GTATA

BY REGD. POST TSI/J/E9.3/TMD/220Date: 27.05.2019

ToThe Chief Conservator of ForestsRegional Office, Eastern Region,Ministry of Environment Forests & CCA-3, Chandrasekharpur,Bhubaneswar-751 023

Dear Sir,

Sub: Six Monthly Compliance Report on Environmental(From 1st October, 2018 to 31StMarch, 2019)

EC Ref. No. J-11011/16/2004-IA (I) dt. 11.11.2004, J-11011/3/98/1A II (I) dt. 14.10.1998 andEC Ref. No. J-11011/16/2004-IA.1I (I) dt. 01.05.2017 and

EC Ref. No- J-11011/16/2004-IA.1I (I) dt. 19.11.2018

Please find enclosed the six monthly compliance report on the environmental performance(including the details of expenditures incurred) of Toto Sponge Iron Limited, Joda, Odisha for theperiod from 1st October, 2018 to 31st March, 2019.

Thanking You,

Yours faithfully,

~ _;-{)rv--PAti::;:

~~(TM DANDAPAT)Head (Safety & Environment)

Cc: Director,Ministry of Environment & Forests(IA Division)Indira Paryavaran Bhavan,

Jorbagh, New Delhi-110003Cc: The Zonallncharge,

Central Pollution Control Board,Southend Conclave# 502, 5th floor,582, Rajdanga Main Road,Kolkata - 700 107

Cc: Member Secretary,State Pollution Control BoardParyavaran Bhavan,A/ 118, Nilakanthanagar,Unit-VIII, Bhubaneswar-751 012

Cc: Regional Officer,State Pollution Control Board Odisha,At/Po: Baniapat, College Road Keonjhar,Dt. Keonjhar, Odisha

TATA SPONGE IRON LIMITEDPO Joda Dist Keonjhar Odisha 758 034 India

Tel +91 6767 278178 Fax 278159 Email info@tatasponge.comCIN No. L271020R1982PLC001091

TATA SPONGE IRON LIMITEDEnvironmental Compliance Report

Period: 01/10/2018 to 31/03/2019

ECRef. No. J-11011/16/2004-IA(I) dt. 11.11.2004 andJ-11 011/3/9811A II (I) dt. 14.10.1998

A. Specific Conditions and its compliance Report:

Specific Conditions Compliance

i. The gaseous emission from various process units shouldconform to the load/mass based standards notified bythis ministry on 19th may, 1993 and standardsprescribed from time to time. The state Board mayspecify more stringent standards for the relevantparameters keeping in view the nature of the industryand its size and location. At no time the emission levelshould go beyond the prescribed standards. In the eventof failure of any pollution control system adopted by theunit, the respective unit should not be restarted untilthe control measures are rectified to achieve the

desired efficiency.ii. There should be no discharge of process effluent. As

reflected in the EIA/EP report; the company shouldundertake water conservation measures by recyclingthe hot water through cooling tower and existingcooling pond to bring down the makeup water

requirement for the proposed 3rd kiln. The existingcooling pond should be used for storage of water for

miscellaneous use. The domestic waste water aftertreatment in STP should be used for green beltdevelopment.

iii. In plant control measures for checking fugitiveemission from spillage /raw materials handling shouldbe provided. Further specific measures like provisions of

dust extraction and dust suppression system for productand raw material handling, water sprinkling system at

the waste disposal area to control the fugitive emission

should be provided. Data on fugitive emission should be

regularly monitored and records maintained.

iv.The company should provide gas cleaning system. The

waste gas should be passed through the dust catcherfollowed by combustion of unreacted COwith excess airin the post combustion chamber. The particulate

emission should be controlled by installation of ESP.

The gaseous emission from various process units conform tothe standard notified by the Govt. The emission data for thelast six months is given in Annexure-I indicating that emissionlevel is within the prescribed limits. The plant is operatedwith all adopted pollution control measures.

