F. No.
J-11011/236/2008- IA II (I)
Government of India
Ministry of Environment and Forests
(I.A. Division)
Paryavaran Bhawan
CGO Complex, Lodhi Road
New Delhi – 110 003
E-mail : pb.rastogi@nic.in
Telefax : 011: 2436 7668
Dated
18th May, 2010
To,
Shri
Dinesh Kumar Singhi
Managing
Director
M/s
B.M.M. Ispat Ltd.
Village
Danapur, Taluk Hospet
District
Bellary, Karnataka
E-mail : silas@bmm.in
/nirmala@bmm.in
; Fax No. : 080-41495664
Subject :
Integrated Steel Plant (2.0 MTPA), Cement Plant (1.4 MTPA) and Captive Power
Plant (230
MW) at Village Danapur, Taluk Hospet, District Bellary, Karnataka by M/s B.M.M.
Ispat Ltd. – Environment clearance reg.
Ref. :
Your letter no. nil dated 15th December, 2009.
Sir,
This has reference to your letter no. nil dated 15th
December, 2009 alongwith Form-I, draft ‘Terms of
Reference’ and Pre-feasibility Report, ‘Terms of References’, EIA/EMP, Public
Hearing Report and related project documents and subsequent letters dated 2nd
& 23rd March, 2010, 19th April, 2010 for seeking environmental
clearance under the EIA Notification, 2006 on the above mentioned
project.
2.0 The Ministry of Environment and Forests has examined the
application. It is noted that proposal
is for the Integrated Steel Plant (2.0 MTPA), Cement Plant (1.4
MTPA) and Captive Power Plant (230 MW) at Village Danapur, Taluk Hospet,
District Bellary, Karnataka by M/s B.M.M. Ispat Ltd. Total land requirement
will be 1,429 ha. No National Park and Wildlife sanctuary is located within 10
Km radius of the project. Gunda RF, Nandibanda RF and Ramgad RF are located at
4 Km, 7 Km and 4 Km respectively. A railway line is passing through the
proposed site and Southern Western Railway, Hubli, Karnataka has issued ‘No
Objection’ for the construction of Steel plant subject to leaving 30 meters
from the railway boundary vide their letter no. H/W.280/II/NOC/DRG dated 28th
January, 2008. Total cost of the project is Rs. 6,233.70 Crores. Following are details of the products and facilities :
|
S.N. |
Items |
Capacity |
|
1 |
Iron ore beneficiation
plant |
3.40 MTPA |
|
2 |
Palletizing Plant |
1.20 MTPA |
|
3 |
DR Plant |
0.70 MTPA |
|
4 |
Coke Oven |
0.80 MTPA |
|
5 |
Sinter Plant |
2.50 MTPA |
|
6 |
Blast furnace |
1.70 MTPA |
|
7 |
EAF & BOF Steel
making |
2.30 MTPA |
|
8 |
Continuous casting
machines Slab Caster Billet
Caster |
1.10 MTPA 1.10 MTPA |
|
9 |
Rolling mills : Hot strip mill Structurals/wire rods |
1.00 MTPA 1.00 MTPA |
|
10 |
Oxygen Plant |
2x500 TPD |
|
11 |
Calcining |
1,080 TPD |
|
12 |
Cement Plant |
1.40 MTPA |
|
13 |
Power Plant |
230 MW |
Following
will be saleable products :
|
S.N. |
Products |
Capacity |
|
1 |
HR Coil |
1.0 MTPA |
|
2 |
Structurals / wire rods |
1.0 MTPA |
|
3 |
Cement |
1.4 MTPA |
3.0 Low-grade iron ore will be beneficiated in beneficiation
plant. The fine-grained concentrate will be agglomerated into pellets and used
for making sinter for feeding the blast furnace. Non-recovery type of the coke oven will be
installed to produce coke from imported coking coal to supply coke to BF and
Coke breeze to sinter plant. Pellets
will be used for the production of DRI in rotary kilns and DRI will be used for
steel making in EAF. EAF and BOF will be
used for the production of hot metal.
