Minutes approved by the Chairn\man on 15th February, 2010

 

MINUTES FOR 7th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY-1) HELD DURING 2nd–3rd February, 2010

 

2nd February, 2010

4.0       New Proposals :

 

VENUE :  S&DP Conference Room, Indian Oil Corporation Ltd., 5th Floor, Core 6, Scope Convention Centre, Institutional Area, Lodhi Road, New Delhi.

 

1.0       Opening Remarks of the Chairman

 

2.0       Minutes of 6th Meeting of the Expert Appraisal Committee (Industry-1) held during 22nd – 23rd December, 2009 are confirmed.

 

3.0              Consideration of the Projects :

 

2nd February, 2010

4.0       New Proposals :

 

4. 1            Expansion of Sponge Iron Plant into Integrated Steel Complex at Sy. No. 233, 234, 236, 238, 245-247, 98, 239 (P), Mines Road, Village Halakundi, Taluka & District Bellary, Karnataka by M/s Popuri Steels Ltd. (EC) 

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken as per Draft Terms of References (TORs) awarded during the 90th Meeting of the Expert Appraisal Committee (Industry) held during 6th-8th January, 2009 for preparation of EIA/EMP.  All the integrated steel plants are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ and appraised at the Central level.

 

M/s Popuri Steels Ltd. have proposed for the expansion of Sponge Iron Plant into Integrated Steel Complex at Sy. No. 233, 234, 236, 238, 245-247, 98, 239 (P), Mines Road, Village Halakundi, Taluka & District Bellary, Karnataka at Sy. No. 233, 234, 236, 238, 245-247, 98, 239 (P), Mines Road, Village Halakundi, Taluka & District Bellary, Karnataka.  Total 50 acres land is acquired and proposed expansion will be on existing land only.  No forest land is involved.  No R & R is involved.  Karnataka and Andhra Pradesh State boundary is at 2.5 km.  Bellary RF (2 km) and Mincheri RF (4 km) are located within 10 km radius of the proposed site. Bellary town is at 15 km.  Nearest village is Halakundi is at 2 km in upwind direction.  Total cost of the project is Rs. 282.40 Crores.  Rs. 23.00 Crores and Rs. 0.83 Crores are earmarked towards capital cost and recurring cost/annum for environmental pollution control measures. Following will be installed:

 

S.N.

Facilities

Existing facilities

Proposed facilities

1

Sponge Iron Plant

30,000 TPA

2,00,000 TPA

2

WHRB Power Plant

--

15 MW

3

Ferro Alloy Plant (sub-merged arc)

--

2x5 MVA

4

Pellet Plant

--

3,00,000 TPA

 

Now, PAs have revised capacity of the WHRB power plant from 15 MW to 16 MW and following will be the details.

 

S.N.

Facilities

Existing facilities

Proposed facilities

1

Sponge Iron Plant

30,000 TPA

2,00,000 TPA

2

WHRB Power Plant

--

16 MW

3

Ferro Alloy Plant (sub-merged arc)

--

2x5 MVA

4

Pellet Plant

--

3,00,000 TPA

 

During presentation, PAs informed that following will be installed :

 

S.

N.

Facilities

Phase-I

Phase-2

Phase-3

Phase-4

Total Capacity

1

Sponge Iron (Existing)

2x50 TPD *(2,50,000 TPA)

1x350 TPD

(87,500 TPA)

--

1x350 TPD

(87,500 TPA)

2,00,000 TPA

2

WHRB Power Plant

--

8 MW

(WHRB & FBC)

--

8  MW

(WHRB & FBC)

16 MW

3

Ferro Alloy Plant (Si-Mn) Submerged Arc Furnace

--

5 MVA

--

5 MVA

15,840 TPA

(10 MVA)

4

Pellet Plant

2x100 TPD (50,000 TPA)

--

1x1000 TPD  (2,50,000 TPA)

--

3,00,000 TPA

*Consent for Establishment’ is obtained from Karnataka SPCB. 

 

Iron ore, coal & limestone will be the raw materials for sponge iron plant; Iron ore fines, bentonite, coke breeze, Lime stone for pellet plant and Manganese ore, slag, quartz and dolomite and electrode paste for ferro alloy plant and waste flue gas and char for captive power plant will be used as raw material.

 

Sponge iron will be manufactured using DRI process with generation of char.  Raw material for Ferro Alloy Plant will be fed to SAF and charged on the top of the furnace.  The Manganese ore will be reduced by coke.   In ferro alloy plant Manganese ore alongwith coal, coke, slag will be changed to SAF.  Molten metal and slag will be tapped separately. Iron ore will be pelletized in the pellet plant.  Raw mix for pellet plant will be fed to disc palletizer and water will be added to obtain pellets of required size.  Green pellets will be fed in the vertical shift kiln where pellets will be properly sintered and cooled.

 

Ambient air quality for SPM & RSPM is monitored during October–December, 2008 on 24 hourly basis, SO2 & NOX at 8 hourly and CO & PAH on 4 hourly basis twice a week for 12 weeks at 8 locations.  Data submitted indicated SPM (105-154 µg/m3), RSPM (26.5–51 µg/m3), SO2 (3.8–12.8 µg/m3), NOx (5.9–14.7 µg/m3), PAH (2.1–10.1 ng/m3), CO (less than 1 ppm) at 98th percentile value.  Maximum GLCs for SPM, SO2 and NOX will be 12.869 µg/m3, 10.159 µg/m3 and 8.583 µg/m3 at 1.2 km respectively and will not exceed 166.869 µg/m3,  22.959 µg/m3  and 23.283 µg/m3  respectively and will be within permissible limits.

 

In DRI kiln of Phase-I, it is proposed that wet scrubber will be installed for sponge Iron plant.  However, Electrostatic precipitator (ESP) will be provided to DRI plant (2x350 TPD), WHRB and FBC boiler. The kiln gases will be vented to atmosphere through a stack of adequate height. In other phases, hot gases from DRI kiln will be passed successively through the dust settling chamber (DSC), after burning chamber (ABC), WHRB and ESP before venting to atmosphere through a stack of adequate height.  Bag filter will be provided to submerged arc furnace and ball mills.  All the gaseous emission will be controlled within 100 mg/Nm3. Dust suppression system will be provided to material unloading, operation and handling areas.  Dust extraction system followed by bag filters will be provided to raw material processing, cooler discharge, product separation and loading areas. All the conveyors will be covered with GI Sheets.

 

Total ground water requirement for the proposed expansion is revised from 40 m3/hr to 37.5 m3/hr and it is informed that permission has been accorded. Cooling tower water will be re-circulated in the cooling water circuits, heat exchangers and discharged to the holding tank. DM plant outlet water will be used for green belt development after neutralization.  Domestic effluent will be sent to septic tank followed by soak pit. All the effluent will be treated and used for dust suppression and green belt development. No effluent will be discharged and ‘zero’ discharge will be adopted.

 

Wet scraper sludge, flue dust from DRI plant alongwith iron ore fines will be used in the pellet plant. Char will be sold to brick making units and cement plants, respectively. Coal dust from coal circuit will be used in the kiln.  Slag from submerged arc furnace will be used as boulders in road or in fly ash brick making.  Ash from the power plant will be sold to brick and cement manufacturers.

 

            Green belt will be developed in 16.5 acres (33%) area. DG sets are provided with silencers. Total Power requirement for the existing plant is 50 KVA.    Phase-wise power requirement of the plant will be as follows: Phase-I (800 KVA), Phase-2 (8,000 KVA), Phase-3 (15,000 KVA), Phase-4 (21,000 KVA). Power requirement will be met from Grid as well as CPP (16 MW). WHRB based CPP (16 MW) is proposed. Coal will be used as fuel.  LDO will be used as fuel for initial start up.

 

The Committee deliberated upon the issues raised during the Public Hearing / Public Consultation meeting conducted by the Karnataka State Pollution Control Board on 5th August, 2009. The various issues raised included villages suffering from diseases due to dust, damage to crop, employment, high salary to other State people and low salary to local people, medical, education facilities, use of APCB for 24 hour, construction of bypass, roads, and plantation around the premises and have satisfactorily been incorporated in the final EIA/EMP report. PAs have assured that industry will take social responsibility in financing educational, health and distributing water facilities to the nearby villagers.  Dust will be controlled by ESP & bag filter.  Green belt will be developed in 16.5 acres out of total 50 acre land.  Employment will be provided as per qualification.

 

            After detailed deliberations, the Committee has recommended the proposal for environmental clearance subject to stipulation of following specific conditions alongwith other environmental conditions :

 

1.      Iron ore, coal and limestone shall be sourced from authorized mine owners only and a copy of the valid environment clearance shall be submitted to the Ministry’s Regional Office at Bangalore.

 

2.      Efforts should be made to reduce RSPM levels in the ambient air and a time bound action plan should be submitted. Continuous stack monitoring facilities for all the stacks should be provided and sufficient air pollution control devices viz. Electrostatic precipitator (ESP), bag filters etc. should be provided to keep the emission levels below 50 mg/Nm3 and installing energy efficient technology. No charcoal should be used as raw material.

 

3.      The National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 should be followed.

 

4.      Gaseous emission levels including secondary fugitive emissions from all the sources should be controlled within the latest permissible limits issued by the Ministry and regularly monitored. Guidelines/Code of Practice issued by the CPCB should be followed. New standards for the sponge iron plant issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008 should be followed.

 

5.      Hot gases from DRI kiln should 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 should be cleaned in ESP before leaving out into the atmosphere through ID fan and stack.

 

6.      Vehicular pollution due to transportation of raw material and finished product should be controlled.  Proper arrangements should also be made to control dust emissions during loading and unloading of the raw material and finished product.

 

7.      Prior ‘Permission’ for the drawl of 37.5 m3/hr water from the concerned department should be obtained and a copy submitted to the Ministry’s Regional Office at Bangalore. Efforts should be made to provide air cooled condensers and closed circuit cooling system to reduce water consumption and water requirement should be modified accordingly.

 

8.      Efforts should be made to make use of rain water harvested. If needed, capacity of the reservoir should be enhanced to meet the maximum water requirement. Only balance water requirement should be met from other sources.

 

9.      Regular monitoring of influent and effluent surface, sub-surface and ground water should be ensured and treated wastewater should 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 should also be regularly carried out and report submitted to the Ministry’s Regional Office at Bangalore, KPCB and CPCB.

 

10.  ‘Zero’ effluent discharge should be strictly followed and no wastewater should be discharged outside the premises.

 

11.  The water consumption should not exceed 16 m3/Ton of Steel as per prescribed standard.

 

12.  Wet scraper sludge, flue dust from DRI plant alongwith iron ore fines should be used in the pellet plant. Coal dust from coal circuit should be used in the kiln. 

 

13.  All the char from DRI plant should be utilized in AFBC boiler of power plant and no char should be disposed off anywhere else. AFBC boiler should be installed simultaneously alongwith the DRI plant to ensure full utilization of char from the beginning.  All the other solid waste including broken refractory mass should be properly disposed off in environment-friendly manner.

 

14.  All the ferro alloy slag should 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 should be disposed in secured landfill as per CPCB guidelines. Otherwise, hazardous substances should be recovered from the slag and output waste and be disposed in secured landfill as per CPCB guidelines. 

 

15.  Slag produced in Ferro-Manganese (Fe-Mn) production should be used in manufacture Silico-Manganese (Si-Mn).

 

16.  Proper utilization of fly ash should be ensured as per Fly Ash Notification, 1999 and subsequent amendment in 2003. All the fly ash should be provided to cement and brick manufacturers for further utilization and ‘Memorandum of Understanding’ should be submitted to the Ministry’s Regional Office at Bangalore.

 

17.  Proper handling, storage, utilization and disposal of all the solid waste should be ensured and regular report regarding toxic metal content in the waste material and its composition, end use of solid/hazardous waste should be submitted to the Ministry’s Regional Office at Bangalore, KPCB and CPCB. 

 

18.  A time bound action plan should be submitted to reduce solid waste, its proper utilization and disposal.

 

19.  A Risk and Disaster Management Plan alongwith the mitigation measures should be prepared and a copy submitted to the Ministry’s Regional Office at Bangalore, KPCB and CPCB within 3 months of issue of environment clearance letter.

 

20.  As proposed, green belt should be developed in 33 % area.

 

21.  All the recommendations made in the Charter on Corporate Responsibility for Environment Protection (CREP) for the Steel Plants should be implemented.

 

22.  Prior permission from the State Forest Department should be taken regarding likely impact of the expansion of the proposed steel plant on the reserve forests. Measures should be taken to prevent impact of particulate emissions / fugitive emissions, if any from the proposed plant on the surrounding reserve forests viz. Bellary RF and Mincheri RF located at 2 and 4 km respectively. Further, Conservation Plan for the conservation of wild fauna in consultation with the State Forest Department should be prepared and implemented.

 

23.  All the commitments made to the public during the Public Hearing / Public Consultation meeting held on 5th August, 2009 should be satisfactorily implemented and a separate budget for implementing the same should be allocated and information submitted to the Ministry’s Regional Office at Bangalore.