There is no discharge of process effluent. The company hastaken 100%water conservation measures by recycling the hotwater through cooling tower. The domestic water and blowdown water after treatment is being reused for Brick plant,dust suppression, road washing, firefighting and gardeningpurpose. STP(Sewage Treatment Plant) has been installed atTSILtownship and the water is used for dust suppression atdump yard.

The control measures for checking fugitive emissions fromspillage /raw materials handling are in place. Dust extractionsystem, chemical dust suppression system and telescopicunloading spouts at different unloading points of bunkers forthe product and raw material handling system have beeninstalled. One movable high pressure water fogging canon isavailable to control sporadic fugitive dust. Two numbers ofwater tankers are used to control fugitive dust emissions atthe waste disposal area and also on the road as well as at therailway siding. Road vacuum cleaner is used for sweepingdust from the roads. 1no. tyre washing facility has beeninstalled at material handling area to minimize road dust. Thedata for fugitive dust emission at 10 (ten) identified points,measured at a distance of 10 meters from the sources is givenin Annexure-II

Suitable gas cleaning systems have been provided. The wastegas passes through the dust catcher (OSe) followed by postcombustion chamber (PCe) where CO reacts with excess air.The particulate emission is controlled through installation ofESPs.The data on particulate emission from stacks is given inAnnexure-I.

TATA SPONGE IRON LIMITED

Specific Conditions ComplianceV. As per the solid waste management plan submitted to

the Ministry, the company should enhance efforts for

reuse of solid waste by brick making and sale for other

useful purposes. The part of the sludge, ESPdust andchar should be disposed off in the dump area for which

a separate area of 17.5ha of area has been earmarked.A garland drain all along the solid waste dump areashould be constructed to prevent the run off during the

rainy season. Further as reflected in the EIA/EMPreport, a compound wall should be constructed along

the river stretch to prevent the ingress of solid waste

into the river.

rvl. A green belt of adequate width and density should be

developed in 25% of plant area, and along theboundary wall of the solid waste dump site as per the

CPCBguidelines.

rvll. Occupational Health Surveillance of the workers

should be done on a regular basis and recordsmaintained as per the Factories Act.

Under solid waste management plan, company hasenhanced its brick manufacturing capacity substantially.During 2018-19, company has utilized 100% of (fly ash)through various initiatives. The solid waste such as char,de-dusting material etc are being sold 100% to theparties for industrial use. The balance quantity of wasteis disposed off at identified areas within the plantpremises. In the year 2018-19, total 92% of waste isbeing utilized or sold. A garland drain has been providedalong the boundary wall to restrict the movement ofsolid waste during monsoon run off.

A thick green belt has been provided along the plantpremises to arrest the propagation of dust. Every yearfocused plantation program is organized. The overallgreen cover is more than 33% of the total area. 50 far1,72,700 trees have been planted by the company withsurvival rate of >95%.

As per Factories Act, company carries out the healthcheckup of its employees and contract workers on everyyear and records of the same is maintained. 100%employees and contract workers were covered for themedical checkup. The data of medical checkup is givenin Annexure-III.

fJlIl. Recommendations made in the CREP should beimplemented.

As per CREP, various control measures are taken tocontrol primary and secondary emission which includeE5Ps, Dust extraction systems, chemical dustsuppression systems, telescopic unloading spouts, roadwater sprinklers, road vacuum cleaning machine, mobilehigh pressure fogging machine, high pressure dry fogsystem at inlet and outlet of raw material conveyor andvibrating screen etc.

TAT A SPONGE IRON LIMITED

B. General Conditions and its compliance Report:

General Conditionsi. The project authorities must strictly adhere to the

stipulations made by the Orissa Pollution Control Board

and the State Government.

ii. No further expansion or modification in the plant

should be carried out without prior approval of theMinistry of Environment and Forests.

iii. At least four ambient air quality-monitoring stations

should be established in the downward direction aswell as where maximum ground level concentration ofSPM,S02 and NOx are anticipated in consultation withthe State Pollution Control Board. Data on ambient air

quality and stack emission should be regularlysubmitted to this Ministry including its Regional Officeat Bhubaneswar and the State Pollution ControlBoard/Central Pollution Control Board once in sixmonths.

iv. Industrial waste water should be properly collectedtreated so as to conform to the standards prescribedunder GSR 422(E) dated 19th May 1993 and 31st

December, 1993 or as amended form time to time. The

treated waste water should be utilized for plantationpurpose.