Liquid steel will be cast into slabs or billets in continuous casting machines and rolled
into desired shape in the rolling mill to produce 1.0 MTPA hot rolled coils,
1.0 MTPA light structures/wire rods. CPP
will be installed to use heat in the off gases from DR kilns and coke oven. Rolled products and cement will be final
products. Granulated slag from blast furnace (BF) will be utilized for cement
manufacturing. Clinker, gypsum and slag will be used to manufacture Portland
slag cement.
4.0 Electrostatic
precipitators (ESPs), dust catcher, ventury scrubbers, dust extraction system
with bag filters and stacks of adequate height will be provided to control
emissions within permissible limits. Total water requirement from Tungabhadra river will be 95.3 MLD and no ground water will be
abstracted although ‘Permission’ for the drawl of 100 MLD from Tungbhadra Dam
has been accorded by the Tungbhadra Board. Clear water will be recovered from
tailings, continuous casting machines shop, rolling mills and utilized for
green belt development. Rainwater
harvesting will be installed in the proposed plant. All the wastewater will be treated in
effluent treatment plant (ETP). No effluent will be discharged outside the
premises and ‘zero’ discharge will be adopted. Coal and coke fines will be recycled
and reused in the process. Flue dust from ESPs, sinter BF return, mill
scale & muck will be collected and recycled in the sinter plant. Scrap will
be reused. Coke breeze will be recycled to coke oven. All the bag filter dust, raw meal dust, coal
dust, clinker dust and cement dust from pollution control devices of the cement
plant will be recycled and reused in the process and used for cement
manufacturing. All the char from
DRI plant will be utilized in AFBC boiler. All the blast furnace (BF) slag will be granulated. BF slag and dust from ESP, bag filters etc. will be provided
to cement manufacturers for further utilization. Tailings from the beneficiation plant will be disposed off properly in
the tailing dam only. All the
slag will be used for land filling inside the plant premises only after passing
through Toxic Chemical Leachability Potential (TCLP) test. Other-wise, toxic
slag will be disposed in secured landfill as per CPCB guidelines.
5.0 Public Hearing/Public Consultation
meeting was conducted on 17th
September, 2009.
6.0. The Ministry of Environment and Forests
hereby accords environmental clearance to the above project under the
provisions of EIA Notification dated 14th September, 2006 subject to
strict compliance of the following specific and general conditions:
A.
SPECIFIC CONDITIONS
:
i)
All the recommendations of the Southern Western Railway, Hubli,
Karnataka mentioned in the ‘No Objection’ for the construction of proposed
steel plant vide letter no. H/W.280/II/NOC/DRG dated 28th January,
2008 shall be strictly implemented and
report submitted to the Ministry and its Regional Office at Bangalore.
ii)
No land shall be acquired next to Railway line. No part of the
steel plant including cement plant or dump yard shall be installed across the
Railway line. Instead, vacant land shall be used for the development of green
belt. A commitment in this regard alongwith revised layout plan shall be
submitted to the Ministry’s Regional Office at Bangalore.
iii)
Efforts shall be made to reduce RSPM levels in the ambient air and a time bound action plan shall
be submitted. On line ambient air quality monitoring and continuous stack monitoring facilities
for all the stacks shall be provided and sufficient air pollution control
devices viz. Electrostatic precipitator (ESP), gas cleaning plant, dust capture,
ventury scrubber, bag filters etc. shall
be provided to keep the emission levels below 50 mg/Nm3 by
installing energy efficient technology. At
no time, the emission level shall go beyond the prescribed standards.
Interlocking facilities shall be provided so that process can be automatically
stopped in case emission level exceeds the limit.
iv)
Electrostatic precipitator (ESP) shall be provided to sponge Iron
plants, iron ore pelletising plant, sinter plant and power plant to clean
process gas and discharged through stacks to control dust emissions within 50
mg/Nm3. Dust extraction system at coal crushing unit, material
transfer points etc. and dust extraction system with bag filters shall be
provided to DR plant, BF plant and coke plant to control dust emissions within
50 mg/Nm3. Dust catcher and
ventury scrubbers shall provided to steel melting shop to clean BOF gas and Bag
filters shall be provided to clean EAF gases within 50 mg/Nm3. Energy
recovery from top blast furnace (BF) gas shall be done to reduce green house
gases. Dust extraction system shall be provided to the Iron ore beneficiation
plant to collect the dust in ore handling points and then cleaned in wet
scrubbers. The clean air shall be let
out into the atmosphere through stack.