 

24.  At least 5 % of the total cost of the project should be earmarked towards the corporate social responsibility and item-wise details alongwith time bound action plan should be prepared and submitted to the Ministry’s Regional Office at Bangalore. Implementation of such program should be ensured accordingly in a time bound manner.

 

 

4. 2            High Carbon Silico-Manganese Plant (8,250 TPA 5 MVA) at Gola, District Ramgarh, Jharkhand by M/s Kameshwar Alloys & Steels Pvt. Ltd. (EC) 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken as per Draft Terms of References (TORs) awarded during the 95th Meeting of the Expert Appraisal Committee (Industry) held during 15th-17th June, 2009 for preparation of EIA/EMP.  All the Ferro alloy plants with less than 20,000 TPA are listed at S.N. 3(a) under Secondary Metallurgy Industries under Category ‘A’ and is appraised at the Central level due to absence of SEIAA/SEAC in Jharkhand.

 

M/s Kameshwar Alloys & Steel Pvt. Ltd. have proposed for the High carbon Silico-Manganese Plant (8,250 TPA, 5 MVA) at Kusumdih Block Gola, District Hazaribagh instead of Ramgarh earlier proposed, Jharkhand. No national Park/wild life sanctuary/reserve forest is located within 10 km radius of the project site. Gomti Nala and Bhera Nadi flows within 10 km radius of the proposed project. Total project area is 8.24 acres instead of 8 acres proposed earlier and land is already acquired.  Total cost of the project is Rs. 981.75 Lakhs. Rs. 86.00 Lakhs and Rs. 9.00 Lakhs will be earmarked towards total capital cost and recurring cost / annum for environmental pollution control measures.

 

            Silico-Manganese will be manufactured in submerged electric arc furnace at 1700oC.  Molten alloy and slag will be tapped from the furnace.  No ferro chrome will be manufactured. Manganese ore, char/coal/coke, limestone, quartz and dolomite will be used as raw materials.

 

Ambient air quality monitoring has been carried out at 9 locations on 24 hourly basis during the period January, 2009-March, 2009 and the data submitted indicated SPM (76.2-138.8 µg/m3), RPM (24.0-51.7 µg/m3), SO2 (13.7-40.2 µg/m3) and NOx (10.5-34.2 µg/m3) at 98th percentile and are within the permissible limit.  Predicted GLCs for SPM and RPM will be 0.83 µg/m3 and 0.17 µg/m3 and resultant GLCs will be 107.6 µg/m3 and 139.6 µg/m3 respectively which are within the permissible limits.   

 

Fume extraction system including damper, heat exchanger, spark arrestor, bag filter, ID fan and 30 m stack will be provided to control gaseous emissions from the furnace within 150 mg/Nm3 but committee asked PAs to achieve 50 mg/Nm3.  Dust suppression system will be provided to raw material handling area.

 

Total ground water requirement from bore wells will be 15 m3/day and have applied for the permission. No industrial effluent will be generated from the proposed project as water will be mainly used only for cooling and domestic purposes. The cooling water will be recycled through cooling tower.  All the effluent will be treated and used for dust suppression and green belt development. Domestic wastewater will be discharged through septic tank followed by soak pit. No effluent will be discharged and ‘zero’ discharge will be adopted.

 

Rain water harvesting will be adopted and water collected will be stored in underground tanks.  Overflow from these tanks will be discharged to properly designed recharge pits.

 

Silico-Manganese slag will be used in road construction and land leveling in nearby low land areas. Bag filter dust will be sold to sinter plants.

 

Green belt will be developed in 2.72 acres, out of total plant area of 8.24 acres. Total power requirement will be 5,300 KVA and sourced from Damodar Valley Corporation. In case of power failure, standby DG set will be used.

 

The Committee deliberated upon the issues raised during the Public Hearing/Public Consultation meeting conducted by the Jharkhand Pollution Control Board on 11th October, 2009. The issues covered included employment, control measure for water, air and noise, shifting of primary school, repairing of road etc. and have satisfactorily been incorporated in the final EIA/EMP report.

 

The proposed unit is located in Ramgarh and is listed at S.N. 65 in the list of Comprehensive Environmental Pollution Index in the Office Memorandum dated 13th January, 2010. PAs were asked to clarify why the proposal should be considered for environment clearance when located in the Ramgarh critically polluted area. PAs clarified that proposed plant is located 24 km away from the critically polluted area. Besides, all the values in the area for SPM (76.2-138.8 µg/m3), RPM (24.0-51.7 µg/m3), SO2 (13.7-40.2 µg/m3) and NOx (10.5-34.2 µg/m3) at 98th percentile are within the permissible limit. PM10 values are also within the permissible limits as per Gazette Notification No. 660 dated 16th November, 2010. Therefore, Office Memorandum dated 13th January, 2010 is not applicable for their plant.

 

            After detailed deliberations, the Committee has recommended the proposal for environmental clearance subject to stipulation of following specific conditions alongwith other environmental conditions :

 

  1. Continuous monitoring facilities for all the stacks and sufficient air pollution control equipments viz. fume extraction system including damper, heat exchanger, spark arrestor, bag filter, ID fan and stack of adequate height to submerged arc furnace should be provided to control emissions below 50 mg/Nm3. 

 

  1. The National Ambient ir Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 should be followed.

 

  1. Secondary fugitive emissions from all the sources should be controlled within the latest permissible limits issued by the Ministry and regularly monitored. Guidelines / Code of Practice issued by the CPCB should be followed.

 

  1. Prior permission for the drawl of 15 m3/day ground water from bore wells should be obtained.

 

  1. Efforts should be made to make use of rain water harvested. If needed, capacity of the reservoir should be enhanced to meet the maximum water requirement. Only balance water requirement should be met from other sources.

 

  1. Regular monitoring of influent and effluent surface, sub-surface and ground water should be ensured and treated wastewater should 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 should also be regularly carried out and report submitted to the Ministry’s Regional Office at Bhubaneswar, JPCB and CPCB.

 

  1. Pet coke should be used as fuel instead of charcoal from unknown sources. No charcoal should be used as fuel.

 

  1. ‘Zero’ effluent discharge should be strictly followed and no wastewater should be discharged outside the premises.

 

  1. 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 should be submitted to the Ministry’s Regional Office at Bhubaneswar, JPCB and CPCB.  .

 

  1. All the Silico Manganese (Si-Mn) slag should be used for land filling inside the plant or used as building material only after passing through Toxic Chemical Leachability Potential (TCLP) test.  Otherwise, hazardous substances should be recovered from the slag and output waste and be disposed in secured landfill as per CPCB guidelines. 

 

  1. No Ferro Chrome should be manufactured without prior approval from the Ministry of Environment & Forests.

 

  1. A Disaster Management Plan should be prepared and a copy submitted to the Ministry’s Regional Office at Bhubaneswar, JPCB and CPCB within 3 months of issue of environment clearance letter.

 

  1. Green belt should be developed in at least 33 %.

 

  1. All the recommendations made in the Charter on Corporate Responsibility for Environment Protection (CREP) for the Ferro Alloy Units should be strictly implemented.

 

15.  All the commitments made to the public during the Public Hearing/Public Consultation meeting held on 11th October, 2009 should be satisfactorily implemented and a separate budget for implementing the same should be allocated and information submitted to the Ministry’s Regional Office at Bhubaneswar. Land for the primary school should be purchased by the project proponent for shifting the school at suitable location

 

16.  At least 5 % of the total cost of the project should be earmarked towards the corporate social responsibility and item-wise details alongwith time bound action plan should be prepared and submitted to the Ministry’s Regional Office at Bhubaneswar.  Implementation of such program should be ensured accordingly in a time bound manner.

 

 

4. 3            Sponge Iron (2x350 TPD) and Captive Power Plant (24 MW) at Borai Industrial Growth Centre, Rasmara, Durg, Chhattisgarh by M/s Capital Sponge Iron & Power Pvt. Ltd. (EC) 

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken as per Draft Terms of References (TORs) awarded during the 85th Meeting of the Expert Appraisal Committee (Industry) held during 23rd to 25th September, 2008 for preparation of EIA/EMP.  All the sponge iron plants (> 200 TPD) are listed at S.N. 3(a) under Category ‘A’.  Proposed sponge iron plant is of 350 TPD and at Central level. 

 

             M/s Capital Sponge Iron & Power Pvt. Ltd. have proposed for the Sponge Iron (2x350 TPD) and Captive Power Plant (24 MW) at Borai Industrial Growth Centre, Rasmara, Durg, Chhattisgarh.  Copy of the notification is not enclosed in EIA/EMP Report.  During presentation, PAs informed that Sponge Iron (2 x 350 TPD) and Captive Power Plant (24 MW) will be installed.  Total project area is 19.80 ha.  Total cost of the project is Rs. 97.64 Crores. Rs. 1.50 Crores and Rs. 0.30 Crores earmarked towards capital cost and recurring cost/annum have been revised to Rs. 9.70 Crores and Rs. 1.40 Crores respectively in EIA / EMP for environmental pollution control measures.  Following will be manufactured :

Products

Proposed capacity (MT)

Sponge Iron lumps

2,00,000 

Sponge iron fines

30,000 

Captive power (WHRB and AFBC)

24 MW

           

Coal (2,60,000 TPA), Iron ore (3,20,000 TPA), Dolomite (7,000 TPA) will be used as raw material. Sponge Iron will be manufactured using direct reduction of iron oxide (Iron ore) using coal as heating medium as well as reductant and dolomite as flux. Sponge iron will be separated from char (dolochar using magnetic separator). Captive power will be generated using waste heat gases from DRI kiln.  Coal/dolochar/char will be used to generate power in AFBC boiler.

 

Ambient air quality is monitored at 10 locations on 24 hourly basis twice a week for 3 months.  Data submitted indicated SPM (88-158 µg/m3), RSPM (27.3 - 64 µg/m3), SO2 (4-9.2 µg/m3) and NOx (6.1-16.5 µg/m3). Poly-aromatic hydrocarbon (PAH) and Benzene soluble fraction (BSF) was found to be below detection limit. Maximum predicted GLC using AERMOD model would be 0.42 µg/m3 for SPM, 17.53 µg/m3 for SO2 and 21.95 µg/m3 for NOX which will be within permissible limits.

 

Electrostatic precipitator (ESP) will be provided to WHRB and AFBC boilers.  The Hot flue gas from rotary kiln will pass through Dust Settling Chamber (DSC) to settle the dust and then passed through After Burning Chamber (ABC) to burn the CO before being sent to WHRB.  Gases will passes through ESP and then to the atmosphere through the chimney.  Fume extraction with cyclone will be provided to induction furnace and bag house to electric arc furnace.  Continuous stack monitoring facilities will be provided.  Dust suppression system will be provided at raw material handling area.  Water sprinkling will be done to control fugitive emissions. Bag filters will be provided to hoppers. Closed belt conveyors will be installed.  Roads will be paved.

 

Total water requirement from Chhattisgarh State Industrial Development Corporation (CSIDC) instead of Sheonath River as proposed earlier will be 2,748 m3/day. Acidic water will be neutralized in neutralization pit.  All the treated wastewater will be used for water sprinkling and green belt development.  No wastewater will be discharged outside the premises and ‘zero’ discharge will be maintained.  Sewage water will be treated in STP.  Rain water harvesting structures will be provided to harvest the rain water around plant area.

 

Coal and char will be used in AFBC boiler. The fly ash from ESP will be stored in ash storage silo and provided to cement/brick manufacturing plants.  All the dust collected from the bag filters will be used in boiler to improve the steam generation.

 

Green belt earlier proposed in 4.9 ha is reduced to 3.6 ha out of total 19.8 ha.  20-30 m. wide green belt around the periphery is proposed.  The Committee insisted for green belt in 33% i.e. 6.6 ha. 24 MW based on WHRB & AFBC will be installed captively. No litigation/court case is in pending against the project / land.

 

            The proposed unit is located in Durg, Chhattisgarh and is listed at S.N. 85 in the list of Comprehensive Environmental Pollution Index in the Office Memorandum dated 13th January, 2010. PAs were asked to clarify why the proposal should be considered for environment clearance when located in the Durg critically polluted area. PAs clarified that proposed plant is located 24 km away from the critically polluted area. Besides, all the values in the area for SPM (76.2-138.8 µg/m3), RPM (24.0-51.7 µg/m3), SO2 (13.7-40.2 µg/m3) and NOx (10.5-34.2 µg/m3) at 98th percentile are within the permissible limit. PM10 values are also within the permissible limits as per Gazette Notification No. 660 dated 16th November, 2010. Therefore, Office Memorandum dated 13th January, 2010 is not applicable for their plant.

 

            After detailed deliberations, the Expert Appraisal Committee (Industry) found the final EIA/EMP report inadequate and incomplete and suggested to include following information in the EIA/EMP report :

 

1.      A copy of the ‘Notification’ issued by the Government of Chhattisgarh regarding location of the project in notified Borai Industrial Area as per TOR at S. N. 2.

