • Avenue plantation should include the following species: • Siris (Albizzia lebbeck) • Gulmohar (Delonix regia • imli (Tamarindus indica) • Siris (Albizzia lebbeck) • Neem (Azadirachta indica) • Druping Ashok (Polyalthia longifoila) • Mango (Mangifera indica) • Peepal (Ficus religiosa)
Richardson & Cruddas (1972) Ltd. IX-69
• Bargad (Ficus bengalisis) • Arjun (Terminalia arjuna) • Cassia (Cassia siamea) • Around Various Shops
As there will be limited space (in height) due to various over head pipelines, thus small
and medium sized species are suggested and they should be planted depending on the
vertical height and lateral space available for the plant growth.
The species selected will be from among the following:
Small Species • Ber (Zyziphus sp.) • Sharifa (Annona squamosa) • Prosopis (Prosopis sp.) • Cassia (Cassia auriculata) • Duranta (Duranta sp.) • Kamayani (Murrya exotica) • Medium Size Species • Kaner (Nerium sp.) • Amaltas (Cassia fistula) • Subabool (Leucaena leucocephala) • Cassia (Cassia alata) • Babool (Acacia arabica)
Around Office and Other Buildings Plantation will be done around various shops, stores and other buildings, along the side of connecting roads. Species suggested for plantation are as follows which are mostly ornamental plants:
• Cassia (Cassia javanica) • Amaltas (Cassia fistula) • Cassia (Cassia siamea) • Amaltas (Cassia fistula) • Arjun (Terminalia arjuna) • Lagerestromea (Lagerestromea flosregennae) • Peltophorum (Peltophorum feruginium) • Gulmohar (Delonix regia) • Druping Ashok (Polyalthia longifoila)
Stretch Of Open land In the proposed plant, green belt will be developed in vacant areas. Species suggested for such areas are:
• Siris (Albizzia lebbeck) • Pakur (Ficus racemosa) • Gulmohar (Delonix regia • Imli (Tamarindus indica) • Peltophorum (Peltophorum feruginium) • Gulmohar (Delonix regia • Siris (Albizzia lebbeck) • Neem (Azadirachta indica) • Mango (Mangifera indica) • Peepal (Ficus religiosa)
Richardson & Cruddas (1972) Ltd. IX-70
• Bargad (Ficus bengalisis) • Arjun (Terminalia arjuna) • Cassia (Cassia siamea)
Mixed plantation will be done to take care of different heights and rates of growth. In and Around Township
In the proposed township plantation will be done in following areas:
- Along the township boundary
- Along the roads
- Stretch of open land
For the above areas the plants to be planted will be from among the list given
above for respective areas in the plant premises. Phase Wise Green Belt Development Plan
Green belt will be developed in a phase wise manner right from the construction phase
of the proposed plant. In the first phase (in the first and second year of construction)
along with the start of the construction activity the plant boundary, the township
boundary, around the proposed waste dumps, and the major roads will be planted. In
the second phase (in the third year of construction) the office building area will be
planted. In the third phase (in the fourth and fifth year of construction) when all the
construction activity is complete plantation will be taken up in the plant area, in
stretch of open land, along other roads and in the township will be taken up. The trees
may be watered using the effluent from the sewage treatment plant. They will be
manured using sludge from the sewage treatment plant. In addition kitchen waste from
the town-ship and plant canteen can be used as manure either after composting or by
directly burring the manure at the base of the plants. The green belt development plan
is shown in Fig. IX.1
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The year-wise planning of the trees & shrubs is presented below.
Year Number of plant species to be planted Shrubs Landscaping
2009-2010 1,00,000 - - 20010-2011 1,50,000 10000 Grasses & Avenue plants 20011-2012 2,00,000 20000 Grasses & Avenue plants 2012-2013 1,00,000 10000 Grasses & Avenue plants 2013-2014 1,00,000 10000 Grasses & Avenue plants
Total 650000 50000 -
Richardson & Cruddas (1972) Ltd. IX-72
Total area : 1429 ha Green Belt Area : 472 ha Management of Water environment: During design stage, water environment
management measures will consider two aspects, that is,
i) Conservation of water by Rain water harvesting, and
ii) Waste water treatment, recycling and disposal system
Rainwater harvesting
BMM is planning to have a system of rainwater harvesting at plant. Rainwater harvesting
is primarily dependent on various site characteristics such as soil properly, catchments
characteristics; rainfall characteristic, and ground water table etc. There are artificial
as well as natural rainwater harvesting system. The recharging system can be
implemented for
i) Individual units
ii) Centralized collection system
Scheme I: Collection of rainwater harvesting from individual building units and
construction of filter beds at individual building unit. Rainwater falling on other open
area is to be collected, through constructed drainage system and discharge system and
discharge to surface out-fall (by passed for rainwater harvesting) Scheme II:
Construction of rainwater filter bed at centralized place where water from individual
unit as well as storm water from open area shall be diverted. The rainwater carries
suspended solids as washed out from open area. A filter bed filters the particles thus
prevent them from reaching / contaminating ground water. The first layer of filter bed
shall be coarse sand the second layer shall be pebbles and third layer shall be gravel.
The filtrate thus collected from the bottom of filter bed shall be piped to recharge bed.
Richardson & Cruddas (1972) Ltd. IX-73
Liquid waste handling system
(i) Clear water sump ensures continuous cleaning of the contaminated water for its
reuse for the operation.
(ii) Unloading sprout helps in avoiding the dust nuisance during the unloading of
coal char from the bunker.
(iii) A large waste dumping yard will be developed in an area at a safe distance
between the plant where the waste products generated during the process of
sponge iron production is disposed. To avoid its flying, a thick layer of sweet soil
is spread over the heaps and grass is planted to make the area clean and green.
(iv) Concrete flooring will be done at such areas inside the plant where the dust
normally settles in some amount. Continuous water spraying will be done to
clean these floors and allow the dust to flow to the nearby drains from where
the dusts are collected and disposed in waste yards.
Wastewater treatment, recycling and disposal
Wastewater will be generated in individual steel production facilities. It is
recommended that each of the production units be designed to utilize less amount of
water and recycle of water to the maximum by cascading use of water. There will be
blow downs from each of the systems. It is suggested that the blow down water be
collected centrally and treated to make the water usable in less critical applications
like slag quenching, green belt development etc.
All efforts will be made to re-use and re-circulation the water and to maintain zero
effluent discharge. The following schemes are proposed for wastewater management
comprising treatment, recycling and disposal systems:
Gas Cleaning Plant wastewater
The Blast Furnace gas cleaning scheme will be of the conventional venturi type which
have become the bench mark for similar application. The effluent coming out of the
wet scrubber will be contaminated with high concentration of suspended solids. The
slurry effluent will be clarified in the clarifier to recover clarified water for recycling to
the wet gas scrubber after cooling in the cooling tower. The sludge settled in the
clarifier will be pumped to the existing pellet plant as a feed material for making
Richardson & Cruddas (1972) Ltd. IX-74
pellets. It is suggested that the blow down water from the cooling water circuits be
used as make up in the gas cleaning re-circulation systems.
Treatment of billet Caster effluent and mill effluents
This effluent will be contaminated mainly with suspended solids and traces of oil. The
effluent from the mill will be collected first in scale pit which is a large settling basin
to separate out the floating oil and settable iron scales The clean water is passed
through sand filters to remove finer particles, after which the water is recycled in the
process. The backwash from the filters is sent to the settling tank for removal of
particulates. The settled sludge is sent to either pellet plant and/or sinter plant for
agglomeration. It is suggested that the blow down water from the cooling water circuits
be used as make up in direct contact re-circulation systems.
Treatment of Power Plant effluent
The power plant effluent will be the backwash of DM water plant. This effluent will be
relatively free from solids and oil and thus the effluent will be treated in a neutralizing
pit for pH correction only. The neutralized effluent will be stored in the treated
effluent lagoon for reuse along with cooling tower blow down in the direct cooling
system.
Use of Cooling Tower blow downs
It is noted that the re circulating water in cooling towers gets contaminated with the
dust in the atmosphere, necessitating blow down. It is recommended that all cooling
towers be provided with side stream pressure filters to reduce the volume of blow
down. The cooling towers shall be designed to operate at high cycles of concentrations
(>8) to conserve water. Further, Cooling Tower blow downs of indirect cooling water
system shall be used for slag quenching, as make up to direct contaminated cooling
water circuits and surplus if any will be stored in the treated wastewater lagoon for in-
plant use.
Richardson & Cruddas (1972) Ltd. IX-75
Design details of proposed wastewater treatment plants
The following scheme shows the proposed Wastewater Treatment plants in BMM ISPAT
LTD.