V. The overall noise levels in and around the plant areashould be kept well within the standards (85 dBA) byproviding noise control measure including acoustic

hoods, silencers, enclosures ect, on all sources of noisegeneration. The ambient noise levels should conform

to the standards prescribed under EPARules, 1989 viz.75 dBA(daytime) and 70 dBA (night time).

VI. The project proponent shall also comply with all the

environmental protection measures and safeguards

recommended in the EIA/EMP report. Further, the

company must undertake socio-economicdevelopment-activities in the surrounding village like

community development programmes, educational

programmes, drinking water supply and health careetc.

ComolianceThe company follows the stipulation made by SPCBandthe State Government.

Company shall not carry out any further expansion ormodification in the plant without prior approval of theMoEF.

3 nos. numbers of online ambient air quality monitoringstations have been installed as per direction of StatePollution Control Board. The online data of ambient airquality & stack emission are going to the SPCBdirectlyfrom the monitoring stations and the same data aredisplaying at company's main Gate in a billboard.Monthly average of online AAQ & stack data's are alsosubmitted to The State Pollution Control Board everymonth and uploaded at company's website. Six monthlyreports of the same is regularly submitted to MoEF &SPCB.AAQ data is shown in Annexure-I.

Industrial waste water after necessary treatment isutilized for brick manufacturing, dust suppression inrailway siding and RM yard, dust suppression in dumpyard, firefighting, road sprinkling and plantationpurpose.

The overall noise level in and around the plant area isbeloW 85 dB(A). However, inside some machine rooms,where the noise level is higher, suitable PPEsare used.Also suitable instruction/signage have been displayed forproper utilization of PPEswhile working inside the sameareas. The noise level is also displayed outside of suchhigh noise areas. Noise monitoring data is given inAnnexure -I

Company has complied with all the environmentalprotection measures and safeguards indicated in theEIA/EMP report.Company has undertaken several initiatives for socio-economic developments in the surrounding villagesincluding community development programs such as;educational programs, drinking water facility, healthcare, distribution of clothes, toilet under swach bharatscheme, developing fruit orchard, Anganwadi Kendra,mosquito- nets etc. Company has a separate departmentof social welfare. Also company is supporting the socio-economic development through a charitable trust named'Vidyashakti Niyas'.

TATA SPONGE IRON LIMITED

VII. The project authorities will provide adequate funds

both recurring and non-recurring to implement the

conditions stipulated by the Ministry of Environmentand Forests as well as the State Government along with

the implementation schedule for all the conditionsstipulated herein. The funds so provided should not be

diverted for any other purposes.

VIII. The Regional office of this Ministry at Bhubaneswar/Central Pollution Control Board/ State Pollution ControlBoard will monitor the stipulated conditions. A sixmonthly compliance report and the monitored dataalong with statistical interpretation should be

submitted to them regularly.

IX. The project proponent should inform the public thatthe project has been accorded environmentalclearance by the Ministry and copies of the clearance

letter are available with the State Pollution Control

Board/ Committee and may also be seen at website ofthe Ministry of Environment and Forests athttp:/envfor.nic.in. This should be advertised withinseven days from the data of issue of the clearanceletter, at least in two local newspapers that are widelycirculated in the region of which one shall be in thevernacular language of the localitv concerned and acopy of the same should be forwarded to the Regionaloffice.

X. The project Authority should inform the Regional Officeas well as the Ministry, the date of financial closureand final approval of the project by the concernedauthorities and the date of commencing the landdevelopment work.