2.      Revised Form I and Prefeasibility for the proposed facilities and products.

3.      Break up captive power plant (WHRB and AFBC).

4.      Source of raw material and analysis.

5.      Period of ambient air quality monitoring data.

6.      Water balance and water analysis report of the Shivnath River.

7.      Details of reserve/protected forests mentioned during presentation.

8.      A note on rain water harvesting and its utilization in various activities at the site.

9.      Action plan and breakup of 5 % allocation for CSR activities.

10.  A note on occupational health surveillance.

11.  Energy balance data for Sponge Iron Plant should be included.

12.  A note on identification and implementation of Carbon Credit project.

 

The proposal is differed and will be considered again after submission of revised EIA/EMP report incorporating the above mentioned information.

 

 

4. 4            Installation of Zinc Smelter (3,00,000 TPA) at Visakhapatnam, Andhra Pradesh by M/s Hindustan Zinc Limited. (TOR)

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Zinc Smelter Plants are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ and appraised at the Central level.

           

            The proposed unit is located in Visakhapatnam, Andhra Pradesh and is listed at S.N. 40 in the list of Comprehensive Environmental Pollution Index in the Office Memorandum dated 13th January, 2010.  PAs were asked to clarify why the proposal should be considered for environment clearance when located in the Visakhapatnam critically polluted area.  PAs informed to the committee that existing smelter plant (56,000 TPA) in 22 acres established in 1976 will be totally dismantled for construction of new green field smelter. Since all the structures to be installed will be new and energy efficient with emission standards within permissible limits, pollution will not enhance much.

 

            However, as per the Office Memorandum dated 13th January, 2010, all the proposals in the industrial clusters with CEPI score above 70 (as listed in S.N. 1 to 43 of the Annexure) received for the Stage I clearance viz. ‘TORs’ or for ‘Environment clearance’ shall be returned to the project proponent.

Accordingly, proposed proposal of M/s Hindustan Zinc Limited for the Installation of new Zinc Smelter (3,00,000 TPA) at Visakhapatnam, Andhra Pradesh is recommended by the Committee for the returning to the project proponent.

 

4. 5            Integrated Steel Plant alongwith Captive Power Plant (375 MW; CFBC 335 MW & WHRB 40 MW) at Village Basadi, Karuakap, Salhana, Tehsil Badwara, District Katni, Madhya Pradesh by M/s Alliance Energy & Steel Ltd. (TOR)

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Integrated Steel Plants are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ and appraised at the Central level.

      

           M/s Alliance Energy & Steel Limited have proposed for the Integrated Steel Plant alongwith Captive Power Plant (375 MW; CFBC 335 MW & WHRB 40 MW) at Village Basadi, Karuakap, Salhana, Tehsil Badwara, District Katni, Madhya Pradesh. Total project area is revised from 300 acres to 307 acres out of which 67 acres is already acquired. PAs have applied for remaining 124.4 acre land and acquisition is under process.  The proposal is not located in the area (Urla, Barjhora, Siltara) where coal, char, coal washery sponge iron plants & captive power plants are banned.  Total cost of the project is Rs. 3,150.00 Crores.  Following were the details of the facilities earlier proposed:

 

S.N.

Details

Unit Configuration

Annual Production (TPA)

1.

Manufacturing of Sponge Iron

4x500 TPD

6,00,000

2.

Induction Furnace unit

10x20 Tons/Heat

6,00,000

3.

Rollin Mill

4x500 TPD

6,00,000

4.

Manufacturing of Ferro Alloys

4x9 MVA

60,000

5.

Power through WHRB Route

4x10 MW &

40 MW

6.

Power through FBC route

1x35 MW &

1x300 MW

335 MW

7.

Coal Beneficiation

3x1.2 Million TPA

36,00,000

8.

Iron Ore Beneficiation & Pelletization Plant

2x1000 TPD

6,00,000

 

During presentation, PAs changed the configuration of sponge iron plant (no change in the final capacity) and CPP (WHRB) from 40 MW to 44 MW as per details given below :

 

S.N.

Details

Unit Configuration

Annual Production (TPA)

1.

Manufacturing of Sponge Iron

4x350 TPD & 6x100 TPD

6,00,000

2.

Induction Furnace unit

10x20 Tons/Heat

6,00,000

3.

Rollin Mill

4x500 TPD

6,00,000

4.

Manufacturing of Ferro Alloys

4x9 MVA

60,000

5.

Power through WHRB Route

4x10 MW + 4 MW

44 MW

6.

Power through FBC route

1x35 MW &

1x300 MW

335 MW

(Total 379 MW)

7.

Coal Beneficiation

3x1.2 Million TPA

36,00,000

8.

Iron Ore Beneficiation & Pelletization Plant

2x1000 TPD

6,00,000

 

            Iron ore (9,60,000 TPA), coal (7,80,000 TPA) and coal (5,360 TPD)  will be used as raw materials

 

            Washed coal will be produced using coal beneficiation process.  Iron ore, coal lime stone will be used for the production of sponge iron in DRI kiln.  Later this sponge iron will be melted in induction furnace alongwith scrap to produce M.S. billets/ingots which will be fed to rolling mill to produce TMT bars/structural sheets.  Pellets will be produced using rotary grate kiln. High grade Iron ore will be beneficiated/ agglomerated in Iron ore beneficiation plant.

            ESP will be provided to DRI kilns, WHRB, AFBC boiler being drawn SPM levels to 50 mg/Nm3. Fume extraction system with bag filters will be provided to track the gases and secondary fugitive emission from the SMS. Waste gases form the kiln will be used in WHRB to generate power.  Water sprinklers will be provided to unloading areas.  All conveyors will be completely covered with GI sheets.  Bag filter will be provided to ball mill, crusher and furnace of pellet plant.  Dust suppression system will be provided in unloading areas.  Dust extraction system with bag filters will be provided in coal crushing and screening, cooler discharge and product separator areas.

Total water requirement from River Mahanadi (Chhoti) will be 45,000 m3/day.  Closed circuit cooling system will be used in pellet plant, DRI plant, coal washery, SMS and no effluent will be generated. Acidic and alkaline effluent from cation and anion units of DM Plant will be neutralized in neutralization tank.  Boiler blow down will be neutralized in the neutralization tank before mixing with other effluent streams.  After neutralization, these two effluents will be mixed with cooling tower blow down in a guard pond. The treated effluent will be used for ash conditioning, dust suppression and green belt development. Service water will be passed through oil separator to remove oil content in the effluent.  Domestic effluent will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.

  

            The char and dolochar (1,80,000 TPA) from the sponge iron plant and middlings from coal washery will be used in AFBC boiler as fuel to generate power.  Ash (1,80,000 TPA), slag from SMS (60,000 TPA) and mill scales (36,000 TPA) will also be generated.  Ash from ESP or FBC boiler and WHRB will be given to cement plants/brick manufacturers.  Slag from SEAF & IF will be used in road construction.  Bag filter dust will be given to brick manufacturers and Agarbatti Manufacturers.  Waste/used/spent oil and used batteries will be sold to authorized recyclers/re-processors.

 

Green belt will be developed in 33 % area. Noise enclosures will be provided to turbines. Power (374 MW) will be generated through captive power plant (CFBC 375 MW; WHRB 40 MW). Coal (50,38,800 MTPA) will be used as fuel.  FO/LDO will be used in reheating furnace.          

 

After detailed deliberations, the Committee observed that captive power requirement for the plant is only 216 MW but PAs have proposed 379 MW power plant. 163 MW power plant is in excess.  Land requirement is also 307 ha which is also in excess and should be restricted to 200 acres. Out of 307 acres, PAs have acquired 67 acre land only.   The Committee differed the proposal and asked PAs to modify the proposal keeping following observations in mind :

 

1.      Revise proposal to include AFBC (106 MW) and WHRB (44 MW) with proper justification regarding actual requirement of the power and land acquisition within 200 acres only.

 

2.      Accordingly, incorporate change in cost of the project, raw material requirement, water requirement, solid waste generation, reutilization and disposal etc.

 

3.      Incorporate all the information desired by the Ministry in the revised proposal

 

Keeping above mentioned facts in mind, the Committee differed the proposal and asked PAs to modify the proposal. The proposal will be reconsidered for TORs as and when submitted.

 

 

4. 6            Expansion of Sponge Iron Plant (57,000 TPA) into Integrated Steel Plant (0.18 MTPA) alongwith  Captive Power Plant (24 MW; WHRB 12 MW & FBC 12 MW) and Ferro Alloy Plant (2x9 MVA) at Jamuria Industrial Estate, Irka, P.O. Jamuria, District Burdwan, West Bengal by by M/s Maan Steel and Power Ltd.  (TOR)

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Integrated Steel Plants are listed at S.N. 3(a) under Primary Metallurgy Industries under Category ‘A’ and appraised at the Central level.

 

M/s Maan Steel & Power Limited have proposed for the expansion of Sponge Iron Plant (57,000 TPA) into Integrated Steel Plant (0.18 MTPA) alongwith  Captive Power Plant (24 MW; WHRB 12 MW & FBC 12 MW) and Ferro Alloy Plant (2x9 MVA) at Jamuria Industrial Estate, Irka, P.O. Jamuria, District Burdwan, West Bengal.  Total land acquired is 40.94 acres.  PAs emphasized that the project is located in the Jamuria Industrial Estate but no copy of the notification is submitted. No national park/wildlife sanctuary/reserve forests are located within 10 km. radius of the project site. Jamuria town as well as some villages and kasbas are located nearby. No rehabilitation and resettlement is involved. NH-2 is at 8 km.  Damodar River is at 8 km.  Total cost of the project is Rs. 342.30 Crores.   Rs 13.70 Crores and Rs 1.19 Crores are earmarked towards capital cost and recurring cost/annum for environment pollution control measures.  Following are the details of the facilities to be installed and product to  be manufactured:

 

 

EXISTING UNITS :

 

Major Units

Capacity

Products

Production (TPA)

End Use

DRI kiln

2x95 TPD

Sponge Iron

57,000

SMS

 

PROPOSED EXPANSION :

 

DRI KILN

4X100 TPD

Sponge Iron

1,20,000

SMS

SMS-IF-LRF/AOD

-Billet Caster

4x15 T

2x30 T

Matching

MS Billets

1,92,000

Rolling Mills

Rolling Mills

550 TPD

Rods/bars/light

Structurals

1,80,000

Sale

CPP-WHRB

+CPP-FBC

12 MW

12 MW

Power

24 MW

Internal use

Ferro Alloys

2x9 MVA

Ferro-Mn /

Silico-Mn

30,000

Internal use/sale

 

PAs informed to the committee that ‘Consent to Establish’ is accorded by the WBPCB for the existing plant.

 

            Iron ore, non-coking coal DRI grade and dolomite will be used as raw materials in sponge Iron plant., Mn ore, pearl coke, quartz and dolo/magnesite  will be used for ferro alloys plant.  Coal will be sourced from ECL and iron ore from Barbail area (250 km). Nearest sea port (Haldia) is at 250 km. which will be used for import/export of raw material and finished products.

 

              Billets (1,92,000 TPA) will be produced using DRI-IF-CCM route.  Rotary kiln will be used for the reduction of iron ore.  A coal injection system will be provided at the discharge end of the rotary kiln to inject the coal pneumatically.  Charge material will be heated at 1000–1050oC.  The product will be screened and separated into magnetic (sponge iron) and non-magnetic (char) and taken to storage bins. Ladle Refining Furnace (LRF) and Sponge Iron will be melted in Argon Oxygen Decarborization (AOD) facilities will also be provided for refining of the steel. Hot metal will be casted in continuous casting machine (CCM).  Steel billets from CCM will be passed through rolling mill to produce rolled products (0.18 MTPA) i.e. small/medium structural size rods/bars etc. Silico-Manganese and Ferro-Manganese will be produced in submerged or furnace. Electrostatic precipitator (ESP) will be provided DRI kilns, FBC boiler.

Existing ambient air data indicates SPM (274 ug/m3), RPM (130 ug/m3), SO2 (8 ug/m3) and NOx (54 ug/m3).  Therefore, committee insisted to incorporate action plan to control ambient air quality as per the NAAQ norms and parameters mentioned in Notification issued by the Ministry on 16th September, 2009 in the final EIA/EMP report. Hot fume gases for the kiln will be through dust settling chamber (DSC) and after burning chamber (ABC) to remove the coarse solids and burn CO and then passed through waste heat recovery boiler (WHRB) and Electrostatic precipitator (ESP) before letting out into the atmosphere through ID fan and stack.  Fume extraction system with duct, gas cooler, bag house, ID fans and stack will be provided to IF. Fugitive dust will be controlled by dust suppression and dust extraction system.  Regular water sprinkling will be carried out to minimize the fugitive dust emission during transportation.