The design of the effluent treatment plant for waste water generated from process
operational system need to be aimed towards zero discharge which means practically
no discharge or minimum discharge. It will be difficult to attain zero discharge, as
repeated recycling will disturb the quality of recycled water, making the plant
operation unsafe. Hence, a part of treated water needs to be discharged through the
plant drain into the guard ponds for maintaining the water quality of recycled water.
It is proposed that in spite of having total recycling based design of the plant, for all
practical purposes, the plant should have drainage provision 15-20 m3/hr of treated
water, in compliance with the regulating standards. That is around 0.4 m3 per MT of
steel. Thus the water usage in the steel plant will be around 99.5%. The drainage of
treated wastewater will be made through the treated waste water lagoon, serving as a
guard pond for quality control of effluent to be drained.
Flow Assessment from Different Sources (m3/hr)
1. Beneficiation plant = 6.0 2. Pellet Plant = 8.0 3. DRI Plant = 5.0 4. Coke oven plant = 13.0 5. BF Plant = 58.0 6. Steel melting shop = 44.0 7. CCM shop = 16.0 8. Calcination & Oxygen plant = 15.0 9. Rolling mill = 114.0 10. Power plant = 320.0 11. Cement Plant = 1.0 ---------- Total 600.0
----------
Richardson & Cruddas (1972) Ltd. IX-76
Recycle
Likely Characteristics of Wastewater
Wastewater Characteristics (mg/l) Sl. No.
Source pH SS Oil and
Grease Metals / others
1. Beneficiation Plant 6.0 – 6.8 6000 - 8000 <3 Fe,
2. Pellet Plant 6.0 – 7.0 1000 – 1500 < 5 Fe, Mn, Zn
3. Sponge Iron Plant 6.0 – 7.0 200 – 300 < 3 -
4. Coke oven plant 8 - 9.5 1500-2000 - -
5 Blast furnace 7-8 1000-1200 < Fe, Mn, Zn
6 Steel Melting shop (EAF +LF 7 -7.5 200 -250 Fe, Mn, Zn
7 CCM 6.5 – 7.0 300 – 400 10 – 30 Mill Scale
8 Calcination & Oxygen plant 10 -10.5 500 -1000 - -
9 Rolling Mills 7 – 8 500 – 600 50 – 70 Mill Scale
10 Captive Power Plant 6 – 7 200 – 300 < 2 –
11 Cement Plant 7 -8 100-200 <1 -
Treatment Processes
Beneficiation plant effluent
The tailings will be first dewatered in hydro-cyclones and then treated in thickeners for
water recovery. The thickener sludge will be filtered to recover water and the solid waste
will be transported in trucks to the dump area.
Tailings Thickeners Water recycling
Hydro-cyclones
Slime Pond To Loading
Point
Richardson & Cruddas (1972) Ltd. IX-77
Pellet Plant
The waste water requires treatment for the removal of suspended solids.
Sponge Iron Plant
No treatment is required. The entire flow is utilized in ash handling and dust
suppression.
Blast Furnace
EAF + LF Plant To guard pond Flow
Collection Tank Ash handling
Dust suppression
Sponge Iron
Plant Flow Pump
Collection Sump Tube Settlers BF Plant
Flow Pump
To guard ponds
Sand Drying Beds
Collection Sump Pellet Plant
Flow To guard ponds
Richardson & Cruddas (1972) Ltd. IX-78
Removal of SS
CCM Plant A. Mould and equipment
Cooling Water blow downs To guard pond Oil & Grease recovery B.
Rolling Mills Captive Power Plant Cooling Water blow down = 172 m3/hr Boiler blowdown = 28.0 m3/hr (UF + RO + MB + Softner + Filter) Rejects = 87.0 m3/hr Side stream Filter rejects = 33.0 m3/hr ---------------
Total 320 m3/hr -----------------
Scale
Pits
Oil and GreaseTrap
Spray water
blowdowns
Sintering
Plant
Mill Scale
To Re-circulation
Scale Pit
Settling Tank
Rolling Mills
Flow
Scale to Sinter Plant
To re-circulation /guard pond
Richardson & Cruddas (1972) Ltd. IX-79
A. B. (SSF Backwash water)+ (UF + RO + MB + Softener + Filter Reject )
Cement Plant Effluent Effluent Guard Pond
Process of Guard Pond Effluent Treatment Seperate guard ponds for major production units will be designed with HDPE lining. The effluents from the ponds will be treated by physical and chemical processes. The treated effluent will be reutilized for various secondary uses. The overall treatment process is presented below.
Direct Re-Use Cooling water blowdowns Boiler blowdowns Collection
Pit Pump
Flash Mixer Plate/Tube Settlers Guard
Ponds Pumps
Treated Effluent
Mixer
Polymer Sludge
Lime + Alum
Floccu lator
Pump
Centrifuge
controlled land fill
Centrate
To guard pond
Richardson & Cruddas (1972) Ltd. IX-80
Richardson & Cruddas (1972) Ltd. IX-81
Uses 1) Slag quenching
2) Ash handling
3) Green belt
4) Dust suppression purposes.
Treatment of Plant Sanitary wastewater
Sanitary waste generated from all sections of the steel plant are collected from a
closed drain and treated by fluidized aerobic biological treatment. The treated
wastewater is utilized for green belt development.
Process description The raw sewage shall be collected in the equalization tank after passing through a bar screen where from it is pumped to the Sewage Treatment Plant comprising the following units.
1. Flash mixer (RCC tank) - Installed with slow speed agitator for chemical
mixing.
2. PAC and Polymer Dosing Systems: (Comprising HDPE Tanks, Dosing pumps
and agitators) - for coagulation and flocculation of Colloidal and suspended
solids.
3. Reactivate or clarifier (RCC tank) - for primary chemical treatment
4. FAB Reactor (RCC tank) - Fluidized Aerobic reactor with diffused aeration
system for bio degration of dissolved organics.
5. Secondary Clarifier (RCC tank) - to provide sedimentation and sludge re-
circulation of activated sludge from FAB.
6. Chlorine Contact Tank (RCC tank) - to disinfect the treated sewage
Estimation of design flow i) Rate of water supply = 60 litres / capital / day ii) Total man power = 4600 iii) Rate of sewage generation = 85% of water supply iv) Quantity of sewage = 0.85 x 60 x 4600 = 234 m3/day Canteen wastewater generation = 250.0 m3/day ∴Total flow = 295 + 200 = 484 m3
= 500 m3/day ∴ Design sewage flow = 500 m3/day
Richardson & Cruddas (1972) Ltd. IX-82
CHIEF DESIGN AND PERFORMANCE PROJECTIONS Chief Design parameters The characteristics of the sewage will be as follows
Parameters Characteristics
1. Total Sewage flow - 500 m3/day 2. pH - 7.5 3. BOD - 200 - 450 mg/L 4. COD - 400 - 900 mg/L 5. TSS - 600 mg/l 6. TS - 1200 mg/l
Performance projections The sewage after the proposed treatment system will give the following output character tics when operated under optimum design conditions.
Parameters Characteristics
1. Total flow - 500 m3/day 2. pH - 6.5 - 7.5 3. BOD - < 10 mg/l 4. COD - < 250 mg/l 5. SS - < 10 mg/l
Management of Air environment
The design and engineering of the proposed production facilities require adequate air
pollution control measures to minimize the adverse impact on air environment . While
adequate pollution control systems have been established for process emissions, the
major area of concern will be to mitigate the fugitive emissions, from non-point sources
both in open and within the shop. The fugitive emission control measures are given in
Table 9.2 . The secondary fugitive emission control measures are given in Table 9.3 and
shown Fig IX.1. The details of stacks provided in the integrated steel plant, cement
grinding unit and captive power is presented in Table 9.4. The dedusting facilities is
given in Table 9.5.
Fugitive dust emissions control of Raw Materials Handling Section (RMHS)
To control the fugitive dust emissions at the stock piles on the ground, stacker
reclaimer, conveyor transfer points, vibrating screens, etc, both water sprinkling and
dry fogging (DF) will be adopted for dust suppression. The DF system generates a layer
of fine water droplets (fog) with which dust particle collide. DF requires only
compressed air and water pressure for atomization through specially designed nozzles.
Richardson & Cruddas (1972) Ltd. IX-83
DF is applicable for coal dusts, coke dust, ore dust etc which are non-reactive with
water. No dust suppression reagent will be used. For lime dust abatement, conventional
dust extraction (DE) will be adopted. No dust suppression agent will be used.