The company has a separate budget allocated for itsenvironmental expenditure. The expenditure during lastsix month is shown in Annexure -II

Six monthly monitoring report is regularly submitted toRegional Office of MoEF at Bhubaneswar, Zonal officeCPCBat Kolkata and SPCB,Bhubaneswar well within thestipulated time.

The company had advertised in the two widely circulatedlocal news papers within a week of grant of environmentalclearance by MoEF as per stipulation made

Information to the Regional office and the Ministry onfinancial closure and other information as desired weregiven for all previous project.

TATA SPONGE IRON LIMITEDAnnexure -I

A. ENVIORNMENTAl PARAMETERS

PM10: (Unit- (.lg/m3)

Location October'18 November'18 December'18 January'19 February'19 March'19

Plant Area 66.00 57.00 52.00 68.00 49.00 43.00

Township Area 66.00 53.00 54.00 84.00 62.00 55.00

Mobile Van at Main Gate 47.00 31.00 31.00 88.00 70.00 57.00

PM2 5: (Unit- Ilg/m3 )

Location October'18 November'18 December'18 January'19 February'19 March'19Plant Area 43.00 40.00 32.00 46.00 24.00 29.00

Township Area 41.00 39.00 29.00 64.00 40.00 39.00

Mobile Van at Main Gate 24.00 16.00 19.00 38.00 30.00 37.00

Measurement of 502, NOx & COParameters

Month LocationS02 ug/rn" NOx ug/rn" CO ug/rn"

October'18 Plant Area 15.90 15.27 1.58Township Area 23.3 31.8 3.12Mobile Van at Main Gate 44.9 20.96 0.98

November'18 Plant Area 13.5 11.89 2.38Township Area 23.2 26.48 1.23

Mobile Van at Main Gate 43.5 17.18 0.97December'18 Plant Area 13.00 11.66 2.30

Township Area 11.5 35.54 1.12Mobile Van at Main Gate 42.4 35.43 0.97

January' 19 Plant Area 11.2 11.51 1.23

Township Area 08.3 23.26 1.02

Mobile Van at Main Gate 23.8 10.01 0.6February' 19 Plant Area 11.50 0.66 1.01

Township Area 14.2 13.17 2.75Mobile Van at Main Gate 22.0 11.01 0.06

March'19 Plant Area 4.8 11.5 0.71Township Area

.1.9615.9 14.9

Mobile Van at Main Gate 18.0 11.01 0.06Stack Emission (Unit- rng/Nm")

Location October'18 November '18 December'18 January' 19 February' 19 March'19

PM S02 PM S02 PM S02 PM S02 PM S02 PM S02ESPOF KILN-I 40.00 150.5 68.00 133.6 62.00 122.0 47.00 144.5 49.00 91.1 50.00 83.0

ESPOF KILN-II 38.00 83.7 33.00 69.3 31.00 39.40 41.00 180.5 59.00 135.4 57.00 144.3

ESPOF KILN-III 50.00 203.3 58.00 92.7 52.00 90.70 60.00 198.0 66.00 157.9 64.00 158.2

DE-I 58.00 - ·61.00 - 63.00 - 63.00 - 60.00 - 62.00 -

DE-II 60.00 - 57.00 - 67.00 - 69.00 - 65.00 - 65.00 -

DE-III 42.00 - 44.00 - 40.00 - 45.00 - 39.00 - 39.00 -

Over all Noise level inside plant area in dB (A)October'18 November'18 December'18 January'19 February'19 March'19

80.82 80.72 81.02 80.89 80.79 80.95

Ambient Noise level inside plant area in dB (A)October'18 November'18 . December'18 January'19 February'19 March'19

52.18 52.4 53.38 53.31 53.6 54.37

TATASPONGE IRON LIMITED

Annexure -IIFugitive dust emission (Unit:llg/m3)

51.No. Location Particulate Matter in (ug/rn")