Total water requirement from Asansol Durgapur Development Authority (ADDA) will be 1,632 m3/day and permission is accorded by the ADDA vide letter dated 29th October, 2009.  Acidic and alkaline effluent from cation and anion units of DM Plant will be neutralized in neutralization tank.  Boiler blow down will be neutralized in the neutralization tank before mixing with other effluent streams.  After neutralization, these two effluents will be mixed with cooling tower blow down in a Central Monitoring Basin. The treated effluent will be used for dust suppression and green belt development. Service water will be passed through oil separator to remove oil content in the effluent.  Domestic effluent will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.  All the storm water will be collected and stored in water harvesting pond.

  

            Char and coal fines will be used in FBC boiler.  Scrap will be recycled in steel melting shop.  Scales from rolling mill and Iron ore fines from raw material handling system will be sold to sinter plant.  Kiln dust, kiln accretion, bottom ash will be used for land filling.  Fly ash will be used as per Fly Ash Notification and collected in dry form. Waste/used/spent oil and used batteries will be sold to authorized recyclers/reprocessors.

 

            Out of 40.94 acres land, green belt will be developed in 13.5 acres. Out of 45 MW power requirement, 24 MW will be generated captively and 21 MW will be sourced from grid.  Char and coal fumes will be utilized as fuel feed in FBC power plant. PAs confirmed that no litigation/court case is in pending against the proposal.

PAs also informed to the committee that proposed unit is located in Jamuria industrial estate which is 40-45 km from Asansol critically polluted area listed at S.N. 42 in the list of Comprehensive Environmental Pollution Index in the Office Memorandum dated 13th January, 2010.  Therefore, CEPI is not applicable in their case.

After deliberating on the facts presented before the Expert Appraisal Committee (Industry), the committee recommended the proposal for the preparation of EIA/EMP as per the following TORs:

 

1.      A site location map on Indian map of 1:10, 00,000 scale followed by 1:50,000/1:25,000 scale on an A3/A2 sheet with at least next 10 Kms of terrains i.e. circle of 10 kms and further 10 kms on A3/A2 sheets with proper longitude/latitude/heights with min. 100/200 m. contours should be included. 3-D view i.e. DEM (Digital Elevation Model) for the area in 10 km radius from the proposal site.

2.      Present land use should be prepared based on satellite imagery. High-resolution satellite image data having 1m-5m spatial resolution like quickbird, Ikonos, IRS P-6 pan sharpened etc. for the 10 Km radius area from proposed site. The same should be used for land used/land-cover mapping of the area.

3.      Location of national parks / wildlife sanctuary / reserve forests within 10 km. radius should specifically be mentioned. A map showing landuse/landcover, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc in 10 km of the project site.

4.      Project site layout plan showing raw materials, fly ash and other storage plans, bore well or water storage, aquifers (within 1 km.) dumping, waste disposal, green areas, water bodies, rivers/drainage passing through the project site should be included.

5.      Details and classification of total land (identified and acquired) should be included.

6.      Proposal should be submitted to the Ministry for environment clearance only after acquiring total land. Necessary documents indicating acquisition of land viz. lease deed, allotment letter should be included.

7.      Rehabilitation & Resettlement (R & R) should be as per policy of the State Govt. and a detailed action plan should be included.

8.      Proof’/‘Notification’ issued by the State Govt., if the project is located in notified industrial area.

9.      Permission and approval for the use of forest land, if any, and recommendations of the State Forest Department regarding impact of proposed expansion on the surrounding reserve forests, if applicable, should be included.

10.  A list of industries containing name and type in 25 km radius should be incorporated.

11.  Residential colony should be located in upwind direction.

12.  List of raw material required and source alongwith mode of transportation should be included. All the trucks for raw material and finished product transportation must be “Environmentally Compliant”.

13.  Petrological and Chemical analysis and other chemical properties of raw materials used (with GPS location of source of raw material) i.e. ores, minerals, rock, soil, coal, iron, dolomite quartz etc. using high definition and precision instruments mentioning their detection range and methodology such Digital Analyzers, AAS with Graphite furnace, ICPMS, MICRO-WDXRF, EPMA, XRD, Nano studies or at least as per I30-10500 and WHO norms. These analysis should include trace element and metal studies like Cr (vi) Ni, Fe, As, Pb, Zn, Hg, Se, S etc.  Presence of radioactive elements (U, Th etc.), if applicable, should also be included.

14.  Petrography, grain size analysis and Major element analysis of raw material and soil from project site and raw material should be done on the same parameters along with analysis for SiO2, Al2O3, MgO, MnO, K2O, CaO, FeO, Fe2O3, P2O5, H2O, CO2.

15.  If the rocks, ores, raw material has trace elements their petrography, ore microscopy, XRD, elemental mapping EPMA, XRF is required to quantify the amount present in it and hence future risk involved while using it and management plan.

16.  Excavation and muck disposal during construction phase.

17.  Studies for fly ash, muck, slurry, sludge material disposal and solid waste generated, if the raw materials used has trace elements and a management plan should also be included.

18.  Manufacturing process details for all the plants should be included.

19.  Mass balance for the raw material and products should be included.

20.  Energy balance data for all the components of steel plant including proposed captive power plant should be incorporated.

21.  Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall should be collected.

22.    Data generated in the last three years i.e. air, water, raw material properties and analysis (major, trace and heavy metals), ground water table, seismic history, flood hazard history etc.

23.    Data on existing ambient air, stack emission, fugitive emissions data; water requirement and water balance cycle; generation, re-utilization and disposal of solid/ hazardous waste for the existing plant and predicted increase in pollution load (GLCs) due to proposed expansion should be incorporated.

24.  Point-wise compliance to the conditions stipulated in the ‘Consent to Establish and Operate’ for the existing plant.

25.  Ambient air quality at 8 locations within the study area of 10 km., aerial coverage from project site with one AAQMS in downwind direction should be carried out.

26.  The suspended particulate matter present in the ambient air must be analyzed for the presence of poly-aromatic hydrocarbons (PAH), i.e. Benzene soluble fraction.  Chemical characterization of RSPM and incorporating of RSPM data.

27.  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.

28.  Air quality modelling for steel plant for specific pollutants needs to be done.  APCS for the control of emissions from the kiln and WHRB should also be included to control emissions within 50 mg/Nm3.

29.  Action plan to follow National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 should be included.

30.  Ambient air quality monitoring modelling alongwith cumulative impact should be included for the day (24 hrs) for maximum GLC alongwith following :

i)        Emissions (g/second) with and without the air pollution control measures

ii)       Meteorological inputs (wind speed, m/s), wind direction, ambient air temperature, cloud cover, relative humidity & mixing height) on hourly basis

iii)     Model input options for terrain, plume rise, deposition etc.

iv)     Print-out of model input and output on hourly and daily average basis

v)      A graph of daily averaged concentration (MGLC scenario) with downwind distance at every 500 m interval covering the exact location of GLC.

vi)     Details of air pollution control methods used with percentage efficiency that are used for emission rate estimation with respect to each pollutant

vii)   Applicable air quality standards as per LULC covered in the study area and % contribution of the proposed plant to the applicable Air quality standard. In case of expansion project, the contribution should be inclusive of both existing and expanded capacity.

viii)  No. I-VII are to be repeated for fugitive emissions and any other source type relevant and used for industry

ix)     Graphs of monthly average daily concentration with down-wind distance

x)      Specify when and where the ambient air quality standards are exceeded either due to the proposed plant alone or when the plant contribution is added to the background air quality.

xi)     Fugitive dust protection or dust reduction technology for workers within 30 m of the plant active areas.

31.  A plan for the utilization of waste/fuel gases in the WHRB for generating power have to be set out.

32.  Impact of the transport of the raw materials and end products on the surrounding environment should be assessed and provided.

33.  One season data for gaseous emissions other than monsoon season is necessary.

34.  An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008.

35.  Presence of aquifer(s) within 1 km of the project boundaries and management plan for recharging the aquifer should be included.

36.  Source of surface/ground water level, site (GPS), cation, anion (Ion Chromatograph), metal trace element (as above) chemical analysis for water to be used. If surface water is used from river, rainfall, discharge rate, quantity, drainage and distance from project site should also be included.

37.  Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management.

38.  Ground water modelling showing the pathways of the pollutants should be included

39.  Column leachate study for all types of stockpiles or waste disposal sites at 20oC-50oC should be conducted and included.

40.  Action plan for rainwater harvesting measures at plant site should be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.  Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayat and Village Heads to augment the ground water level.

41.  Permission for the drawl of 1,632 m3/day water from ADDA from the concerned authority should be included. Water balance data including quantity of effluent generated, recycled and reused and discharged is to be provided. Methods adopted/to be adopted for the water conservation should be included.

42.  A note on the impact of drawl of water on the nearby River during lean season.

43.  Surface water quality of nearby River (60 m upstream and downstream) and other surface drains at eight locations must be ascertained. 

44.  If the site is within 10 km radius of any major river, Flood Hazard Zonation Mapping is required at 1:5000 to 1;10,000 scale indicating the peak and lean river discharge as well as flood occurrence frequency.

45.  A note on treatment of wastewater from different plants, recycle and reuse for different purposes should be included.

46.  Provision of traps and treatment plants are to be made, if water is getting mixed with oil, grease and cleaning agents.

47.  If the water is mixed with solid particulates, proposal for sediment pond before further transport should be included. The sediment pond capacity should be 100 times the transport capacity.

48.  Wastewater characteristics (heavy metals, anions and cations, trace metals, PAH) from washed / beneficiated plants / washery or any other source should be included.

49.  The pathways for pollution via seepages, evaporation, residual remains are to be studied for surface water (drainage, rivers, ponds, lakes), sub-surface and ground water with a monitoring and management plans.

50.  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.

51.  Geotechnical data by a bore hole of upto 40 mts. in every One sq. km area such as ground water level, SPTN values, soil fineness, geology, shear wave velocity etc. for liquefaction studies and to assess future Seismic Hazard and Earthquake Risk Management in the area.

52.  Action plan for solid/hazardous waste generation, storage, utilization and disposal particularly slag from all the sources, char and fly ash. Copies of MOU regarding utilization of ash should also be included.

53.  A note on the treatment, storage and disposal of all type of slag should be included. Identification and details of land to be used for SMS slag disposal should be included. Details of secured land fill as per CPCB guidelines should also be included.

54.  End use of solid waste and its composition should be covered.  Toxic metal content in the waste material and its composition should also be incorporated particularly of slag.

55.  All stock piles will have to be on top of a stable liner to avoid leaching of materials to ground water.

56.  Commitment that no ferro chrome shall be manufactured without prior approval of the Ministry.

57.  Acton plan for the green belt development plan in 33 % area should be included. The green belt should be around the project boundary and a scheme for greening of the traveling roads should also be incorporated. All rooftops/terraces should have some green cover.

58.  Detailed description of the flora and fauna (terrestrial and aquatic) should be given with special reference to rare, endemic and endangered species.

59.  At least 5 % of the total cost of the project should be earmarked towards the corporate social responsibility and item-wise details alongwith time bound action plan should be included. Socio-economic development activities need to be elaborated upon.

60.  Disaster Management Plan including risk assessment and damage control needs to be addressed and included.

61.  Occupational health of the workers needs elaboration. Health effects of other metals used and health hazard plans based on monthly correlation of these metal related diseases and people affected and mitigation plans. Arsenicosis Management Plan, if Arsenic is present in ore, rock, coal, fly ash, water. Action Plan for protecting the workers against hazardous chemicals such as Sulphuric acid, pesticides, solvents etc.

62.  Occupational health of the workers needs elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring and periodical monitoring should be carried out. The detailed plan to carry out above mentioned activity should be mentioned.

63.  Environment Management Plan (EMP) to mitigate the adverse impacts due to the project along with item wise cost of its implementation. Total capital cost and recurring cost/annum for environmental pollution control measures.

64.  Plan for the implementation of the recommendations made for the steel plants in the CREP guidelines must be prepared.

65.  A note on identification and implementation of Carbon Credit project should be included.

66.  Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart. 

67.  Any litigation pending against the project and / or any direction / order passed by any Court of Law against the project, if so, details thereof. 

 

            The Expert Appraisal Committee (Industry-1) decided that PAs may be communicated the above ‘TORs’ for the preparation of EIA/EMP.  As soon as the draft EIA/EMP report is prepared as per the ‘General Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006, the same may be submitted by the PAs to the  West Bengal Pollution Control Board (WBPCB) for conducting public hearing as per EIA Notification, 2006. On finalization of EIA/EMP prepared as per TORs addressing all concerns raised during public hearing/consultation in EIA/EMP should be submitted to the MOEF for prior environmental clearance.

 

 

4. 7            Expansion of Steel Plant (48,000 TPA) by installation of Sponge Iron Plant (60,000 TPA), Ferro Alloy (2x9 MVA, 30,000 TPA) and Captive Power Plant (12 MW; WHRB 4 MW and AFBC 4 MW) at Jamuria Industrial Estate, Ikra, Jamuria, Burdwan, West Bengal by M/s Calstar Sponge Ltd. (TOR)

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Steel plants are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ and appraised at the Central level. 