The DE system based on electrostatic precipitator (ESP) and fabric filter will be
provided for room air cleaning such as Sinter Plant Stock House, BF Stock FA House and
BF Cast House fume extraction. The EAF Shop will be one of the prime sources of
fugitive dust emissions during charging/tapping/blowing, argon rinsing, steel pouring,
de-slagging etc. The EAF shop will thus be provided with secondary emission control
system by means of dust and fume extraction system followed by bag filter/ESP. The
converters will be totally enclosed during the oxygen blowing operations. The
summarized list of APC measures for the production facilities is given in Table 9.1.
Table - 9.1 : SUMMARISED LIST OF APC MEASURES FOR THE PRODUCTION FACILIIES
Sl. No Area of operations Air pollution control measures proposed
to be adopted
Raw material handling · Dust suppression systems (chemical and dry fog type)
Fugitive emissions in material handling · Water sprinklers 1
· DE systems with bag filters in case of
conveyors, lime handling
2 Sponge Iron Plants Electrostatic precipitators, bag filters 3 Sinter Plant
Raw material preparation and handling (procurement of proposed sized materials to minimize crushing and screening) · DE systems with bag filters
Sintering process · ESP for collected waste gases
Sinter screening and transport · Bag filters 4 Pelletization Plant
Raw Material Preparation and Handling · DE System with bagfilters.
Pelletization Process · ESP
5 Blast Furnaces De-dusting with bag filters
6 Cacination · Bag filters
7 Steel melting shop Bag filetrs
8 Coke oven plant De-dusting with bag filters
9 Rolling mills Use of Low sulphur fule
10 Power Plant WHRB & AFBC · Electrostatic Precipitator
11 Coal Handling Plant · Bag filters
12 Cement plant · Bag filters
Richardson & Cruddas (1972) Ltd. IX-84
Table 9.2 Characteristics of Secondary Fugitive Emissions
Sl. No.
Item
Secondary fugitive Emissions
Control Strategy
1) Leaking of Pipe Connection
Iron Oxide, coal dust, H2S, CO, NOx, SO2 etc Weld together
2) Valves Iron Oxide, coal dust, H2S, CO, NOx, SO2 etc Seal-less Design
3) Fans, Compressors
Iron Oxide, coal fines, H2S, SO2, NOx and other
Closed vent system Dual mechanical seal
4) Raw material preparations Iron Oxide, Coals, recycled ducts
Binding agent in the water spray dedusting with bag filters. plantation around source
5) Sinter and pellet plants
Dust from sinter plant cooler and transfer points
Recovery by suctionhood installation with bag filters. Recycling of cleaned heated air
6) Coke ovens Coal or coke dusts sulfur oxide or, carcinogenic emissions, smoke, steam
Dust capturing devices coke side enclosure hoods and fans to reduce emissions at all transfer points.
7) Blast furnace Iron Oxides, H2S, cast house fumes, CO, coke dust
Closed conveyers, hoods to bag filters converted hoods at all transfer points runner side root extraction
8) Hot metal treatment Na2O, K2O, Lime Oxide fume, Dust, iron Extraction of fumes and scrubbing/ bag
filters. Acid – alkali neutralization.
9) Steel making Fine Iron Oxide, Alloy flumes Hoods with fume extraction followed
by bag filters partial enclosures.
10) Casting Fume, lead, SOX, Fluorides Fume extraction, water spray
11) Rolling Fumes Dust extraction and venting, side stream water spray
12) Cooling Chlorined hydrocarbons Solvents, acid mist
Extraction of fume followed by wet chemical scrubbing / bag filter.
Richardson & Cruddas (1972) Ltd. IX-85
Table 9.3 Fugitive Emission Control Measures
Fugitive EmissionSource Control Technique Control Equipments
Categorization OfControl System
Capabilities
Active Storage Piles
a) Watering b) Windscreens c) Plantations
- Water Sprinkler on yard RACT
Conveyor & Transfer Points
b) Water Sprays b) Hooding &
Ducting
- Dust suppression system - Bag Filters RACT
Product Handling a) Windscreen b) Hooding &
Ducting - Bag Filters RACT
Loading & Unloading
a) Windscreens b) Water Sprays - Water Sprinkler on yard RACT
Internal Road Transportation
a) Water Spray b) Concrete/Tar
Road c) Plantation
- Water Sprinkler - Construction of Internal roads
- Plantation at road sides
RACT
Crushing & Screening
a) Watering b) Windscreens c) Hooding &
Ducting
- Dust Separation system - Bag Filters
RACT
Waste Gas a) Heat Recovery b) Dust Collection
- WHRB - Electrostatic Precipitator BACT
Waste Sites
a) Chemical Stabilizers
b) Vegetative Cover
c) Windscreens d) Plantations
LAER
RACT – Reasonable available Control technology
BACT – Best Available Control Technology LAER – Lowest Available Emission Rate
Richardson & Cruddas (1972) Ltd. IX-86
Fig. IX.1 Schematic diagram of Secondary emission control in Electric Arc Furnace
Richardson & Cruddas (1972) Ltd. IX-87
Table 9.4 Details of Chimney
Plant unit Flow rate, Nm3/h No. of
Chimneys Height,
m Diameter, m top/ bottom
Scrubber/ ESP and its efficiency
Pelletising plant 930,000 1 55 4.0/ 7.5 ESP > 98% DR plant 376,000 2 90 4.1 ESP > 98% Coke plant 266,000 8 70 3.5/5.0 -- Sinter plant 660000 2 45 3.25/4.5 ESP > 98% BF plant 125000 4 55 2.0 -- Calcination plant 36000 2 30 1.26 Bag filter > 98 % Rolling mills 100000 2 80 1.54 -- Cement grinding unit
650000 1 60 4/6 Bag filter > 98 %
Power plant 458,000 1 220 3.0/4.5 ESP > 98% Steel making shop 60000 1 40 1.4 Bag filter > 98 %
Table 9.5 Details of Dedusting Units
Plant unit Location of dedusting systems
No. of dedusting systems
Air cleaning system Stack height, m
Proportioning bins 1 Bag filter 30 Cooler discharge area 1 ESP > 98% 30 Pelletising plant Coal grinding system 1 Bag filter 30 Day bins 2 Bag filter 30 Coal preparation unit 2 Bag filter 30 DR plant Product handling unit 2 Bag filter 30 Coal preparation unit 2 Bag filter 30
Coke plant Coke quenching station 2 Bag filter 30 Flux crushing unit 1 Bag filter 30 Coke crushing unit 1 Bag filter 30 Proportioning bins 2 Bag filter 30 Sinter plant Cooler discharge and sinter screening unit
2 Bag filter 30
Stock house 2 Bag filter 30 Coal pulverizing system 1 Bag filter 30 Cast house 2 Bag filter 30
BF plant
PCM shop 1 -- 5 m above roof Limestone/ dolomite screening unit
1 Bag filter 30 Calcination plant
Product screening unit 1 Bag filter 30 Granulated slag drying system
1 Bag filter 40
Cement grinding Materials Transfer points de-dusting system
2 Bag filter 30
Power plant Coal crushing unit 1 Bag filter 40
Richardson & Cruddas (1972) Ltd. IX-88
Point source dust emission control: BF stoves and reheating furnace mills use cleaned
fuel gases as fuel as such no dust emission control devices are proposed.
Process dust emission control: In case of sinter plant and lime kilns. the waste gases
contain large amount of dust and will require ESP/bag filter to arrest the particulates.
The ESP/Bag filters will be designed to limit the emissions to less than 50 mg/NM3.
S02 emission control: The main source of sulphur dioxide from the steel plant
operations is the metallurgical coal. In consideration to this, it is proposed to use low
sulphur blended coal. (S < 0.5 wlw). A major portion of sulphur present in coal or coke
will be fixed in BF and EAF slag. The other major source of SO2 emission is due to coal
firing in power plants. Since it is envisaged to use relatively sulphur free fuel gases for
power generation. the sulphur dioxide emissions will be drastically reduced. The other
sources of sulphur dioxide emissions are from the sponge iron and sinter plants. The
emissions can be reduced by using metallurgical coal with low sulphur (<0.5%) and also
by incorporating waste heat recovery systems.
NOx emission control: NOx will be formed during combustion of fuels. It is therefore
proposed to have combustion control devices by adopting waste gas re-circulation in
the combustion process and using low NOx burners so as to minimize the formation of
NOx.
Carbon monoxide emission control: The sources of carbon monoxide generation are
from the waste gases from the combustion operations. The control of air/fuel will be
adjusted in such a way that formation of carbon monoxide is minimized in the presence
of excess oxygen in the flues.