December'18 March'1901 Kiln-I 15B area 1103.00 1165.0002 Kiln-II 15Barea 1057.00 1173.0003 Kiln-III 15Barea 1196.00 1108.0004 Kiln-I cooler discharge area 988.00 1112.0005 Kiln-II cooler discharge area 801.00 866.0006 Kiln-III cooler discharge area 1103.00 988.0007 Iron ore feed hopper area 1023.00 1010.0008 Coal feed hopper area 983.00 875.0009 Iron ore screen area 904.00 1016.0010 Coal crusher area 973.00 918.00

Average 1013.10 1023.11

Expenditure Incurred in Pollution Control for running & maintenance of pollution controlequipment etc. during 01.10.2018 to 31.03.2019

SI. Particulars AmountNo.i) ESP-I,!I & III maintenance 4.19lakhs

ii) DE-I,ll & III systems maintenance 5.50lakhs

iii) Electricity charges of DE systems+ ESPsystem 133.56 lakhs

iv) Cooling water system of Kiln-I, Kiln-II & Kiln-lit (maintenance of Cooling Tower) 5.00 Lakhs

v) Vacuum Cleaning Machines 8.10lakhs

vi) Spraying of water and cleaning of roads:- 8.40 lakhs

vii) Repair & maintenance of roads and drains 40.001akhs

viii) Handling& Disposal waste materials 58.321akhs

ix) Digging of trenches & sweet soil spreading 5.00lakhs

x) Housekeeping of Platform, walkways, etc 23.40Iakhs

xi) Cost involved in Personal Protective Equipment's 7.50lakhs

xii) Ash handling system of (Boiler-l.ll & III) 2.00lakhs

xiii) Waste water treatment 6.20lakhs

xiv) Dust Suppression system 3.20lakhs

xv) Monitoring & Measurement of environmental parameters 2.25lakhsv

xvi) Expenditure for tree plantation 6.50lakhs

xvii) Any other expenditure on account of Control of pollution of air and water. 21.00lakhs

Total 340.12 Lakhs

TAT A SPONGE IRON LIMITED

C. HEALTH CHECKUP STATUS:-

MEDICAL CHECKUP for EmployeesFY 2018-19

Annexure -III

Medical checkup carried out- 364 (100% Compliance)

Risk LevelHealth Aspect ic------,,------

Normal Moderate

BMI10.71%BMI > 30

47·53% 41.76%BMI < 25 BMI25 - 30

DIABETES 72.80%< 140mg/dl

20.05%140-

199m9/dlHealth Index of Employees

7.14%> zoornq/dl

MEDICAL CHECKUP for Contract Worker~ __ ~~ (fY 2018-19)

HYPERTENSION 18.68% 42.58%120/80 or less 121-139/81-89

Total No of Contract Worker- 915Medical checkup carried out- 915 (100% Compliance)Average BM! Index- 22.43

HealthReport

BMI

Sugar Level

BloodPressure

Risk Level

Normal

2.08%< 100/60

3.17%BMI > 30

7·5%> 160 rnq/dl

Moderate

79·35%BMI < 25

17.48%BM125-30

9.72%> 140/90

92.45 %< 160 mg/dl

88.20%>100-140/

60-90

Health Index of Contract Worker~--------------

=

TATA SPONGE IRON LIMITED

Environment Clearance Compliance Report

Period- 01.10.2018 to 31.03.2019

ECRef No- ECRef. No. J-11011/16/2004-IA.1I(I) dt. 01.05.2017(Enhancement of DRIproduction 35,000TPAfrom 3,90,000 MTPAto 4,25,000 MTAP in the existing

facility)

A. Specific condition and its Compliance Report:

Specific Conditions Compliancei.The project proponent should install 24X7 airmonitoring devices to monitor air emission asprovided by the CPCB and submit report toMinistry and its RegionalOffice.

ii. All the conditions prescribed in theenvironmental clearance letter No. J-11011/16/2004- IA.II (I) dt. 11.11.2004.shallbestrictly complied with.