The dust collected in bag filters and ESP shall be recycled in the
process. All the stacks shall have
adequate height as per CPCB guidelines.
v)
Hot gases from DRI kiln shall be passed
through Dust Settling Chamber (DSC) to remove coarse solids and After Burning
Chamber (ABC) to burn CO completely and used in waste heat recovery boiler
(WHRB). The gas then shall be cleaned in
ESP before leaving out into the atmosphere through ID fan and stack.
vi)
An action plan shall be prepared and
submitted to the Ministry’s Regional Office at Bangalore for the control of SO2
emissions from the captive power plant.
vii)
All the standards prescribed for the coke oven plants shall be
followed as per the latest guidelines. Proper and full utilization of coke oven
gases in power plant using heat recovery steam generators shall be ensured and
no flue gases shall be discharged into the air.
viii)
Only dry quenching method in the coke oven shall be adopted and
water requirement shall be reduced accordingly.
ix)
The National Ambient Air Quality Emission Standards issued by the
Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 shall be
followed.
x)
Gaseous emission levels including secondary fugitive emissions from all the sources shall be
controlled within the latest permissible limits issued by the Ministry and
regularly monitored. Guidelines/Code of Practice issued by the CPCB shall be
followed. New standards for the
sponge iron plant issued by the
Ministry vide G.S.R. 414(E) dated 30th May, 2008 shall be
followed.
xi)
Vehicular pollution due to transportation
of raw material and finished product shall be controlled. Proper arrangements shall also be made to
control dust emissions during loading and unloading of the raw material and
finished product. All the raw materials
including fly ash shall be transported in the closed containers only and shall
not be overloaded. Vehicular emissions
shall be regularly monitored and records kept.
xii)
In-plant control measures like tarring
of roads, green belt and good house keeping shall be done to control fugitive emissions
from all the vulnerable sources. Fume
extraction system with bag filters shall be provided to control fugitive
emissions from steel melting shop (SMS) and treated gases shall be let out into
the atmosphere through a stack. Dust suppression system shall be provided in
unloading areas. All the material transfer
points, discharge points, raw material storage and conveyors area shall be completely covered. All the internal roads shall be
asphalted to control fugitive dust emissions.
Water spraying shall be done to prevent the dust emissions due to
vehicular movement. Monitoring of
fugitive emissions in the work zone environment shall be carried out regularly
as per the CPCB guidelines and reports submitted to the Ministry’s Regional
Office at Bangalore, KPCB and CPCB.
xiii)
Total water requirement from
Tungabhadra dam shall not exceed 95.3 MLD due to adoption of dry quenching in
the coke oven plant and air cooled condensers although ‘permission’ from the State Govt. is obtained for 100 MLD vide
letter no. CI/312/SPI/2008 dated 21st October, 2008. As proposed, no ground water shall be used.
Air cooled condensers and closed circuit cooling system shall be provided to
further reduce water consumption and water requirement shall be further reduced
accordingly and shall inform to the Ministry and its Regional Office at
Bangalore. The cooling water from palletizing plant, DR plant, sinter plant, BF
plant, steel making units and rolling mills will be recycled/re used for
gas/equipment cooling. Thickeners shall be provided to recover clear water from
the tailings of the beneficiation plant. Settling tanks and thickeners shall be
provided to recover clear water from tailings, continuous casting machines
shop, rolling mills and reduce fresh water requirement. The effluent from power plant such as boiler blow down, DM plant
regeneration wastewater shall be neutralized in a neutralization tank and
treated effluent shall be used for ash conditioning, dust suppression, green
belt development and other plant
related activities within the plant premises. Sanitary waste generated
from all sections of the steel plant shall be collected in a closed drain from
tailings, continuous casting machines shop, rolling mills to reduce fresh water
requirement and treated water will be utilized for green belt development.