 

M/s Calstar Sponge Ltd.have proposed for the Integrated Steel Plant (48,000 TPA), Sponge Iron Plant (1,20,000 TPA), Ferro Alloy (2x9 MVA, 30,000 TPA) and Captive Power Plant (12 MW) at Jamuria Industrial Estate, Ikra, Jamuria, Burdwan, West Bengal.  A copy of ‘notification’ issued by the Government of West Bengal regarding location of the project in Jamuria Industrial Estate is not submitted.  Total 19.38 acres land is acquired. No rehabilitation and resettlement is involved. Jamuria township and some villages are located within 10 km radious. Total cost of the project is Rs. 137.60 Crores.  Rs. 5.15 Crores and Rs. 48.00 Lakhs are earmarked towards capital cost and recurring cost/annum for environment pollution control measures. The committee observed that environmental clearance is sought for the second phase of expansion i.e. DRI (60,000 TPA; 2x100 TPD) but at the same time ‘Consent to Establish’ for the existing DRI (60,000 TPA; 2x100 TPD) is obtained from the State Govt. PAs clarified that proposed expansion also involves Ferro Alloy Plant (30,000 TPA) and CPP (8 MW).  Following will be manufactured:

 

 Major Units

Capacity

Product

Production (TPA)

End Use

DRI Kiln

2x100 TPD

Sponge Iron

60,000

SMS

 

NOC obtained from DoE, Govt. of West Bengal

 

SMS-IF

2x8

Steel billets

48,000

Sale

WHRB-CPP

4MW

Power

4MW

Internal use

 

Proposed expansion :

 

DRI Kiln

2x100 TPD

Sponge Iron

60,000

Sale

CPP-WHRB +CPP-FBC

4 MW +

4 MW

Power

8 MW

Internal use

Ferro Alloys

2x9 MVA

Fe-Mn & Si-Mn

30,000

Sale

 

            Iron ore (2,24,000 TPA), DRI coal (1,70,000 TPA), dolomite (6,000  TPA), Mn Ore (75,500 TPA), Pearl coke/coal (18,000 TPA). Quartz (8,900 TPA etc. will be used as raw materials.

 

            Sponge iron will be manufactured in DRI kilns at 10500C. Submerged arc electric furnaces (2x9 MVA) will be installed to produce ferro alloys (Fe-Mn & Si-Mn; 30,000 TPA) Fe-Mn will be manufactured using Mn ore, steam coal, pearl coke (as reductant) and fluxes.  Mill scale / iron scrap will be added to the charge mix.  Molten ferro alloy and slag melted at 1600-17000C will be tapped separately.  Ferro alloy will be casted in casting beds.  WHRB (4 MW0 for the utilization of DRI gases and CFBC (4MW) for the utilization of char from sponge iron plant will be installed during expansion.  WHRB (4 MW) is already existing.

            Hot gases for DRI kiln will be passed through dust smelting chamber (DSC) to remove coarse particles, after burning chamber (ABC) to burn CO and passed through waste heat recovery boiler (WHRB) and then cleaned in electrostatic precipitator (ESP) before letting out into the atmosphere through ID fan and stack.  ESP will be provided to DRI Kilns and CFBC boiler to control emission within 100 mg/Nm3. Dust suppression and dust extraction system will be then led to screen, transfer points and gas cleaning devices.

Total water requirement from Asansol Durgapur Development Authority (ADDA) will be 630 m3/day and have applied for the ‘Permission’ to the Asansol Durgapur Development Authority.  Air cooled condenser will be provided to CPP.  All the wastewater from DRI kilns, SMS, CCM, CPP-cooling and ash handling plant will be recycled/reused in the process itself for ash conditioning, dust suppression and green belt development. Acidic and alkaline effluent from cation and anion units of DM Plant will be neutralized in neutralization tank. Boiler blow down will be neutralized in the neutralization tank before mixing with other effluent streams.  After neutralization, these two effluents will be mixed with cooling tower blow down in a Central Monitoring Basin. Service water will be passed through oil separator to remove oil content in the effluent.  Domestic effluent will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.

 

            Char (36,000 TPA) and coal fines (14,000 TPA) will be used on FBC power plant.  Kiln dust (12,000 TPA), kiln accretion (500 TPA), bottom ash (2,000 TPA) etc. will be used for land filling and SMS slag (9,000 TPA) for road making.  Fly ash (12,000 TPA) will be used as per Fly Ash utilization Notification. Iron ore fines (20,000 TPA) will be sold to sinter plants.

 

            Raw water harvesting pond will be constructed to collect water from roof top and other attachment areas inside the plant premises.

 

            Out of 19.38 acres, green belt will be developed in 6.38 acres.  Action Plan for development of green belt in 33% area is submitted. Total power requirement will be 23MW out of which 11 MW will be sourced from GRID. CPPC (12 MW) is proposed. PAs have confirmed that no litigation / court case is pending against the proposal.

 

PAs confirmed that proposed plant is not located in the critically [polluted area.  After deliberating on the facts presented before the Expert Appraisal Committee (Industry), the committee recommended the proposal for the preparation of EIA/EMP as per the following TORs:

 

1.      Proof’/‘Notification’ issued by the State Govt., if the project is located in notified industrial area.

2.      A map indicating distance between project site and Asansol critically polluted area and a certification from the CPCB/WBPCB.

3.      A site location map on Indian map of 1:10, 00,000 scale followed by 1:50,000/1:25,000 scale on an A3/A2 sheet with at least next 10 Kms of terrains i.e. circle of 10 kms and further 10 kms on A3/A2 sheets with proper longitude/latitude/heights with min. 100/200 m. contours should be included. 3-D view i.e. DEM (Digital Elevation Model) for the area in 10 km radius from the proposal site.

4.      Present land use should be prepared based on satellite imagery. High-resolution satellite image data having 1m-5m spatial resolution like quickbird, Ikonos, IRS P-6 pan sharpened etc. for the 10 Km radius area from proposed site. The same should be used for land used/land-cover mapping of the area.

5.      Location of national parks / wildlife sanctuary / reserve forests within 10 km. radius should specifically be mentioned. A map showing landuse/landcover, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc in 10 km of the project site.

6.      Project site layout plan showing raw materials, fly ash and other storage plans, bore well or water storage, aquifers (within 1 km.) dumping, waste disposal, green areas, water bodies, rivers/drainage passing through the project site should be included.

7.      Details and classification of total land (identified and acquired) should be included.

8.      Proposal should be submitted to the Ministry for environment clearance only after acquiring total land. Necessary documents indicating acquisition of land viz. lease deed, allotment letter should be included.

9.      Rehabilitation & Resettlement (R & R) should be as per policy of the State Govt. and a detailed action plan should be included.

10.  Permission and approval for the use of forest land, if any, and recommendations of the State Forest Department regarding impact of proposed expansion on the surrounding reserve forests, if applicable, should be included.

11.  A list of industries containing name and type in 25 km radius should be incorporated.

12.  Residential colony should be located in upwind direction.

13.  List of raw material required and source alongwith mode of transportation should be included. All the trucks for raw material and finished product transportation must be “Environmentally Compliant”.

14.  Petrological and Chemical analysis and other chemical properties of raw materials used (with GPS location of source of raw material) i.e. ores, minerals, rock, soil, coal, iron, dolomite quartz etc. using high definition and precision instruments mentioning their detection range and methodology such Digital Analyzers, AAS with Graphite furnace, ICPMS, MICRO-WDXRF, EPMA, XRD, Nano studies or at least as per I30-10500 and WHO norms. These analysis should include trace element and metal studies like Cr (vi) Ni, Fe, As, Pb, Zn, Hg, Se, S etc.  Presence of radioactive elements (U, Th etc.), if applicable, should also be included..

15.  Petrography, grain size analysis and Major element analysis of raw material and soil from project site and raw material should be done on the same parameters along with analysis for SiO2, Al2O3, MgO, MnO, K2O, CaO, FeO, Fe2O3, P2O5, H2O, CO2.

16.  If the rocks, ores, raw material has trace elements their petrography, ore microscopy, XRD, elemental mapping EPMA, XRF is required to quantify the amount present in it and hence future risk involved while using it and management plan.

17.  Excavation and muck disposal plan during construction phase.

18.  Studies for fly ash, muck, slurry, sludge material disposal and solid waste generated, if the raw materials used has trace elements and a management plan should also be included.

19.  Manufacturing process details for all the plants should be included.

20.  Mass balance for the raw material and products should be included.

21.  Energy balance data for all the components of steel plant including proposed power plant should be incorporated.

22.  Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall should be collected.

23.    Data generated in the last three years i.e. air, water, raw material properties and analysis (major, trace and heavy metals), ground water table, seismic history, flood hazard history etc.

24.    Data on existing ambient air, stack emission, fugitive emissions data; water requirement and water balance cycle; generation, re-utilization and disposal of solid/ hazardous waste for the existing plant and predicted increase in pollution load (GLCs) due to proposed expansion should be incorporated.

25.  Point-wise compliance to the specific and general conditions stipulated in the ‘Consent to Establish and Operate’ for the existing plant.

26.  Ambient air quality at 8 locations within the study area of 10 km., aerial coverage from project site with one AAQMS in downwind direction should be carried out.

27.  The suspended particulate matter present in the ambient air must be analyzed for the presence of poly-aromatic hydrocarbons (PAH), i.e. Benzene soluble fraction.  Chemical characterization of RSPM and incorporating of RSPM data.

28.  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.

29.  Air quality modeling for steel plant for specific pollutants needs to be done.  APCS for the control of emissions from the kiln and WHRB should also be included to control emissions within 50 mg/Nm3.

30.  Action plan to follow National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 should be included.

31.  Ambient air quality monitoring modelling alongwith cumulative impact should be included for the day (24 hrs) for maximum GLC alongwith following :

                    i)      Emissions (g/second) with and without the air pollution control measures

                   ii)      Meteorological inputs (wind speed, m/s), wind direction, ambient air temperature, cloud cover, relative humidity & mixing height) on hourly basis

                 iii)      Model input options for terrain, plume rise, deposition etc.

                 iv)      Print-out of model input and output on hourly and daily average basis

                  v)      A graph of daily averaged concentration (MGLC scenario) with downwind distance at every 500 m interval covering the exact location of GLC.

                 vi)      Details of air pollution control methods used with percentage efficiency that are used for emission rate estimation with respect to each pollutant

               vii)      Applicable air quality standards as per LULC covered in the study area and % contribution of the proposed plant to the applicable Air quality standard. In case of expansion project, the contribution should be inclusive of both existing and expanded capacity.

              viii)      No. I-VII are to be repeated for fugitive emissions and any other source type relevant and used for industry

                 ix)      Graphs of monthly average daily concentration with down-wind distance

                  x)      Specify when and where the ambient air quality standards are exceeded either due to the proposed plant alone or when the plant contribution is added to the background air quality.

                 xi)      Fugitive dust protection or dust reduction technology for workers within 30 m of the plant active areas.

32.  A plan for the utilization of waste/fuel gases in the WHRB for generating power have to be set out.

33.  Impact of the transport of the raw materials and end products on the surrounding environment should be assessed and provided.

34.  One season data for gaseous emissions other than monsoon season is necessary.

35.  An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008.

36.  Presence of aquifer(s) within 1 km of the project boundaries and management plan for recharging the aquifer should be included.

37.  Source of surface/ground water level, site (GPS), cation, anion (Ion Chromatograph), metal trace element (as above) chemical analysis for water to be used. If surface water is used from river, rainfall, discharge rate, quantity, drainage and distance from project site should also be included.

38.  Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management.

39.  Ground water modelling showing the pathways of the pollutants should be included

40.  Column leachate study for all types of stockpiles or waste disposal sites at 20oC-50oC should be conducted and included.

41.  Action plan for rainwater harvesting measures at plant site should be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.  Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayat and Village Heads to augment the ground water level.

42.  Permission for the drawl of 630 m3/day water from ADDA or concerned authority and water balance data including quantity of effluent generated, recycled and reused and discharged is to be provided. Methods adopted/to be adopted for the water conservation should be included.

43.  A note on the impact of drawl of water on the nearby River during lean season.

44.  Surface water quality of nearby River (60 m upstream and downstream) and other surface drains at eight locations must be ascertained. 

45.  If the site is within 10 km radius of any major river, Flood Hazard Zonation Mapping is required at 1:5000 to 1;10,000 scale indicating the peak and lean river discharge as well as flood occurrence frequency.

46.  A note on treatment of wastewater from different plants, recycle and reuse for different purposes should be included.

47.  Provision of traps and treatment plants are to be made, if water is getting mixed with oil, grease and cleaning agents.

48.  If the water is mixed with solid particulates, proposal for sediment pond before further transport should be included. The sediment pond capacity should be 100 times the transport capacity.

49.  Wastewater characteristics (heavy metals, anions and cations, trace metals, PAH) from washed / beneficiated plants / washery or any other source should be included.

50.  The pathways for pollution via seepages, evaporation, residual remains are to be studied for surface water (drainage, rivers, ponds, lakes), sub-surface and ground water with a monitoring and management plans.