The company have been installed 3 nos.numbers of 24X7 online ambient air qualitymonitoring stations as per direction of StatePollution Control Board. The online data ofambient air quality & stack emission are goingto the SPCB directly from the monitoringstations and the same data are displaying atcompany's main Gate in a billboard. Monthlyaverage of online AAQ & stack data is alsosubmitted to The State Pollution Control Boardevery month and uploaded at company'swebsite. Six monthly reports of the same isregularly submitted to MoEF& SPCB.Six monthly monitoring report is regularlysubmitted to Regional Office of MoEF atBhubaneswar, Zonal office CPCBat Kolkata andSPCB,Bhubaneswar well within the stipulatedtime.We are compiling all the conditions prescribedin the environmental clearance letter No.J-11011/16/2004- IA.II (I) dt. 11.11.2004.

TATA SPONGE IRON LIMITED

Environment Clearance Compliance Report

Period- 01.10.2018 to 31.03.2019

ECRef No- ECRef. No. J-11011/16/2004-IA.1I (I) dt. 19.11.2018(Enhancement of DRI production 40,000 TPAfrom 4,25,000 MTPA to 4,65,000 MTAP in the existing

facility)

A. Specific condition and its Compliance Report:

Specific Conditions ComplianceI. All the conditions prescribed in the We are complying all the conditions prescribed inenviron menta I clearance vide file No. J- the environmental clearance letter No. J-11011/16/2004-IA.1I (I) dt. 11.11.2004 and 11011/16/2004- IA.II (I) dt. 11.11.2004 and01.05.2017 shall remain unchanged. 01.05.2017. The compliance status for both the

letter no has given above.II. The project proponent shall reduce the Sp. Consumption 2017-18 2018-19specific consumption of coal, energy, water Coal (T) (Ground

0.948 0.912and specific emission/discharge/production of Consumption)PM, 502, C02, waste water and solid waste as Coal (T) (Specificsubmitted and committed in their online Consumption)

0.899 0.881

proposal. Periodic compliance status in this Energy (MJ/Ton) 25.5 25.5regard shall be submitted to the Regional Water (KL/Tof DRI) 3.068 2.956office of the MOEF&CCat Bhubaneswar along

Specific Emission/generationwith the six monthly compliance report.PM (llg/m3) 49 50SO~(kg/hr) 115.89 76.58C02 (T/T of DRI) 1.83 1.85Solid Waste (T/ T ofDRI) 0.460 0.436

III. The PPshall take corrective action Compliance to letter no 101-162/EPE datedimmediately to the observations made in the 06.07.2018 issued by Regional office-certified compliance of Regional Office- Bhubaneswar, MOEFCC has been submitted onBhubaneswar issued vide letter No.101- 12.07.2018 vide our letter no162/EPEdated 06/07/2018 and action taken TSI/J/E9.3/TMD/ 440.report shall be submitted to the ministry anyRegionaloffice- Bhubaneswar within threemonths from the date of issue of thisEnvironmental clearance.IV. PPshall plant 10,000 trees as avenue The NH-520 construction is just started and notplantation with tree guard along NH adjacent yet completed, there is no free land available atto the plant site. present. Continuously We are in contact with the

NH authority. Once there will be availability offree space, the plantation activity will be started.

V.100% utilization of fly ash shall be achieved We are utilizing around 65% of fly ash generatedthrough brick production

,for brick manufacturing. In the financial year 1.13crore of fly ash bricks have manufactured. Rest of

the fly ash is being used for NH-520 constructionand reclamation of low laying area. 100%utilization of fly ash utilization has been achieved.We have an agreement with the NH authority tosupply 4 lakhs ton of fly ash for NH-520construction. The fly ash is supplied for the NH-520 construction as per their requirement.

VI. Installation of advance controller for We have installed the advance ESPcontroller inefficiency enhancement of ESPshall be done kiln-2 ESP. For Kiln-1 and Kiln-3 ESP, purchase

order has been placed and installation of advanceESP controller will be completed by September2019.

VII. The PPshall obtain fresh environmental There will no change in the scope of theclearance in case of change in scope of the production enhancement process. We agree toproject if any. the stipulation to obtain fresh environmental

clearance if there is any change in the scope of theproject.