Energy conservation measures: Energy conservation measures at the design stage are
equally important as pollution prevention and control measures, since the energy
consumption has a direct linkage to the emission of carbon dioxide, a green house gas.
It is suggested that the energy conservation measures be adopted wherever possible to
reduce the specific energy consumption. The incentives offered for energy conservation
by the National and international bodies like CDM mechanism should be used to
conserve energy.
The project at the design stage, envisages energy consumption of 6.0 Gcal/tcs, but
after plant stabilization, further reduction of energy consumption needs to be
attempted.
Richardson & Cruddas (1972) Ltd. IX-89
Other considerations of EMP at the Design Stage The following aspects also need to be looked into:
Noise emission control: The design criteria for selection of noise prone moving
machineries should be of low noise design. These equipment require dynamic balancing
and vibrations dampened by suitable mounting mechanisms and proper grouting. The
work zone standard noise level shall be maintained at 85 dB(A) Leq for 8 hrs continuous
exposure. Where there is a high noise prone equipment generating continuous noise
above 90 dB(A) Leq, the same needs to be housed separately to ensure that continuous
attendance is not necessary. The operational control rooms and pulpits will be provided
with noise shield walls. In addition, administrative control will be required to adopt the
practice of using ear plugs in very high noise prone areas.
Air conditioning and ventilation: The design shall look into best practicable congenial
work environment from occupational health care point of view. The control rooms, pulpits
and control cabins will be provided with chilled water air conditioning facility. The room
inside temperature will be maintained at 25±2°C and relative humidity at 55 ± 5%.
It is suggested that CFC free refrigerants be used in air conditioning.
The production shops will be designed with adequate natural ventilation. The additional
heat within the shop floor may be ventilated by forced air clean supply system.
Dust handling: It is a common source of instantaneous fugitive emissions while
collecting the dust from the DE equipment and transportation of collected dust to the
other plant units. While designing the dust handling system, pneumatic transport or
covered conveyor system will be preferred if layout permits. Otherwise, the collected
dust will be moistened or pug milled and transportation of the same by in-plant
vehicular transport system covered with Tarpaulin so that no further dust is emitted to
the plant environment.
Provision for continuous monitoring of stack emissions : It is proposed to install on-
line continuous monitor for particulate matter in the major stacks like Sinter Plant
waste gas stacks, Power Plant combustion stacks and BOF& BF secondary emission
stack. On-line monitored values will be logged in the process computer of each plant or
a central data logging computer.
Landscaping: While developing the Plant General Layout, it needs to be ensured that
no unpaved areas will remain vacant. The unpaved areas will either have black
top/cemented or will have grass lawn cover to prevent wind borne fugitive dust.
Richardson & Cruddas (1972) Ltd. IX-90
Each production shop layout shall leave open land area by the sides of the access road
for landscaping purpose with plantation of flowering trees, water fountains for
beautification purpose.
9.4.2 Environmental management measures during Construction period
Construction activities at site will also require environmental management measures,
which are as follows:
• The earmarked zones where the construction activities will be taken up will be
fenced so as to prevent entry of unauthorized persons.
• The storage site for stockpiling of construction materials will be contained within
the temporary bund wall of low height. The storage site should be such that no spill
of construction materials like sand, gravels & stone chips, choke the plant drain.
• The excavated earth left over after land filling will be used for grade level
preparation, terracing and filling up of low lying areas.
• Attempt will be made to bring the plant equipment by rail.
Batching plant washings will be drained only after passing through Settling chamber.
This sentence is deleted.
• Alf construction personnel will be given safety training and will use compulsorily
safety helmets, gum boots, goggles as required by the construction safety manual.
• Safety surveillance on each working day.
• No child labour
• Cleaning of site after completion of construction and erection activities at the
respective construction zones.
• The construction wastes will be disposed of in an earmarked site within the steel
plant till its safe disposal place is found out or sold out.
Richardson & Cruddas (1972) Ltd. IX-91
9.4.3 Environmental management measures during Operation
Once the plant is ready for commercial production, the following pre- commissioning checks will be done:
• Witnessing the environmental performance test for the APC equipment and
wastewater treatment plant as stipulated in the design specification.
• Implementation of necessary corrective measures for the installed facilities for
environment protection
• Training of operating personnel who will run and supervise these environment
protection equipment
The plant operation will be brought under comprehensive Environmental Management
System (EMS) in accordance with ISO 14001:2004.
Solid waste management
It is proposed to dispose / reuse solid wastes as per plan given below.
Beneficiation of Tailings
Tailings are only the solid waste in beneficiation plant. The quantity of tailing are
about 220 T/day on dry basis.
Management System
Tailing will be dewatered before dumping in the earmarked area.
Pellet Plant
Sl. No. Waste Generation Location Nature of Waste Quantity (T/day)
1. Flue Dust from ESP Dust 220
Management System
Flue dust from ESP will be collected and recycled into the sintering plant.
Richardson & Cruddas (1972) Ltd. IX-92
Solid Waste Generation in sponge iron plants
Sl. No. Waste Generation Location Nature of Waste Total Quantity
(T/day)
1. Dust Settling Chamber / Wet Scrubber Sludge 20.0 2. De-dusting System Dust 48.0 3. Product Separator System (Char) Fines 648.0 4. Heat Exchanger and ESP Dust with fly ash 215.0 Management System
The solid waste generated from the plant is collected in bunkers through bag filters
and magnetic separation system
Sludge will be reused in sintering plant.
The dust with fly ash collected from heat exchanger and ESP will be temporarily
stored in waste disposal yard and to cement manufacturing
Dolochar and dust from bag filters will be collected and used as a fuel in WHRB of
Captive power plant.
Sintering Plant
Sl. No. Waste Generation Location Nature of Waste Quantity (T/day)
1. Flue dust from ESP Dust 220.0
Management System
Flue gases dust collected from ESP will be collected and recycled into the pellet
plant
Richardson & Cruddas (1972) Ltd. IX-93
Blast Furnace
Sl. No.
Waste Generation Location Nature of Waste Total Quantity
(T/day)
1. Sinter B.F. Return Sinter 178
2. B.F. Slag Slag 1766
Management System
Sinter B.F. returns are recycled back into a sinter plant.
B.F. Slag for production of cement.
Steel Melting Shops (EAF + LF)
Sl. No.
Waste Generation Location Nature of Waste Total Quantity (T/day)
1. Slag Slag 732 2. Flume dust from bag filter Dust 415
Management System
Slag is discharged into suitably designed landfill.
Fume dust is utilized in sintering plant.
Continuous Casting Machine
Sl. No. Waste Generation Location Nature of Waste Total Quantity
(T/day)
1. Scale & Muck Scales 110
2. Scrap - 266
Management System Mill Scale is returned to sintering plant.
Scrap will be reused.
Rolling Mills
Sl. No.
Waste Generation Location Nature of Waste Total Quantity
(T/day)
1. Scrap Scrap 211.0
Richardson & Cruddas (1972) Ltd. IX-94
3. Scale & Muck Scale 211.0
4. Oil and Grease Traps Oil and Grease 0.3
5. Reheat Furnace Broken Refractories 200*
* Annual Discharge
Management System Scrap will be collected and reused.
Reheating and rolling mills scales will be recycled in sintering plant.
Oil and Grease collected in drums and sold to authorized vendors.
Broken brick refractories will be dump in suitably designed landfill.
Coke oven Plant
Sl. No. Waste Generation Location Nature of Waste Total Quantity
(T/day)
1. Coke breeze dust 466
3. Dust from bag filters dust 31.0
Management System
Coke breeze will be recycled to Coke oven
Bag filter dust will be utilized in cement manufacturing
Cement Plant
Sl. No. Waste Generation Location Nature of Waste Total Quantity (T/day)
1 Dust from EAP dust 38.0
Richardson & Cruddas (1972) Ltd. IX-95
Management System
Re-use in cement plant
Captive Power Plant
Sl. No. Waste Generation source Nature of Waste Total Quantity
(T/day)
1 Ash including Fly ash Dust 316.2
2 Bottom ash dust 79.2
Management System The solid waste in the form of bottom ash and fly ash will be utilized for
manufacture of cement, brick manufacture, road and embankment constructions.
Ash pond
The Fly ash generated in the captive power plant and other ESPs of the plant unit will
be totally utilized in the captive cement plant proposed. How ever an ash pond for
emergency usage at the plant site will be established. The ash pond will be lined with
geo textile membrane to make the pond impermeable. The coordinates of ash pond is
given in Fig IX.2.