51.  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.

52.  Geotechnical data by a bore hole of upto 40 mts. in every One sq. km area such as ground water level, SPTN values, soil fineness, geology, shear wave velocity etc. for liquefaction studies and to assess future Seismic Hazard and Earthquake Risk Management in the area.

53.  Action plan for solid/hazardous waste generation, storage, utilization and disposal particularly slag from all the sources, char including from the existing sources and fly ash. Copies of MOU regarding utilization of ash should also be included.

54.  A note on the treatment, storage and disposal of all type of slag should be included. Identification and details of land to be used for SMS slag disposal should be included. Details of secured land fill as per CPCB guidelines should also be included.

55.  End use of solid waste and its composition should be covered.  Toxic metal content in the waste material and its composition should also be incorporated particularly of slag.

56.  All stock piles will have to be on top of a stable liner to avoid leaching of materials to ground water.

57.  Commitment that no ferro chrome shall be manufactured without prior approval of the Ministry.

58.  Acton plan for the green belt development plan in 33 % area should be included. The green belt should be around the project boundary and a scheme for greening of the travelling roads should also be incorporated. All rooftops/terraces should have some green cover.

59.  Detailed description of the flora and fauna (terrestrial and aquatic) should be given with special reference to rare, endemic and endangered species.

60.  At least 5 % of the total cost of the project should be earmarked towards the corporate social responsibility and item-wise details alongwith time bound action plan should be included. Socio-economic development activities need to be elaborated upon.

61.  Disaster Management Plan including risk assessment and damage control needs to be addressed and included.

62.  Occupational health of the workers needs elaboration. Health effects of other metals used and health hazard plans based on monthly correlation of these metal related diseases and people affected and mitigation plans. Arsenicosis Management Plan, if Arsenic is present in ore, rock, coal, fly ash, water. Action Plan for protecting the workers against hazardous chemicals such as Sulphuric acid, pesticides, solvents etc.

63.  Occupational health of the workers needs elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring and periodical monitoring should be carried out. The detailed plan to carry out above mentioned activity should be mentioned.

64.  Environment Management Plan (EMP) to mitigate the adverse impacts due to the project along with item wise cost of its implementation. Total capital cost and recurring cost/annum for environmental pollution control measures.

65.  Plan for the implementation of the recommendations made for the steel plants in the CREP guidelines must be prepared.

66.  A note on identification and implementation of Carbon Credit project should be included.

67.  Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart. 

68.  Any litigation pending against the project and / or any direction / order passed by any Court of Law against the project, if so, details thereof. 

 

            The Expert Appraisal Committee (Industry-1) decided that PAs may be communicated the above ‘TORs’ for the preparation of EIA/EMP.  As soon as the draft EIA/EMP report is prepared as per the ‘General Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006, the same may be submitted by the PAs to the  West Bengal Pollution Control Board (WBPCB) for conducting public hearing as per EIA Notification, 2006. On finalization of EIA/EMP prepared as per TORs addressing all concerns raised during public hearing/ consultation in EIA/EMP should be submitted to the MOEF for prior environmental clearance.

 

 

4. 8            Integrated Mini Steel Plant (MS Ingots, 24,000 TPA & Pig Iron 6,000 TPA) at Plot No. 1562/2565, Village Balanda, P.O. Kalunga, District Sundergarh, Orissa  by M/s Vishal Ferro Alloys Pvt. Ltd.

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Steel Plants are listed at S.N. 3(a) under Primary Metallurgical Industries under Category ‘A’ and appraised at the Central level. Total product from IF & EAF will be 30,000 TPA and belongs to ‘A’ Category as per amendment Notification dated 1st December, 2009.

 

           M/s Vishal Ferro Alloys Pvt. Ltd. have proposed for the Integrated Mini Steel Plant (MS Ingots, 24,000 TPA & Pig Iron 6,000 TPA) at Plot No. 1562/2565, Village Balanda, P.O. Kalunga, District Sundergarh, Orissa. Total land acquired is 5 acres.  Nearest village is at 0.8 km.  Balanda RF (10 km), Kumaria FG (6 ha), Jambua RF (7.5 km), Sgjor RF (7 km), Ratkupiri RF (7.5 km) are located within 10 km from the project site.  Total cost of the project is Rs. 18.80  Crores.  Rs. 21.00 lakhs and Rs. 3.70 Lakhs are earmarked towards capital cost and recurring cost/annum for environment pollution control measures. Following are the details of the  facilities to be installed and products to be manufactured:

 

S.N.

Products

Furnace Capacity

Capacity (TPD)

Annual Production Capacity

1.

Pig Iron

2.5 MVA Arc Furnace

20 TPD

6000 TPA

(20x300 Days)

2.

M.S. Ingot

1x8 MVA Induction Furnace

80 TPD

24000 TPA

(80x300 Days)

 

During presentation, PAs informed the Committee that they have planned to install rolling mill too and following will be the configuration :

 

S.N.

Products

Furnace Capacity

Capacity (TPD)

Annual Production Capacity

1.

Pig Iron

2.5 MVA Arc Furnace

20 TPD

6000 TPA

(20x300 Days)

2.

M.S. Ingot

1x8 MVA Induction Furnace

80 TPD

24000 TPA

(80x300 Days)

3.

M.S. Rod (Rolling Mill)

-

-

30,000 TPA

 

           Iron ore fines (9,900 TPA) Steam Coal (2,100 TPA) Pearl Coke (2,700 TPA), quartz (18 TPA), dolomite (600 TPA) and lime stone (2,100 TPA) will be used as raw materials

 

            Pig iron will be produced in electric arc furnace. Iron ore fine using dolomite / limestone will be smelted in arc furnace. To make the steel molten pig iron will be poured into a basic furnace to remove carbon and produce ingots and then into a continuous caster to produce slab, billet or bloom. In induction furnace, the requisite scrap and sponge iron will be charged to melt the steel.  Ferro alloys and carbon will be added. The molten metal will be poured into the moulds to cast ingots.

            Flue gas and dust will be generated from the furnace. Swiveling hood for fume extraction and spark arrestor followed by filter will be passed to induction furnace to control particulate emissions in the stack (30 m) attached to the furnace 100 mg/Nm3. The flue gas from arc furnace will be passed through heat exchanger followed by bag filter with stack (30 m) to control particulate emissions. The oil fired 3 reheating furnace will be provided with adequate height stack (30 m) for disposal of emissions from reheating furnace. Water sprinkling will be done to control fugitive emissions from raw material handling, product handling etc.  Internal roads will be black topped.

Total ground water requirement from tube wells will be enhanced from 40 m3/day to 50 m3/day. Effluent generated from the soft water re-generation plant and cooling tower will be treated in settling tank and reused for dust suppression and green belt development. Service water will be passed through oil separator to remove oil content in the effluent.  Domestic effluent will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.

 

 Dust from air pollution control devices (200 TPA), slag from induction furnace (4,000 TPA) (4,200 TPA) will be generated as solid waste and are furnace will be reused in the process.  IF and LAF slag will be used for road making and balance will be sent to solid waste dump area.  Waste/used/spent oil (0.5 KLPA) and used batteries will be sold to authorized recyclers/re-processors.

  

            Out of total 5 acres land, 1,66 acre is earmarked for the green belt development. Acoustic enclosure will be provided to D.G. Sets.  Power (5,00 KVA) will be used and sourced from WESCO.

 

After deliberations, the committee felt that pig iron manufacturing will not only a costly affair but also environment-unfriendly since it will use lot of electric energy. Project may not be viable too.

 

            Keeping the above mentioned fact in mind, the committee differed the proposal and asked PAs to submit the revised proposal. The proposal will be considered afresh on priority as and when submitted to the Ministry.

 

 

4. 9            Mini Integrated Steel Plant and Thermal Power Plant (2x25 MW) at Village Ayyanahalli, Taluq Hospet, District Bellary, Karnataka by M/s Hanuman Infra Energy Pvt. Ltd. (TOR)

 

Project authorities didn’t attend the meeting and it was decided that proposal should be considered afresh whenever requested by the PAs.

 

 

4. 10        Mini Integrated Steel Plant at Village Oteband, Karhi and Pashid, District Raipur, Chhattisgarh by M/s Sunil Ispat & Energy Private Limited (TOR)

 

PAs vide their letter dated 28th January, 2010 informed to the Ministry that they wo’nt be able to attend the EAC(I) meeting on 2nd February, 2010 due to some unavoidable circumstances and requested for the next meeting. The committee decided that proposal should be considered afresh as per the priority.

 

 

4. 11        Mini Integrated Steel Plant (82,500 TPA) alongwith Captive Power Plant (20 MW) at Sy. No. 25, 27, 28, 44, 47-49, Village Arasinakere, Taluk & District Koppal, Karnataka by M/s PBS Steel and Power Industries Pvt. Ltd. (TOR)

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Steel Plants are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ and appraised at the Central level.

 

M/s PBS Steel and Power Industries Pvt. Ltd. have proposed for the Mini Integrated Steel Plant (82,500 TPA) alongwith Captive Power Plant (20 MW) at Village Arasinakere, Taluk & District Koppal, Karnataka. Total land acquired is 80 acres. A copy of the lease deed is submitted. No national parks/wild life sanctuary/reserve forests is located within 10 km radius. Village Arsinkere is located at 12 km.  Total cost of the project is revised from Rs. 200.89 Crores to Rs. 202.33 Crores.  Following facilities will be installed:

 

S.N.

Unit

Facility

1.

Sponge Iron Plant

2x100 TPD

2.

Induction Furnace

2x15 T

3.

Billet Caster

1x2 Strand

4.

Bar & Rod Mill

82,500 TPA

5.

Captive Power Plant

              WHRB – 4 MW

               AFBC – 16 MW

20 MW

 

            Iron ore (1,78,000 TPA), coal (1,81,300 TPA), lime stone (4,000 TPA), steel scrap / pig iron (23,700 TPA0), ferro alloys (1,350 TPA), pet coke (1,600 TPA) will be used as raw materials.  Non-coking coal will be used as reductant.

 

            Coal based rotary kilns process will be used for direct reduction of Iron (DRI) ore to produce sponge iron. WHRB and AFBC power plant will be installed to make use of waste fume gases and char respectively. Hot metal will be produced in DRI kiln (Iron making) and liquid steel in induction furnace (steel making). Secondary refining will be carried out in ladle reefing furnace (LRF) and casted in continuous casting machine (CCM) and billets / ingots will be rolled in rolling mill.

            Electrostatic precipitator (ESP) and bag filters will be provided to DRI, WHRB and AFBC boilers to control pollution to control emissions within 100 mg/Nm3 but committee insisted for achieving 50 mg/Nm3.  Hot gas from sponge iron plant will pass through dust settling chamber (DSC) and after burning chamber (ABC) and disbursed through ID fan and stack of adequate height.  Fume extraction system will be provided to SMS.  Chimney of adequate height will be provided to reheating furnace. Bag filters will be provided to control fugitive dust from conveyor transfer points.  Water spraying will be done on raw materials and road for controlling flying dust during unloading and loading.

Total ground water requirement from bore wells will be 40.5 m3/hr instead of 108 m3/hr earlier proposed.  Cooling system will be adopted to recycle/reuse water.  Acidic and alkaline effluent from cation and anion units of DM Plant will be neutralized in neutralization tank.  Boiler blow down will be neutralized in the neutralization tank before mixing with other effluent streams.  After neutralization, these two effluents will be mixed with cooling tower blow down in a Central Monitoring Basin. The treated effluent will be used for ash conditioning, dust suppression and green belt development.  The wastewater from billet caster and after cooling will be collected in scale pit. Service water will be passed through oil separator to remove oil content in the effluent.  Domestic effluent will be treated in septic tank followed by soak pit/sewage treatment plant (STP) and used for green belt development.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted. 

 

            Char, fly ash, bed ash and ESP dust will be generated as solid waste.  Char will be used in captive power plant.  Fly ash will be sold to brick manufacturing units.  SMS slag will be dumped in dump area for future productive use. Scrap will be reused in the process.   Waste/used/spent oil (2000 l/yr) and grease (1,000 kg/yr) and used batteries will be sold to authorized recyclers / re-processors.

 

            Rain water harvesting scheme will be adopted to maintain water table.  Silencers will be provided to noise generating equipments. Power (18.6 MW) will be required and CPP (2x10 MW) is proposed.  ADG set (100 KVA) is also proposed for emergency. There is no litigation / court case in pending against the proposal.

 

After deliberating on the facts presented before the Expert Appraisal Committee (Industry), the committee recommended the proposal for the preparation of EIA/EMP as per the following TORs:

 

1.      A site location map on Indian map of 1:10, 00,000 scale followed by 1:50,000/1:25,000 scale on an A3/A2 sheet with at least next 10 Kms of terrains i.e. circle of 10 kms and further 10 kms on A3/A2 sheets with proper longitude/latitude/heights with min. 100/200 m. contours should be included. 3-D view i.e. DEM (Digital Elevation Model) for the area in 10 km radius from the proposal site.