xiv)
Efforts shall be made to make use of rain water harvested. If
needed, capacity of the reservoir shall be enhanced to meet the maximum water
requirement. Only balance water requirement shall be met from other sources.
xv)
All the wastewater from the different
plants shall be treated in effluent treatment plant. All the treated wastewater
shall be monitored for pH, BOD, COD, oil & grease, cyanide, phenolic
compounds, Chromium+6 etc. besides other relevant parameters.
xvi)
‘Zero’ effluent discharge shall be strictly followed and no
wastewater shall be discharged outside the premises.
xvii) The water
consumption shall not exceed 16 m3/Ton of Steel as per prescribed
standard.
xviii) Regular
monitoring of influent and effluent surface, sub-surface and ground water shall
be ensured and treated wastewater shall meet the norms prescribed by the State
Pollution Control Board or described under the E(P) Act whichever are more
stringent. Leachate study for the effluent generated and analysis shall also be
regularly carried out and report submitted to the Ministry’s Regional Office at
Bangalore, KSPCB and CPCB.
xix)
Coal and coke fines shall be recycled and reused in the
process. Flue dust from ESPs, sinter BF return, mill scale & muck shall be
collected and recycled in the sinter plant. Scrap shall be reused. Coke breeze
shall be recycled to coke oven. All the
bag filter dust, raw meal dust, coal dust, clinker dust and cement dust from
pollution control devices of the cement plant shall be recycled and reused in
the process and used for cement manufacturing. Spent oil and batteries shall be
sold to authorized recyclers / reprocessors only.
xx)
All the char from DRI
plant shall be utilized in AFBC boiler of power plant and no char shall
be disposed off anywhere else. AFBC boiler shall be installed simultaneously
alongwith the DRI plant to ensure full utilization of char from the
beginning. All the blast furnace (BF) slag shall be
granulated. BF slag and dust from ESP,
bag filters etc. shall be provided to cement manufacturers for further
utilization. SMS slag shall also
be properly utilized. Tailings from the beneficiation plant shall
be disposed off properly in the tailing dam only. All the other solid waste including broken refractory mass shall be properly
disposed off in environment-friendly manner.
xxi)
All the slag shall be used for land filling inside the plant or
used as building material only after passing through Toxic Chemical
Leachability Potential (TCLP) test.
Toxic slag shall be disposed in secured landfill as per CPCB guidelines.
Otherwise, hazardous substances shall be recovered from the slag and output
waste and be disposed in secured landfill as per CPCB guidelines.
xxii) Proper
house keeping shall be ensured and all the raw material including scrap, coal
etc. shall be stored at designated places.
xxiii) Proper
handling, storage, utilization and disposal of all the solid waste shall be
ensured and regular report regarding toxic metal content in the waste material
and its composition, end use of solid/hazardous waste shall be submitted to the
Ministry’s Regional Office at Bangalore,
KSPCB and CPCB.
xxiv) A time
bound action plan shall be submitted to reduce solid waste, its proper
utilization and disposal.
xxv)
Proper utilization of fly ash shall be ensured as per Fly Ash
Notification, 1999 and subsequent amendment in 2003 and 2010. All the fly ash from the captive power plant
shall be used maximum in making Pozollona Portland Cement (PPC) in the proposed
cement plant.
xxvi) A Risk
and Disaster Management Plan alongwith the mitigation measures shall be
prepared and a copy submitted to the Ministry’s Regional Office at Bangalore, KSPCB and CPCB within 3
months of issue of environment clearance letter.
xxvii) As
proposed, green belt shall be developed
in 472 ha. (33 %) out of
total 1,429 ha in and all around the
plant boundary and wherever space is available to mitigate the effects of air
emissions as per CPCB guidelines in consultation with local DFO.
xxviii)
Prior permission from the State Forest Department shall be taken
regarding likely impact of the expansion of the proposed steel plant on the
reserve forests. Measures shall be taken to prevent impact of particulate
emissions / fugitive emissions, if any from the proposed plant on the
surrounding reserve forests viz. RF (4 Km), Nandibanda RF (4 Km) and Sandur RF
(4 Km) located within 10 km radius of the project. Further, Conservation Plan for the conservation
of wild fauna in consultation with the State Forest Department shall be
prepared and implemented.