Incineration Ash Oil socked cotton waste, organic wastes collected in steel plant, paper, plastics, waste bag filters etc. will be about 2200 MT / annum. These will be incinerated in the incineration plant. Approximately about 22 T/annum of ash will be generated. This is disposed into the suitably designed landfill.
Lead Acid Batteries
About 2500 – 3000 number of lead acid batteries will be generated per annum. These
will be stored properly and sold to the authorized vendors.
Richardson & Cruddas (1972) Ltd. IX-96
Fig 1x.2
DESIGN OF CONTROLLED LANDFILL
Design Data 1. Quantity of Solid Waste (T/year)
SMS sludge : 219600
Broken Brick Refractories : 200
Incineration Ash : 22 --------------- Total 219822
Richardson & Cruddas (1972) Ltd. IX-97
2.0 Design Life of the Landfill : 15 Years
3.0 Average till depth : 10 m
4.0 Solid waste to cover ratio : 4 : 1
5.0 Average bulk density of solid waste : 1.45 MT/m3
Calculations Total quantity of solid waste per annum : 2,19,822 MT/year
2,19,822 Volume of solid waste = -------------- = 151601 m3/year 1.45
Additional Volume required for soil cover = 37900 m3/year
Total required volume = 189501 m3/year
189501 Area required = ------------ = 18950.1 m2/year 10
Life of the Land fill = 15 years
Area required for the entire life
period of the land fill = 18950.1 x 15
= 284251 m2
= 28.42 Hectares
Additional land area required for access roads, greenbelt and buildings = 20%
Gross area required (for 15 years) = 34.10 Hectares.
A typical landfill section is presented in Fig. IX.2
Richardson & Cruddas (1972) Ltd. IX-98
Fig. IX.2 Schematic diagram of Composite Double liner system for Land fill
Richardson & Cruddas (1972) Ltd. I-1
Leachate Collection And Management
Leachate is generated during rainy season. This leachate is a liquid that contains a number of dissolved and suspended materials. The leachate volume so generated is calculated based on: Leachate Volume = (Volume of Precipitation) +
(Volume of Pre Squeeze Liquid)
– (Volume Loss through evaporation)
– (Volume of water absorbed by the waste)
Leachate Management 1. Recirculation
One of the methods for the treatment of leachate is to recirculate it through the
landfill. This has two beneficial effects: a) the process of landfill stabilization is
accelerated and b) the constituents of the leachate are attenuated by chemical
and physical changes occurring in the landfill. Recirculation of leachate requires
the design of a distribution system to ensure that the leachate passes uniformly
throughout the entire waste.
2. Evaporation of Leachate
Another technique used to manage leachate is to spray it in lined leachate ponds and allow the leachate to evaporate. Such ponds have to be covered with geo membranes during the high rainfall periods. The leachate is exposed during the summer months to allow evaporation. The above two methods are quite satisfactory for management of hazardous solid
wastes of integrated steel plants. If required lime is added to the leachate for
immobilization and precipitation of soluble metallic constituents.
It is suggested to install an incinerator to handle organic wastes that do not have
any use or cannot be sold to out side parties. The incinerator shall be designed to
handle all solid & liquid wastes. The ash collected from the incinerator shall be
stored in a specifically designed pit with impervious lining and covered to prevent
rainwater ingress.
Richardson & Cruddas (1972) Ltd. I-2
Hazardous Management
All solid wastes found to be hazardous will be handled and disposed of in
accordance with the procedures laid down in the Hazardous Wastes (Management
and Handling) Rules, 2003 and as directed by the Karnataka State Pollution Control
Board. The following table gives the type of waste, their quantity and mode of
disposal. No hazardous waste will be used in the process.
Name of the waste Approximate quantity per year Mode of disposal
Waste Oil 400-500 KL To be used in the non-recovery coke/coal for process improvements
Lead acid batteries 2500 – 3000 Nos. Sold to authorized vendors
Oil soaked cotton waste, organic wastes collected in steel plant
450 – 500 To be incinerated
Safety surveillance: From a safety perspective, the steel making process is a high
temperature and bulk solids processing operation. This requires significant amount
of thermal and electrical energy, water, handling of molten metals, bulk material
and product handling. The steel plant therefore requires best practice of safety
surveillance for which no compromise is made. Some of the key areas requiring
routine safety surveillance are listed below;
• Fuel gas distribution pipe work — its pressure, temperature, line isolation
device and purging device with portable gas leakage monitoring instrument,
control valves etc.
• Corrosive chemicals, acid/alkali storage and handling
• Electrical installations, tripping devices
• Smoke detection alarms and operation of automatic fire extinguishers
• Fire hydrant systems
• Emergency systems like DG sets, lighting, evacuation areas etc.
• Quality of house keeping
• Compulsory use of safety appliances like gum boots, helmets, ear muffs,
goggles and heat insulated hand gloves
Richardson & Cruddas (1972) Ltd. I-3
A full-fledged safety department headed by GM (Safety) along with a team of
trained staff, which looks after the safety aspects will be set up for the plant. This
arrangement is adequate, with up gradation of facilities and staff to handle the
additional requirements. The productivity of the plant is linked with the plant
safety, the lapses of which will lead to loss of man-hours and productivity loss.
9.5 Organization
In order to implement the suggested measures, it is necessary to have the
adequate team in place. A Environment Management Department, headed by GM
(EMD) is to be created. This department will have staff and monitoring facilities as
detailed earlier.
Training: To have the good results of comprehensive environmental management
system of the steel plant, it becomes essential to train the operational and
maintenance personnel, including senior executives by formulating appropriate
training modules. The objective of the training will be to make aware of
environmental performance of the plant, amendments in the environmental
regulations, corporate policy on environment, health and safety, and community
perception.
Social Upliftment
As a responsible corporate organization, BMM ISPAT LTD cannot survive only on the
growth of business potential unless it has got much wider vision to the overall
development of the society. The BMM ISPAT LTD should take several initiatives in
encouraging entrepreneurship among locals, female education, primary education
etc with established Liaison department. The following are the areas where Social
uplifment will be initiated by the BMM ISPAT LTD.
Encouraging Entrepreneurship among locals – Vocational Training.
Encouraging Female Education
Upgrading One/Two Primary Schools
Improvement of Road Network in the nearby villages.
Tree Plantation in Wastelands.
Richardson & Cruddas (1972) Ltd. I-4
Adoption of few village for infrastructure developments (Sanitation,
Education, Health & Water Supply)
9.6 Occupational safety and health
Maintenance of occupational safety and health is very closely related to
productivity and good employer-employee relationship. In addition to these, safety
of employees during construction, operation and maintenance of plant and
equipment shall be achieved by following proper safety measures.
For occupational safety, the following will be provided.
• Inspection and maintenance of pollution control systems only after getting
official shutdown or with permission of authorized officer.
• Regular cleaning of floors, road, rooftops, conveyer galleries and any other
dusty place.
• Checking for availability of spray water system for moistening the coal
yard/dump. Heat insulation of hot surfaces
• All pollution control systems will be interlocked with operation of process
equipment.
• The workers exposed to noisy equipment will be provided with ear plugs. If
necessary, the duty hours will be rotated, so that noise exposure time is kept
within specified limits.
• Regular medical check up for the employees will be done.
9.7 Environment management department (EMD) An Environment Management Department (EMD) headed by a General Manager with
adequate number of analysts, scientists and engineers, who will be responsible for
environmental monitoring and also initiate environment improvement in line with
ISO-14001 systems will be established.
The EMD will interact with the various units of plant, Environmental Laboratory &
Horticulture Department, for functional requirements primarily responsible for
work environment monitoring and industrial hygiene. The EMD will also conduct
Richardson & Cruddas (1972) Ltd. I-5
monitoring of air, water, noise and soil in and around the plant. The major portion
of work under EMP Implementation and monitoring will be carried out by EMD.
To achieve the objectives of pollution control, it is essential not only to provide
best pollution control and monitoring systems but also provide trained manpower
to operate and maintain such systems. So, the Environmental Management
Department (EMD) personnel will be provided with additional specialized training
to operate, maintain the equipment to be deployed on the installation. All persons
will be trained to deal with pollution emergencies also.
Richardson & Cruddas (1972) Ltd. I-6
CHAPTER X SUMMARY AND CONCLUSION
1.0 Introduction
M/s BMM Ispat Ltd. (BMMl) is a registered company under Companies Act 1956,
promoted by Mr. Dinesh Kumar Singhi, proprietor of Singhi Group of companies in
Bellary District, Karnataka. The Singhi group is a well known business group in the
field of mining iron ore and has its mining operations in Bellary-Hospet-Sandur belt.