2.      Present land use should be prepared based on satellite imagery. High-resolution satellite image data having 1m-5m spatial resolution like quickbird, Ikonos, IRS P-6 pan sharpened etc. for the 10 Km radius area from proposed site. The same should be used for land used/land-cover mapping of the area.

3.      Location of national parks / wildlife sanctuary / reserve forests within 10 km. radius should specifically be mentioned. A map showing landuse/landcover, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc in 10 km of the project site.

4.      Project site layout plan showing raw materials, fly ash and other storage plans, bore well or water storage, aquifers (within 1 km.) dumping, waste disposal, green areas, water bodies, rivers/drainage passing through the project site should be included.

5.      Details and classification of total land (identified and acquired) should be included.

6.      Proposal should be submitted to the Ministry for environment clearance only after acquiring total land. Necessary documents indicating acquisition of land viz. lease deed, allotment letter should be included.

7.      Rehabilitation & Resettlement (R & R) should be as per policy of the State Govt. and a detailed action plan should be included.

8.      Permission and approval for the use of forest land, if any, and recommendations of the State Forest Department regarding impact of proposed expansion on the surrounding reserve forests, if applicable, should be included.

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.

11.  List of raw material required and source alongwith mode of transportation should be included. All the trucks for raw material and finished product transportation must be “Environmentally Compliant”.

12.  Petrological and Chemical analysis and other chemical properties of raw materials used (with GPS location of source of raw material) i.e. ores, minerals, rock, soil, coal, iron, dolomite quartz etc. using high definition and precision instruments mentioning their detection range and methodology such Digital Analyzers, AAS with Graphite furnace, ICPMS, MICRO-WDXRF, EPMA, XRD, Nano studies or at least as per I30-10500 and WHO norms. These analysis should include trace element and metal studies like Cr (vi) Ni, Fe, As, Pb, Zn, Hg, Se, S etc.  Presence of radioactive elements (U, Th etc.), if applicable, should also be included..

13.  Petrography, grain size analysis and Major element analysis of raw material and soil from project site and raw material should be done on the same parameters along with analysis for SiO2, Al2O3, MgO, MnO, K2O, CaO, FeO, Fe2O3, P2O5, H2O, CO2.

14.  If the rocks, ores, raw material has trace elements their petrography, ore microscopy, XRD, elemental mapping EPMA, XRF is required to quantify the amount present in it and hence future risk involved while using it and management plan.

15.  Action plan for excavation and muck disposal during construction phase.

16.  Studies for fly ash, muck, slurry, sludge material disposal and solid waste generated, if the raw materials used has trace elements and a management plan should also be included.

17.  Manufacturing process details for all the plants should be included.

18.  Mass balance for the raw material and products should be included.

19.  Energy balance data for all the components of steel plant including proposed power plant should be incorporated.

20.  Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall should be collected.

21.  Data generated in the last three years i.e. air, water, raw material properties and analysis (major, trace and heavy metals), ground water table, seismic history, flood hazard history etc.

22.  Ambient air quality at 8 locations within the study area of 10 km., aerial coverage from project site with one AAQMS in downwind direction should be carried out.

23.  The suspended particulate matter present in the ambient air must be analyzed for the presence of poly-aromatic hydrocarbons (PAH), i.e. Benzene soluble fraction. Chemical characterization of RSPM and incorporating of RSPM data.

24.  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.

25.  Air quality modelling for steel plant for specific pollutants needs to be done.  APCS for the control of emissions from the kiln and WHRB should also be included to control emissions within 50 mg/Nm3.

26.  Action plan to follow National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 should be included.

27.  Ambient air quality monitoring modelling alongwith cumulative impact should be included for the day (24 hrs) for maximum GLC alongwith following :

                    i)      Emissions (g/second) with and without the air pollution control measures

                   ii)      Meteorological inputs (wind speed, m/s), wind direction, ambient air temperature, cloud cover, relative humidity & mixing height) on hourly basis

                 iii)      Model input options for terrain, plume rise, deposition etc.

                 iv)      Print-out of model input and output on hourly and daily average basis

                  v)      A graph of daily averaged concentration (MGLC scenario) with downwind distance at every 500 m interval covering the exact location of GLC.

                 vi)      Details of air pollution control methods used with percentage efficiency that are used for emission rate estimation with respect to each pollutant

               vii)      Applicable air quality standards as per LULC covered in the study area and % contribution of the proposed plant to the applicable Air quality standard. In case of expansion project, the contribution should be inclusive of both existing and expanded capacity.

              viii)      No. I-VII are to be repeated for fugitive emissions and any other source type relevant and used for industry

                 ix)      Graphs of monthly average daily concentration with down-wind distance

                  x)      Specify when and where the ambient air quality standards are exceeded either due to the proposed plant alone or when the plant contribution is added to the background air quality.

                 xi)      Fugitive dust protection or dust reduction technology for workers within 30 m of the plant active areas.

28.  A plan for the utilization of waste/fuel gases in the WHRB for generating power have to be set out.

29.  Impact of the transport of the raw materials and end products on the surrounding environment should be assessed and provided.

30.  One season data for gaseous emissions other than monsoon season is necessary.

31.  An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008.

32.  Presence of aquifer(s) within 1 km of the project boundaries and management plan for recharging the aquifer should be included.

33.  Source of surface/ground water level, site (GPS), cation, anion (Ion Chromatograph), metal trace element (as above) chemical analysis for water to be used. If surface water is used from river, rainfall, discharge rate, quantity, drainage and distance from project site should also be included.

34.  Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management.

35.  Ground water modelling showing the pathways of the pollutants should be included

36.  Column leachate study for all types of stockpiles or waste disposal sites at 20oC-50oC should be conducted and included.

37.  Action plan for rainwater harvesting measures at plant site should be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.  Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayat and Village Heads to augment the ground water level.

38.  Permission for the drawl of 40.5 m3/day ground water from bore well from the SGWB/CGWA or concerned authority and water balance data including quantity of effluent generated, recycled and reused and discharged is to be provided. Methods adopted/to be adopted for the water conservation should be included.

39.  A note on the impact of drawl of water on the nearby River during lean season.

40.  Surface water quality of nearby River (60 m upstream and downstream) and other surface drains at eight locations must be ascertained. 

41.  If the site is within 10 km radius of any major river, Flood Hazard Zonation Mapping is required at 1:5000 to 1;10,000 scale indicating the peak and lean river discharge as well as flood occurrence frequency.

42.  A note on treatment of wastewater from different plants, recycle and reuse for different purposes should be included.

43.  Provision of traps and treatment plants are to be made, if water is getting mixed with oil, grease and cleaning agents.

44.  If the water is mixed with solid particulates, proposal for sediment pond before further transport should be included. The sediment pond capacity should be 100 times the transport capacity.

45.  Wastewater characteristics (heavy metals, anions and cations, trace metals, PAH) from washed / beneficiated plants / washery or any other source should be included.

46.  The pathways for pollution via seepages, evaporation, residual remains are to be studied for surface water (drainage, rivers, ponds, lakes), sub-surface and ground water with a monitoring and management plans.

47.  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.

48.  Geotechnical data by a bore hole of upto 40 mts. in every One sq. km area such as ground water level, SPTN values, soil fineness, geology, shear wave velocity etc. for liquefaction studies and to assess future Seismic Hazard and Earthquake Risk Management in the area.

49.  Action plan for solid/hazardous waste generation, storage, utilization and disposal particularly slag from all the sources, char and fly ash. Copies of MOU regarding utilization of ash should also be included.

50.  A note on the treatment, storage and disposal of all type of slag should be included. Identification and details of land to be used for SMS slag disposal should be included. Details of secured land fill as per CPCB guidelines should also be included.

51.  End use of solid waste and its composition should be covered.  Toxic metal content in the waste material and its composition should also be incorporated particularly of slag.

52.  All stock piles will have to be on top of a stable liner to avoid leaching of materials to ground water.

53.  Acton plan for the green belt development plan in 33 % area should be included. The green belt should be around the project boundary and a scheme for greening of the traveling roads should also be incorporated. All rooftops/terraces should have some green cover.

54.  Detailed description of the flora and fauna (terrestrial and aquatic) should be given with special reference to rare, endemic and endangered species.

55.  At least 5 % of the total cost of the project should be earmarked towards the corporate social responsibility and item-wise details alongwith time bound action plan should be included. Socio-economic development activities need to be elaborated upon.

56.  Disaster Management Plan including risk assessment and damage control needs to be addressed and included.

57.  Occupational health of the workers needs elaboration. Health effects of other metals used and health hazard plans based on monthly correlation of these metal related diseases and people affected and mitigation plans. Arsenicosis Management Plan, if Arsenic is present in ore, rock, coal, fly ash, water. Action Plan for protecting the workers against hazardous chemicals such as Sulphuric acid, pesticides, solvents etc.

58.  Occupational health of the workers needs elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring and periodical monitoring should be carried out. The detailed plan to carry out above mentioned activity should be mentioned.

59.  Environment Management Plan (EMP) to mitigate the adverse impacts due to the project along with item wise cost of its implementation. Total capital cost and recurring cost/annum for environmental pollution control measures.

60.  Plan for the implementation of the recommendations made for the steel plants in the CREP guidelines must be prepared.

61.  A note on identification and implementation of Carbon Credit project should be included.

62.  Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart. 

63.  Any litigation pending against the project and / or any direction / order passed by any Court of Law against the project, if so, details thereof. 

 

            The Expert Appraisal Committee (Industry-1) decided that PAs may be communicated the above ‘TORs’ for the preparation of EIA/EMP.  As soon as the draft EIA/EMP report is prepared as per the ‘General Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006, the same may be submitted by the PAs to the  Karnataka State Pollution Control Board (KSPCB) for conducting public hearing as per EIA Notification, 2006. On finalization of EIA/EMP prepared as per TORs addressing all concerns raised during public hearing/consultation in EIA/EMP should be submitted to the MOEF for prior environmental clearance.

 

 

4. 12        Expansion of Sponge Iron Plant into Integrated Steel Complex (0.8 MTPA) alongwith Captive Power Plant (120 MW) at Gundichapara Industrial Estate, P.O. Gudichapara, District Dhenkanal, Orissa by M/s Narbheram Power & Steel Pvt. Ltd. (TOR)

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Integrated Steel Plants are listed at S.N. 3(a) under Primary Metallurgical Industries under Category ‘A’ and appraised at the Central level.

           M/s Narbheram Power & Steel Pvt. Ltd. have proposed for the expansion of Sponge Iron Plant into Integrated Steel Complex (0.8 MTPA) alongwith Captive Power Plant (120 MW) at Gundichapara Industrial Estate, P.O. Gudichapara, District Dhenkanal, Orissa. Total project area is 430 acres.  202 acres land in Gundichapara Industrial Estate is acquired from IDCO and 228 acres is under acquisition.  The area is notified as industrial area by Industries Department, Government of Orissa Vide Notification no. XXHI 16/2009-11308/I dated 04.08.2009. Village Gundichapara is located at 2 km. Dhenkanal town is at 5 km.  Korian RF (0.3 km), Megha RF (8.0 km), Charkhala RF (7 km), Mayura RF (6 km), Kankadahda RF (9 km), Ghantabaja RF (5.5 km), Tamanda Rf (5.5 km) and Maharagadi RF (8 km) are located within 10 km radius of the proposed project site. Total cost of the project is Rs. 1106.00 Crores.   Rs. 93.76 crore & Rs 23.09 Crores has been earmarked for capital cost and recurring cost respectively for pollution control measures. Following facilities are existing:

S.N.

Products

Plant Facilities

Capacity

1.

Sponge Iron

1x300 TPD DRI

1.0 Lakh TPA

2.

Billet

SMS Plant 2x7 Ton/Heat IF

2 Strand CCM

42,000 TPA

3.

Power

WHRB

8 MW

 

Following are the details of the facilities and products to be manufactured :

 

S.

N.

Product

Existing

Proposed

Ultimate Configuration

Phase-I

Phase-II

1.

Sponge Iron

1x300 TPD

 (1.0 Lakh TPA)

1x300 TPD

(1.0 Lakh TPA)

& 2x100 TPD

(0.5 Lakh TPA)

2x500 TPD

(2x1.5 Lakh TPA)

2x300 TPD

2x100 TPD &

2x500 TPD

(5.5 TPA)

2.

Billets & Slab

SMS Plant

2x7 TPH (IF)

2 Strand CCM 42,000 TPA

SMS Plant

2x15 T LRF 1x3

Strand CCM

(90,000 TPA)

SMS Plant

2x500 T EAF

1x50 T LRF

1x6 Strand CCM

6,68,000 TPA

SMS Plant

(2x7 T IF, 2x15 T IF, 1x15 T LRF, 2x50 T EAF, 1x50 T LRF)

(8,00,000 TPA0

3.

Pig Iron

Nil

Nil

2x262 m3 MBF

4,00,000 TPA

2x262 m3 (MBF)

4,00,000 TPA

4.