xxix) All
the recommendations made in the Charter on Corporate Responsibility for
Environment Protection (CREP)
for the Steel Plants shall be implemented.
xxx)
All the commitments made to the
public during the Public Hearing / Public Consultation meeting held on 17th September, 2009 shall
be satisfactorily implemented and a
separate budget for implementing the same shall be allocated and information
submitted to the Ministry’s Regional Office at Bangalore.
xxxi)
At
least 5 % of the total cost of the project i.e. Rs. 310.00 Crores shall be earmarked
towards the corporate social responsibility and item-wise details alongwith
time bound action plan shall be prepared and submitted to the Ministry’s
Regional Office at Bangalore. Implementation of such program shall be ensured
accordingly in a time bound manner.
xxxii)
Rehabilitation
and Resettlement Plan for the project affected population
including tribals as per the policy of the State Govt. in consultation with the
State Govt. of Karnataka shall be implemented. Compensation paid in any case
shall not be less than the norms prescribed under the National Resettlement and
Rehabilitation Policy, 2007.
xxxiii)
The company shall provide housing
for construction labour within the site with all necessary infrastructure and
facilities such as fuel for cooking, mobile toilets, mobile STP, safe drinking
water, medical health care, crèche etc. The housing may be in the form of
temporary structures to be removed after the completion of the project.
B. GENERAL CONDITIONS :
i.
The project authorities shall strictly adhere to the stipulations
made by the Karnataka Pollution Control Board (KPCB) and the State Government.
ii.
No further expansion or modifications in the plant shall be
carried out without prior approval of the Ministry of Environment and Forests.
iii.
The gaseous emissions from various process units shall conform to
the load/mass based standards notified by this Ministry on 19th May,
1993 and standards prescribed from time to time. The State Board may specify
more stringent standards for the relevant parameters keeping in view the nature
of the industry and its size and location. On-line continuous monitoring system
shall be installed in stacks to monitor SPM and interlocking facilities shall
be provided so that process can be automatically stopped in case emission level
exceeds the limit.
iv.
At least four ambient air quality monitoring stations shall be
established in the downward direction as well as where maximum ground level
concentration of SPM, SO2 and NOX are anticipated in
consultation with the KPCB. Data on ambient air quality and stack emission
shall be regularly submitted to this Ministry including its Regional Office at
Bangalore / KPCB and CPCB once in six months.
v.
Industrial wastewater shall be properly collected and treated so
as to conform to the standards prescribed under GSR 422 (E) dated 19th
May, 1993 and 31st December, 1993 or as amended form time to time.
The treated wastewater shall be utilized for plantation purpose.
vi.
The overall noise levels
in and around the plant area shall be kept well within the standards (85 dBA)
by providing noise control measures including acoustic hoods, silencers,
enclosures etc. on all sources of noise generation. The ambient noise levels
shall conform to the standards prescribed under EPA Rules, 1989 viz. 75 dBA (day
time) and 70 dBA (night time).
vii.
The company shall develop
surface water harvesting structures to harvest the rain water for utilization
in the lean season besides recharging the ground water table.
viii.
All the measures regarding
occupational health surveillance of the workers shall be undertaken and regular
medical examination of all the employees shall be ensured as per the Factories
Act and records maintained.
ix.
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-economic development activities in the surrounding villages like
community development programs, educational programs, drinking water supply and
health care etc.
x.
As proposed, Rs.
412.00 Crores and 42.25 Crores shall be earmarked towards
capital cost and recurring expenditure/annum for environment pollution control
measures and shall be used to implement the conditions stipulated by the
Ministry of Environment and Forests as well as the State Government. An
implementation schedule for all the conditions stipulated herein shall be
submitted to the Regional Office of this Ministry at Bangalore. The funds so
provided shall not be diverted for any other purpose.
xi.
A
copy of clearance letter shall be sent by the proponent to concerned Panchayat,
Zila Parishad / Municipal Corporation, Urban Local Body and the local NGO, if
any, from whom suggestions / representations, if any, were received while
processing the proposal. The clearance letter shall also be put on the web site
of the company by the proponent.
xii.