The group is also operating a mini steel plant producing Sponge Iron, TMT Bars and
Electric Power at Danapur, Hospet Taluk in Bellary District of Karnataka. The Group
sales turnover is exceeding Rs. 442 crores. The companies belonging to Singhi
Group are
• BMM Ispat Ltd., Danapur
• HKT Mining Pvt Ltd., Danapur
• Bharat Mines and Minerals, Bellary
BMM intend to put up a 2.0 Mt/yr Integrated Steel Plant to produce rolled steel
products and 1.4 MT of BF slag based cement plant. The power requirement for the
steel plant will be met by captive power plant of 230 MW.
1.1 Scope of the EIA study
A detailed presentation was made before the Expert Appraisal Committee of the Ministry of Environment & Forests (MoEF) on 7th July, 2008. MoEF have provided the TOR vide their letter no. F. No. J-11011/236/2008-IA-II dtd. 07.07.2008 for the preparation of EIA / EMP report. The EIA/EMP report has been prepared as per the approved Terms of Reference issued by MoEF.
2.0 Project Description
It is proposed to provide iron ore Beneficiation which can convert low grade iron
ore into a high grade concentrate to feed the Pellet Plant and sinter plant.
Depending on the characterization of the ore, gravity and magnetic separation
methods will be employed to beneficiate the ore. Non recovery type Coke Ovens
Plant will be installed to supply coke to Blast Furnaces and coke breeze to Sintering
Plant. The sensible heat in the coke ovens gas will be used for power generation. A
230 MW Captive Power generation using coke oven gases, DRI kiln gases and coal is
Richardson & Cruddas (1972) Ltd. I-7
proposed. A Pellet Plant is proposed to manufacture pellets, which would be used
to feed DR plant and replace lump iron ore in the Blast Furnace. Sinter Plant will
supply fluxed sinter to the Blast Furnace and will aid in achieving high productivity.
Sinter Plant will be supplied with high grade iron ore concentrate from the
Beneficiation Plant. Liquid iron or hot metal, as it is known in steel industry, will
be produced in high energy efficient Blast Furnaces, where coal dust injection will
be practiced to reduce the requirement of metallurgical coke. Electric steel
making and oxygen blown steel making are considered to produce liquid steel and
feed the continuous casting machines. The feed to the hot strip mill will be slabs
and to non flat rolling mills, it will be billets. The Rolling Mill will be designed to
produce both flat and non flat products utilizing the state of art technology.
Granulated slag from Blast Furnace, clinker, gypsum and coal are used for
manufacturing of Portland cement.
The various unit operations envisaged under the proposed 2 Mt/year Integrated Steel Plant are indicated in the below table.
Manufacturing Units Unit Capacity
Iron Ore Beneficiation Plant Mt/year 3.4 Pelletization Plant Mt/year 1.20 DRI Plant Mt/year 0.7 Coke Ovens Mt/year 0.8 Sinter Plant Mt/year 2.5 Blast Furnace Mt/year 1.7 EAF & BOF steel making Mt/year 2.3
Continuous casting machines • Slab Caster • Billet caster
Mt/year 1.10 1.10
Rolling Mills • Hot strip mill • Structural / wire rods
Mt/year
1.00 1.00
Oxygen Plant t/year 2x500 Calcining kilns t/year 1080 Cement Plant Mt/year 1.4 Power Plant MW 230
Estimated cost of the project : Rs. 6151.3 Crores
Project Completion Target : September 2012
2.1 Raw Material Requirement
Richardson & Cruddas (1972) Ltd. I-8
Raw material Quantity Mt/year Source
Low grade iron ore fines 4.4 Captive mines and from indigenous sources
Iron ore pellets 0.43 Indigenous source Bentonite 0.008 Indigenous source Non coking coal 1.243 Imported Coking coal 0.92 Imported Limestone 0.53 Indigenous source Dolomite 0.34 Indigenous source Quartzite 0.13 Indigenous source Clinker 0.73 Indigenous source Gypsum 0.04 Indigenous source 2.2 Man power
The manpower required for the proposed integrated steel plant, cement plant and
Captive power plant is indicated below.
Sl.No Category Nos.
1 Managerial 340
2 Supervisory 1070
3 Skilled 2680
4 Unskilled 510
Total 4600
3.0 Description of Environment 3.1 Location
The proposed plant is located near Danapura village in Mariammanahalli Hobli,
Hospet Tq, Bellary (Dist.), Karnataka. The latitude and longitude of the project site
is 15°5’ - 15°10’N and 76°22’ – 76°27’E respectively in the Topo sheet no 57A/8.
The proposed plant area is surrounded by iron ore mines.
3.2 Land
Richardson & Cruddas (1972) Ltd. I-9
The government of Karnataka has already allotted 1429 Hectors of land in
Danapura, Nagalapura, Danayanakere and Garaga villages in Hospet Taluk in Bellary
district and acquisition of land is in progress.
3.3 Water requirement
The Government of Karnataka has already allotted 100 MLD (22 MGD) of water from
downstream of TB dam/Almathi dam/ ground water.
3.4 Power
The annual electrical energy consumption in the plant is estimated to be about
1740 million units. The average demand of the plant is estimated to be 230 MW. It
is proposed to meet the entire requirement of electric power from captive sources
taking the support of State Electricity grid for stability.
3.5 Baseline Environment
Monitoring of Ambient Air, Noise level, Surface & Ground Water quality, Soil &
Socio Economic Study was carried out during December`07- February`08 (winter)
3.6 Micro Meteorology
Meteorological data collected during the study reveals the following status.
Predominant wind was from Northeast quadrant. Wind velocity readings were
ranging from 1.2 to 18.8 Kmph. Temperature values were ranging from 15.0 °C to
30.5°C. The mean relative humidity value was found to be 66.7%. Sky was clear
during the study period. The mean atmospheric pressure was found to be 752 mm
of Hg. A total rainfall of 17.3 mm was recorded during the study period.
• Ambient air quality: Ambient air quality in both core zone and buffer zone (10
km radius from core zone) showed the SPM, RSPM, SO2 and NOx are well within
the NAAQ standards specified for rural and residential area.
• Noise levels monitored in core zone and buffer zones were found to be well
within limits.
• Water samples collected within study area showed compliance of all
parameters with the prescribed standards.
• Soil samples analysis showed moderate fertility.
• Socio-economic status of the study area is found to be moderate.
Richardson & Cruddas (1972) Ltd. I-10
• Ecological Environment. No endangered and Endemic species have been
identified. As such, conservation plan is not needed.
4.0 Anticipated Environmental Impacts and Mitigation Measures
4.1 Environmental Attributes likely to be affected and the activities responsible
are indicated below.
Table 4.1 Impact Identification Matrix
Actions Raw material storage and handling, Steel production and other allied activities
Post Operational
Phase
Environmental Attributes
Cons
truc
tion
Pha
se
Ope
rati
onal
Pha
se
Mat
eria
l Han
dlin
g
Ore
Sto
rage
/
hand
ing
Wat
er d
raw
l (S
urfa
ce w
ater
)
Wat
er d
isch
arge
Mai
nten
ance
W
orks
hop
Pow
er g
ener
atio
n by
DG
set
Gre
en B
elt
deve
lopm
ent
Empl
oym
ent
Urb
aniz
atio
n (B
uffe
r zo
ne)
Tran
spor
tati
on
Ambient air
Water resources
Water quality
Ambient Noise
Flora & Fauna
Soil & Land use
Infrastructure
Health & Safety
Socio-economics
Aesthetics
Adverse Impact Beneficial Impact 4.2 Air Pollution Control Measures proposed for various sources to
mitigate Air Emission and to meet the standard stipulated by the State Pollution Control Board are furnished below.
Sl. No Area of operations Air pollution control measures proposed
to be adopted 1 Raw material handling
· Dust suppression systems (chemical and dry fog
Richardson & Cruddas (1972) Ltd. I-11
type) Fugitive emissions in material
handling · Water sprinklers
· DE systems with bag filters in case of conveyors,
lime handling
2 Sponge Iron Plants Electrostatic precipitators, bag filters 3 Sinter Plant
Raw material preparation and handling (procurement of proposed sized materials to minimize crushing and screening) · DE systems with bag filters
Sintering process · ESP for collected waste gases Sinter screening and transport · Bag filters 4 Pelletization Plant
Raw Material Preparation and
Handling · DE System with bag filters. Pelletization Process · ESP 5 Blast Furnaces De-dusting with bag filters
6 Cacination · Bag filters
7 Steel melting shop Bag filetrs 8 Coke oven plant De-dusting with bag filters 9 Rolling mills Use of Low sulphur fule
10 Power Plant WHRB & AFBC · Electrostatic Precipitator
11 Coal Handling Plant · Bag filters 12 Cement plant · Bag filters
4.3 Air Environment: Post - Project Scenario
Ambient Air Quality at the station monitored are furnished below together with the predicted values due to the proposed activity. The post project scenario is compared with the stipulated standards. The details are furnish in the below table.
(Units in µg/m3)
Baseline scenario (max) Predicted values Post Project
scenario NAAQ standards Sl. No.
Location name SPM SO2 NOx SPM SO2 NOx SPM SO2 NOx SPM SO2 NOx
1 Proposed Plant (A1) 176 9 18 41.3 41.2 25.6 217.3 50.2 43.6 500 120 120 2 Existing Plant (A2) 186 16 30 24.5 31.6 28.2 210.5 47.6 58.2 500 120 120 3 Dhanapura (A3) 146 7 10 23.1 28.4 26.1 169.1 35.4 36.1 200 80 80 4 Marimanhalli (A4) 145 8 18 21.0 12.6 12.5 166.0 20.6 30.5 200 80 80 5 Nagalapura (A5) 132 7 12 9.2 21.2 11.8 141.2 28.2 23.8 200 80 80
6 Mugimavinahalli (A6) 146 8 18 3.8 6.8 1.2 149.8 14.8 19.2 200 80 80
7 Haravanahalli (A7) 115 7 10 4.8 8.9 1.8 119.8 15.9 11.8 200 80 80 8 Ramgad (A8) 132 8 16 3.9 2.1 0.8 135.9 10.1 16.8 200 80 80 9 Medarahalli (A9) 134 8 14 4.9 1.3 0.4 138.9 9.3 14.4 200 80 80 10 Vysankari (A10) 112 7 12 3.6 2.4 1.4 115.6 9.4 13.4 200 80 80
4.4 Water Environment The estimated water requirement for the industry is 100 MLD mostly used as
makeup water. The industry is adopting state of Art Technology in its water use
and “Zero discharge” of effluents Concept is adopted.
Richardson & Cruddas (1972) Ltd. I-12
Water Pollution Control Measures adopted in the industry are furnished below.
Sl. No
Source Pollutants
Control system / Treatment
1. Raw material handling yard SS Catch pits followed
2 Raw Water Treatment plant SS, Colloidal matter,
Dissolved gases, micro-organism
Chemical coagulation with sedimentation and filtration
3. Beneficiation Plant Hydrocyclones, Thickneres, slim pond
4. Pellet Plant Collection sump, guard pond
5. Sponge Iron Plant Collection tank & Ash handling dust suppression
6 Blast furnace SS Clarifier, Thickener, Sludge
Pond 7 DM Plant pH Neutralization pit 8 Steel Melting shop SS Guard pond
9 CCM Suspended Solids, Oil & Grease
Settling Tanks fitted with Oil & Grease Trap
10 Calcination & Oxygen plant SS, Alkalinity Settling with Guard pond
11 Rolling Mills SS, Oil & Grease , mill scale
Settling Tanks fitted with Oil & Grease Trap
12 Captive Power Plant Direct use in ash handling & excess to guard pond
Cooling Tower & Boiler bow down
Temperature, Dissolved Solids
Reused in the plant for dust suppression and slag granulation
13 Sewage Treatment system BOD, Suspended Solids Sewage treatment plant
4.5 Based on the above studies following conclusions are drawn • Air Environment : No significant impact is expected on Air Environment • Water Environment: No significant impact is expected on water quality
• Noise Environment: No significant impact on Noise Environment. The
predicted noise levels will be within the limits as prescribed by CPCB
both during construction and operational phases of the industry.
• Land Environment : No significant impact on land environment
• Biological Environment : No significant impact
• Socio-Economic Environment: The project will have positive impact in terms
of employment, infrastructure facilities and enhancement of per capita
income in the near by region.
5.0 Environmental Monitoring Program
Richardson & Cruddas (1972) Ltd. I-13
A monitoring strategy is required to ensure that all environmental resources which may be subject to contamination are kept under review and hence monitoring of the individual elements of the environment is necessary. BMM will install a Automatic weather monitoring stations to measure Wind speed and direction, Rainfall and temperature and humidity on hourly basis. On-line continuous monitoring system will be installed in stacks to monitor particulate matter. BMM will monitor the ambient air quality regularly at five locations in and around the plant (downwind direction and where Max. GLC of SPM, SO2 & NOx) to ascertain the effect of process emissions on the ambient air quality. Surface and ground water will be sampled regularly once in a season from various locations in and around proposed plant to ascertain the trend of variation in the water quality, if any. Treated process wastewater quantity will also be monitored for pH, TSS, COD and Oil& Grease regularly. Ambient and work zone noise levels will be measured on quarterly basis- Occupational health surveillance of the workers will be done on regular basis especially for those to be engaged in handling hazardous substances and high noise generating equipment. Trees survival rate will be monitored in the plantation areas and will be maintained at about 80% by replacement of dead trees. The BMM will have structured interactions with the plant surrounding village’s people to disseminate the measures taken by the BMM and also to elicit suggestions for overall improvement of the surrounding villages. A separate Environment Management cell equipped with full-fledged laboratory facilitate will be set up to carry out environmental management and monitoring functions.
Richardson & Cruddas (1972) Ltd. I-14
6.0 Additional Studies
6. 1 Disaster Management Plan
• Identification of hazards
• Risk assessment of hazards
• Risk management applications
I . Preventive measures
II. On site emergency preparedness plan
• Off site emergency preparedness plan
• Industrial safety and fire fighting
• Rescue and repair services
• Shop level disaster control cell
• Central disaster control room
• Information flow
6.2 Resettlement & Rehabilitation Plan
The State Government in its order No.CI/312/SPI/2008 dated 21.10.2008
has permitted the proponent to acquire 1429 hectares of land (3530.70
acres) coming in the jurisdiction of Danapura, Nagalapura, D.N. Kere,
Byalkundi, Garaga villages. Out of 1429 hectors, 785.54 hectares is
patta land and the remaining 643.35 hectares is Government Lands.
The proponent is willing to adopt a benevolent farmer, friendly
Rehabilitation and Resettlement Policy and is willing to discharge
its social responsibility to benefit the surrounding villages.
6.3 Objectives of R&R Plan
Though there is no displacement of any farmer or landless laborer from their
Habitation and yet the proponent is willing to adopt a benevolent farmer
friendly Rehabilitation and Resettlement Policy and is willing to discharge
its social responsibility to benefit the surrounding villages. The features of
such a policy may include the following.
Richardson & Cruddas (1972) Ltd. I-15
1. The recommendations of Sarojini Mahishi committee report will be
adopted in the recruitment of staffs.
2. As far as possible the recommendations of the National Rehabilitation and
Resettlement policy 2007 pronounced by Government of India will be
adopted.
3. The Proponent is willing to provide one job either to the Khatedar who
has sold the land to the company or to one member of his family to be
identified by the Khatedar, commensurate with his or her education
qualification, age and suitability for the job.
If needed, the proponent is willing to deploy to the extent of man power
required for the development of the green belt each year, the services of
landless labourers and farmers belonging to the above 5 villages in this
program.
6.4 In addition to a benevolent rehabilitation policy, the proponent is
likely to carry out the following social responsibilities.
• The company may adopt few villages located in the Study Area.
• The company will improve the drinking water supply, street light and
maintain them.
• The company will provide adequate drainage & sanitation facility to these
villages and plant trees in the village limits & develop green belt around the
villages.
• The company will build additional rooms to the existing schools wherever it is
needed, provide drinking water and adequate sanitation facilities in these
schools.
• The company will extend financial help in providing Mid-day meal to school
going children.
• The company through their hospital will extend medical facilities to such
villages.
Richardson & Cruddas (1972) Ltd. I-16
• Widows and unmarried daughters of the land loosers from these villages will
be trained in tailoring and sewing machines will be supplied to each one of
them.
• If the village authorities desire, the company will be willing to take up
maintenance of the water body (Tank) of these villages.
6.5 Diversion of inter connecting village roads passing through the Project
area Following village connecting roads are passing through the proposed project area.
1. Danapur – Garaga Tanda
2. DN Kerre – Garaga Tanda
3. Mariammanahalli – Garaga Tanda
4. Nagalapura – Garaga village
The above village roads need to be diverted to provide connectivity to the road
users. The project proponent is willing to undertake diversion of these roads at his
cost in consultation with concerned village elected representatives. The project
proponent is making adequate budget provision for diversion of these roads.