The
project proponent shall upload the status of compliance of the stipulated
environment clearance conditions, including results of monitored data on their
website and shall update the same periodically.
It shall simultaneously be sent to the Regional
Office of the MOEF, the respective
Zonal Office of CPCB and the KPCB. The criteria pollutant levels namely; SPM,
RSPM, SO2, NOx (ambient levels as well as stack emissions) or critical
sectoral parameters, indicated for the projects shall be monitored and
displayed at a convenient location near the main gate of the company in the
public domain.
xiii.
The
project proponent shall also submit six monthly reports on the status of the
compliance of the stipulated environmental conditions including results of
monitored data (both in hard copies as well as by e-mail) to the Regional
Office of MOEF, the respective Zonal Office of CPCB and the KPCB. The Regional
Office of this Ministry / CPCB / KPCB shall monitor the stipulated conditions.
xiv.
The
environmental statement for each financial year ending 31st March in
Form-V as is mandated to be submitted by the project proponent to the concerned
State Pollution Control Board as prescribed under the Environment (Protection)
Rules, 1986, as amended subsequently, shall also be put on the website of the
company alongwith the status of compliance of environmental conditions and
shall also be sent to the respective Regional Offices of the MOEF by e-mail.
xv.
The Regional Office of
this Ministry at Bangalore / CPCB / KPCB shall monitor the stipulated
conditions. A six monthly compliance
report and the monitored data along with statistical interpretation shall be
submitted to them regularly.
xvi.
The Project Proponent
shall inform the public that the project has been accorded environmental
clearance by the Ministry and copies of the clearance letter are available with
the KPCB and may also be seen at Website of the Ministry of Environment and
Forests at http:/envfor.nic.in. This shall be advertised within seven days from
the date of issue of the clearance letter, at least in two local newspapers
that are widely circulated in the region of which one shall be in the
vernacular language of the locality concerned and a copy of the same should be
forwarded to the Regional office at Bangalore.
xvii.
Project authorities shall
inform the Regional Office as well as the Ministry, the date of financial
closure and final approval of the project by the concerned authorities and the
date of commencing the land development work.
7.0. The Ministry may revoke or suspend the
clearance, if implementation of any of the above conditions is not
satisfactory.
8.0. Any appeal against this environmental
clearance shall lie with the National Environment Appellate Authority, if
preferred within a period of 30 days as prescribed under Section 11 of the
National Environment Appellate Act, 1997.
9.0 The Ministry reserves the right to
stipulate additional conditions if found necessary. The Company in a time bound
manner shall implement these conditions.
10.0. The above
conditions shall be enforced, inter-alia under the provisions of the Water
(Prevention & Control of Pollution) Act, 1974, the Air (Prevention &
Control of Pollution) Act, 1981, the Environment (Protection) Act, 1986,
Hazardous Wastes (Management and Handling) Rules, 2003 and the Public
(Insurance) Liability Act, 1991 along with their amendments and rules.
(Dr. P. B. Rastogi)
Director
1. The Secretary, Department of Environment & Forests, Government
of Karnataka, Bangalore, Karnataka.
2. The Chairman, Karnataka State Pollution Control Board, Parisar
Bhavan, No. 49, 4th & 5th Floor, Church Street,
Bangalore – 560 001, Karnataka.
3. The Chairman, Central Pollution Control Board, Parivesh Bhavan,
CBD-cum-Office Complex, East Arjun Nagar, Delhi -110032.
4. The Chief Conservator of Forests (Central), Regional Office (SZ),
Kendriya Sadan, IVth Floor, E&F Wing, 17th Main Road, Koramangala,
Bangalore-560034, Karnataka.
5. Adviser, IA-II, Ministry of Environment and Forests, Paryavaran
Bhavan, CGO Complex, New Delhi- 110003.
6. Monitoring Cell, Ministry of Environment and Forests, Paryavaran
Bhavan, CGO Complex, New Delhi- 110003.
7. Guard file.
8. Monitoring file.
9. Record file.
(Dr. P. B. Rastogi)
Director