7.0 Project benefits
• State Industrial & Mining Policy is favoring the proposed project
• Direct employment for about 4600 people.
• Earnings by the Govt. by way of taxes levies and duties like ED, IT, VAT, TDS
etc
• Business opportunities for the local entrepreneurs to set up small and
medium scale industries
• Business opportunities for the local entrepreneurs serving as service
providers, suppliers, contractors
• Investment opportunity for local infrastructure development
• Improvement In The Physical Infrastructure like road and rail net work
• BMM Ispat Ltd will undertake various community welfare measures for
upliftment of plant surrounding villages.
• Plant township hospital and schooling facilities which will also help local
population to enjoy the fruit of better facilities in nearby.
Richardson & Cruddas (1972) Ltd. I-17
8.0 Environnemental Management Plan
8.1 Air Pollution Control
Fugitive dust emission will be extracted by extractors with dry fogging and will
be treated in bag house and discharged through tall stacks for atmospheric
dispersion. Suspended particulate matters are arrested by ESP and discharged
through tall stacks by induced draft fans. Material and product yard fugitive
emissions are controlled by dust suppression with sprinkling water. A general
enforcement in air pollution control process is observed which include
Stable and consistent operation of all steel production units
Correct proportion of feed materials
Hood and dust extraction, wherever required
8.2 Water pollution control
These measures include conservation of water by Rainwater harvesting and
waste water treatment, recycling and reuse. The zero discharge concept will be
adopted.
8.3 Conservation of water
• Rain water harvesting
• Design of units for less amount of water and recycle of water to the
maximum by cascading use of water
• Use of boiler blow downs and cooling water blow downs for slag quenching,
green belt development
8.4 Waste water treatment, recycling and reuse
Richardson & Cruddas (1972) Ltd. I-18
Gas cleaning plant waste water, billet cast and mill effluents, thermal power
plant, cooling tower blow downs are separately treated with standard process
and the treated effluent are utilized for slag quenching, ash handling. Excess
treated effluents are stored into a guard pond for further secondary use in the
plant and for Green Belt Development activities. Treated sanitary waste water
will also be used for gardening.
8.5 Noise pollution control
• Design of equipment for less noise generation
• Dynamic balancing and vibration damping by suitable mounting mechanism
and proper grouting
• Separate housing of high noise product machinery
• Use of ear plugs in very high noise prone areas
• Green belt development around each unit
• Road side tree plantation
8.6 Solid Waste Management
Major solid waste will be reused in the plant itself. Fly ash will be utilized in
cement manufacturing. Other solid waste generated, which are not usable for
any purpose will be disposed in control land filling in an identified area with in
the plant premises.
8.7 Energy conservation measures
• Adoption of CDM mechanisms
• Adoption of “power saving is power produced” principle
8.8 Green belt development
Out of the total area of 1429 Hectors Green Belt will be develop on 472
Hectres. The local plant species will be selected based on soil quality. The
plantation will be taken up at the following areas.
• At plant boundary
• At road sides
Richardson & Cruddas (1972) Ltd. I-19
• Around various steel producing units
• Around office and other buildings
• Stretch of open land
The year -wise planning of the trees & shrubs is presented below.
Year Number of plant species to be planted Shrubs Landscaping
2009-2010 1,00,000 - - 20010-2011 1,50,000 10000 Grasses & Avenue plants 20011-2012 2,00,000 20000 Grasses & Avenue plants 2012-2013 1,00,000 10000 Grasses & Avenue plants 2013-2014 1,00,000 10000 Grasses & Avenue plants
Total 650000 50000 -
8.9 Cost of Pollution Control/ Environmental protection Measures
Area of Expenditure Recurring cost per
annum (Rs. in Crores)
Capital Cost (Rs. in Crores)
Air Pollution Control 10.0 200.0
Water Treatment System 10.0 50.0
Waste Water Treatment System 3.0 30.0
Solid Waste Management System 5.0 50.0
Noise Pollution Control 0.50 2.0
Environmental Monitoring and Management
2.50 10.0
Social corporate responsibilities 2.0 10.0
Road diversion/development/Modification 2.0 15.0
Occupational Health 1.50 3.0
Greenbelt Development 5.0 25.0
Others 0.25 2.0
Total 41.75 397.00
Percent of recurring cost in terms of Capital Cost for pollution control measures
10.52 -
Percent of capital cost of pollution control measures in terms of total project cost
- 6.45
Richardson & Cruddas (1972) Ltd. I-20
9.0 Conclusion
The potential environmental, social and economic impacts of the project have been assessed and comprehensive mitigation and community developmental plans have also been developed integrating the safety and health system in the work place.
M/s. BMM Ispat Limited will successfully implement the environmental protection and safeguard measures as per EMP at a capital cost of Rs.397.00 Crores and a recurring expenditure of Rs.41.75 crore per annum. Environmental Management Plan will be exercised at
Design stage
Construction stage
Operational stage to meet all the consent norms of KSPCB and
Environmental condition as per MoEF / CPCB direction.
With commitment and dedication, BMM Ispat Ltd. will commission the Integrated
Steel Plant, cement plant and captive power plant with modern equipments.
Recommendations made in the CREP for the integrated steal plant and draft
guidelines by CPCB for Sponge Iron Plant will be totally implemented. BMM Ispat
Ltd. has committed to responsible environmental protection. BMM Ispat Ltd has
been discharging its social responsibility and is willing into carry this forward and
strictly implements its declared R&R policy and helps this area to achieve
economical Prosperity.
Richardson & Cruddas (1972) Ltd. I-21
CHAPTER XI
CONSULTANT DETAILS
11.1 Environment Impact Assessment Study
Richardson & Cruddas (1972) Ltd., Chennai
A Govt. of India undertaking under Ministry of Heavy Industry, one of the pioneers in
the field of Environmental Engineering for the past three decades. R&C Laboratory is
recognised as Environmental Laboratory by the Central Pollution Control Board
(CPCB), Ministry of Environment & Forests (MoEF) under the Environmental
Protection Act, 1986 and is, also, recognised by Tamil Nadu Pollution Control Board
for carrying out air and waste water emissions monitoring as per Air (Prevention and
Control of pollution) Act, 1981 and Water (Prevention and Control of Pollution) Act,
1974. We are also recognised by various other State Pollution Control Boards as
Environmental Consultants for such studies.
R&C is regularly undertaking EIA, EMP, DMP, Risk Analysis, Pollution Atlas,
Prediction Modelling studies besides ambient air, stack emission, water/
wastewater/sewage, sediment/ soil quality monitoring, analysis & operation and
maintenance of Treatment plants.
11.2 Feasibility/ Environmental Study
FerroGreen Technologies Pvt. Ltd, Bangalore.
FerroGreen Technologies Pvt. Ltd., (FGT) is promoted by Dr. S. K. Gupta and Dr. T. M. Srinivasan with the aim of providing engineering and technology implementation and associated consultancy/advisory services in the Iron & Steel domain comprising iron and steel, mining, mineral engineering, power & industrial gases. The services include Engineering, Construction & Project Management, Environmental Management, etc, to cater to the needs of various Clients. Following divisions constitute FerroGreen Technologies:
• Technology Development
• Technology Implementation
• Assistance for Take-Over/Acquisition of Steel Companies by carrying
out Asset Valuation & Technical Due Diligence of Steel Plants
Richardson & Cruddas (1972) Ltd. I-22
FGT will provide expert services whenever requested/required and offers a single
window services to the promoter(s) / investor(s).
Environment & Power Technologies Private Limited, Bangalore
Environment & Power Technologies Private Limited, [EPTPL] is a private company
manned by eminent and qualified Technocrats having practical experience for
more than three decades, in the field of Environmental Protection & Power
Technologies. The main objective of the company, while offering technical
consultancy is to protect/conserve environment and contribute to sustainable
power development through renewable energy sources. Till date the company has
handled, Environmental Issues concerning Bulk Drugs and Pharmaceutical
Industries, Sugar, Distillery, Thermal Power Plants, Mining Industry, Integrated
Steel Plants, Cement Plants, Residential Layouts, Hospital, Wind Mills, Mini Hydel
Plants, etc., and helped these industries in getting necessary Statutory Clearance
such as Single Window Clearance from State government, Environmental Clearance,
Consent for Establishment, Consent for Operations, Water permissions, Renewal of
consents, etc. Besides 10 Directors (one PhD Holder, six Post Graduates in
Environmental Engineering, one in Power Engineering and one Mechanical Engineer,
and one Software Engineer) it has three Environmental Engineers, one Civil
Engineer and two administrative Staff assisting EPTPL as supporting staff.