Power

8 MW

(WHRB)

12 MW (WHRB)

(2x10 TPH+1x40 TPH) & 30 MW (AFBC) (1x130 TPH)

2x10 MW (WHRB)

(2x45 TPH)

2x25 MW (AFBC)

(2x110 TPH)

40 MW

(WHRB) &

80 MW

(FBC)

5.

a) Washed      

    coal (50%)

b) Middlings

    (35%)

c) Coal dust &

    Rejects (15%)

-

4.0 Lakh TPA

2.8 Lakh TPA

1.2 Lakh TPA

(2x75 TPH)

4.0 Lakh TPA

2.8 Lakh TPA

1.2 Lakh TPA

(2x75 TPH)

8.0 Lakh TPA

5.6 Lakh TPA

2.4 Lakh TPA

(4x75 TPH) with throughput of 16 Lakh TPA)

6.

Rolled Products

Nil

Nil

Rolling Mill

5.0 Lakh TPA

5.0 Lakh TPA

7.

Sintered Iron Ore

Nil

Nil

Sinter Plant

(1x48 m2)

4,20,000 TPA

Sinter Plant

(1x48 m2)

4,20,000 TPA

8.

Coke Oven

Nil

Nil

2,40,000 TPA

2,40,000 TPA

9.

Oxygen

Nil

Nil

400 m3/hr

400 m3/hr

 

            Washed coal iron ore, dolomite / limes stone for DRI plant; iron ore finer, coke, limestone, dolomite for sinter plant; coke, iron ore lump, sintered iron ore, dolomite, quartz, coal finer for MBF; sponge iron, pig iron, scrap, ferro alloy for SMS; coal for coal washery, char middlings, coal fines, coal for AFBC Power plant and coking coal for coke oven plant will be used as raw materials.  Quantity-wise details are submitted.  Material and energy balance is submitted. Iron ore will be sourced from captive iron mine (M/s K.N. Ram & Co.).

 

         Steel will be manufactured using DRI-MRF-IE/EAC continuous caster route. Sponge iron plant exists and also proposed to be manufactured in DRI kiln.  Char and sponge iron will be used by non-magnetic and magnetic methods. Non-recovery type of coke oven will be installed.  Sinter plant will be installed to agglomerate iron ore fines/blue dust, coke breeze and fluxes and produce sinter.  Hot metal will be produced in blast furnace.  Slag will be granulated in slag granulation unit. Hot metal from BF will be sent to steel melt shop (IF, EAC and LF) and then transferred to continuous casting machine (CCM) to manufacture billets.  Billets will be re-heated at 10500C to manufacture TMT bars. Coal will be washed in coal washery and used in DRI plant and will mainly involve coal crushing and screening and washing + 5 to 22 mm size coal will be fed to washery for beneficiation and further feeding to DR plant -5 mm will be used in FBB.  +20 mm will be sent to crusher again.  WHRB to make use of flue gases and AFBC to CPP will be installed.

            Electrostatic precipitator, bag filters will be provided to control particulate matter emissions from the chimney attached to DRI plant, captive power plant, MBF, EAF, IF, sinter plant etc. within 50 mg/Nm3.  All the flue gases from non-recovering type of coke oven will be completely burnt and cleaned gas will be discharged through stack. BF gas will be cleaned in gas clearing plant (GCP) having cyclone and two-stage venturing system. Hot gases from DRI will be passed through DSC, ABC, WHRB and ESP to control emissions within 50 mg/Nm3.  ESP will be provided to EFBC, WHRB sinter plant, DRI kiln etc. Dust extraction system with pulse jet type bag filter will be provided to BF stockhouse. Water sprinkling/dry fog system will be used to suppress fugitive emissions from coal washery.  Internal roads will be black topped.  Dust extraction system will be provided to raw material handling area. Swiveling hood, fume extraction system, spark arrestor, slack will be provided to IF.  Adequate stack will be provided to rolling mill.

Total water requirement from River Brahmini will be 1200 m3/hr.  Water quenching for non-recovery type of coke oven is proposed.  Cooling water blow down from coke over, sinter plant, SMS, rolling mill will be collected in settling tanks and re-circulated with make up water.  Acidic and alkaline effluent from cation and anion units of DM Plant will be neutralized in neutralization tank.  Boiler blow down will be neutralized in the neutralization tank before mixing with other effluent streams.  After neutralization, these two effluents will be mixed with cooling tower blow down in a Central Monitoring Basin. Effluent from coal washery and scrubbed effluent from GCP of blast furnace will be taken to thickener and over flow will be used in thickener and under flow for dust suppression.  Quenching water for slag granulation unit will be used for dust suppression. The treated effluent will be used for ash conditioning, dust suppression and green belt development.  No effluent will be generated for the non-recovery type of coke oven. Service water will be passed through oil separator to remove oil content in the effluent from garland drain and settling pit.  Domestic effluent will be treated in septic tank followed by soak pit.  Canteen effluent will be treated in sewage treatment plant (STP) and used for plantation. No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.

  

            Char (1,65,000 TPA) will be used for power generation through fluidized bed boiler (FBB) and also disposed in char dump area. Coal fines (55,000 TPA) from coal washery will be used for power generation and also for injection in blast furnace.  Ash from AFBC Power plant will be used for cement / brick manufacturing, road construction and also taken to ash mound. Dust from APC devices (18,000 TPA), kiln accretion (1,000 TPA) from DRI Plant; thickener sludge and flue dust (15,000 TPA) from blast furnace i.e. dust from APCS of IF, EAF, LF (1,000 TPA will be sent to designated dump area. BF slag (2,00,000 TPA) will be granulated and given to cement manufacturers.  IF & EAF slag (78,000 TPA) will be used for road construction and low land filling. Sludge (4 TPA) from canteen will be value-composted.  Dust from sinter plant (2,000 TPA) will be reused in sinter plant.  Waste/used/spent oil and used batteries will be sold to authorized recyclers / re-processors.

 

            Out of 430 acres, 140 acres is earmarked for green belt development (p. 18/c). 10 ha vide green belt is proposed around the proposed site.  Acoustic enclosures will be provided to control noise. Total power requirement will be 93 MW and captive power plant (120 MW) is proposed.  1200 KLPA HSD fuel will be used as fuel.

 

After deliberations, the committee observed that :

 

1.      Total project area is 430 acres.  202 acres land in Gundichapara Industrial Estate is acquired from IDCO and 228 acres is under acquisition. The land seems to be too much for the size of the plant and should be logically reduced.

2.      Similarly, power requirement should not be more than 60 MW and should be reduced from 120 MW proposed.

3.      Coke oven (0.24 MTPA) capacity is not feasible and it will create more pollution than fulfilling the requirement for the plant.

4.      Details of facilities and products needs to be reassessed.

5.      Material balance also needs to be reassessed.

6.      Burning of coke oven gases and release into the environment is not allowed and have to use for generating power through WHRB.

7.      Possibility of air quenching in the coke oven instead of water quenching should be explored.

8.      Accordingly, water requirement should be reduced.

 

Keeping above mentioned facts in mind, the committee differed the proposal and asked PAs to submit the revised proposal incorporating above mentioned information/ clarifications for consideration of the proposal. The proposal will be considered afresh on priority as and when submitted.

 

 

4. 13        Expansion of Sponge Iron Plant (30,000 TPA to 60,000 TPA) alongwith Captive Power Plant (8 MW; 4 MW WHRB & 4 MW AFBC) at Sy. No. 142, Village Belagal, Taluq & District Bellary, Karnataka by M/s Sajjala Iron & Steel Private Ltd. (TOR)

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Sponge Iron plants (100 TPD) are listed at S.N. 3(a)(b) under Primary Metallurgy Industry under Category ‘B’ and appraised at the Central level due to location of the project within 10 km of institute boundary as per General Conditions. 

    

           M/s Sajjala Iron & Steel Private Ltd.have proposed for the expansion of Sponge Iron Plant (30,000 TPA to 60,000 TPA) alongwith Captive Power Plant (8 MW; 4 MW WHRB & 4 MW AFBC) at Sy. No.142, Village Belagal, Taluq & District Bellary, Karnataka. Total project area available is revised from 14.8 acres earlier proposed to 15.5 acres. Total cost of the project is Rs. 41.16 Crores.  Sponge iron plant (100 TPD) is already existing and another Sponge iron plant (100 TPD) alongwith Captive Power Plant (8 MW; 4 MW WHRB & 4 MW AFBC) is proposed.  Karnataka SPCB has accorded ‘Consent to Establish’ and ‘Consent to Operate’ vide letter dated 6th May, 2005 and 14th November, 2007.

           

            Iron ore (60,000 TPA), coal (45,000 TPA) and lime store (1,500 TPA) will be used as raw materials.  Sponge iron will be manufactured in DRI Kiln at 10500C. Coal will be used as reductant.

           

Electrostatic precipitator (ESP) will be provided to DRI kilns and AFBC-CPP to maintain emissions within 75 mg/Nm3.   Hot gases from DRI will be passed through dust settling chamber (DSC) after burning chamber (ABC), WHRB, ESP and stack (42 m). SO2 emissions by erecting chimney of adequate height and NOx emission by controlled firing in the boiler will be adopted. Water sprinkling will be carried out to control dust during unloading and loading.  Bag filters will be provided at conveyor transfer points to control fugitive dust emissions.

Total ground water requirement from bore wells will be 220 m3/day instead of 200 m3/day earlier proposed. Air cooled condenser will be provided to CPP.  Acidic and alkaline effluent from cation and anion units of DM plant will be neutralized in neutralization tank.  Boiler blow down will be neutralized in the neutralization tank before mixing with other effluent streams.  After neutralization, these two effluents will be mixed with cooling tower blow down in a Central Monitoring Basin. The treated effluent will be used for ash conditioning, dust suppression and green belt development.  Service water will be passed through oil separator to remove oil content in the effluent.  Domestic effluent will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.

 

            Char will be used as fuel in CPP.  Fly ash will be sold to cement manufacturers.  Used oil and grease will be sold to recyclers/re-processors.

 

Green belt will be developed in 33 % area. Power (1000 KVA) will be sourced from GESCOM.  CPP (8 MW) is also proposed.

 

            After detailed deliberations, the Expert Appraisal Committee (Industry) recommended the proposal for the preparation of EIA/EMP as per the following TORs:  

 

1.      Proof’/‘Notification’ issued by the State Govt., if the project is located in notified industrial area.

2.      A map indicating distance between project site and critically polluted area, if any, and a certificate from the CPCB/SPCB certifying the same.

3.      A site location map on Indian map of 1:10, 00,000 scale followed by 1:50,000/1:25,000 scale on an A3/A2 sheet with at least next 10 Kms of terrains i.e. circle of 10 kms and further 10 kms on A3/A2 sheets with proper longitude/latitude/heights with min. 100/200 m. contours should be included. 3-D view i.e. DEM (Digital Elevation Model) for the area in 10 km radius from the proposal site.

4.      Present land use should be prepared based on satellite imagery. High-resolution satellite image data having 1m-5m spatial resolution like quickbird, Ikonos, IRS P-6 pan sharpened etc. for the 10Km radius area from proposed site. The same should be used for land used/land-cover mapping of the area.

5.      Location of national parks / wildlife sanctuary / reserve forests within 10 km. radius should specifically be mentioned. A map showing landuse / landcover, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc in 10 km of the project site.

6.      Actual land requirement, classification of land, acquisition status, rehabilitation and resettlement as per the policy of the Govt. of Karnataka should be incorporated.

7.      A list of industries containing name and type in 25 km radius should be incorporated.

8.      Project site layout plan showing raw materials, fly ash and other storage plans, bore well or water storage, aquifers (within 1 km.) dumping, waste disposal, green areas, water bodies, rivers/drainage passing through the project site should be included.

9.      List of raw material required and source alongwith mode of transportation should be included. All the trucks for raw material and finished product transportation must be “Environmentally Compliant”.

10.  Petrological and Chemical analysis and other chemical properties of raw materials used (with GPS location of source of raw material) i.e. ores, minerals, rock, soil, coal, iron, dolomite quartz etc. using high definition and precision instruments mentioning their detection range and methodology such Digital Analyzers, AAS with Graphite furnace, ICPMS, MICRO-WDXRF, EPMA, XRD, Nano studies or at least as per I30-10500 and WHO norms. These analysis should include trace element and metal studies like Cr (vi) Ni, Fe, As, Pb, Zn, Hg, Se, S etc.  Presence of radioactive elements (U, Th etc.).

11.  Petrography, grain size analysis and Major element analysis of raw material and soil from project site and raw material should be done on the same parameters along with analysis for SiO2, Al2O3, MgO, MnO, K2O, CaO, FeO, Fe2O3, P2O5, H2O, CO2.

12.  If the rocks, ores, raw material has trace elements their petrography, ore microscopy, XRD, elemental mapping EPMA, XRF is required to quantify the amount present in it and hence future risk involved while using it and management plan.

13.  Studies for fly ash, muck disposal, slurry, sludge material and solid waste generated should also be included, if the raw materials used has trace elements and a management plan.

14.  Manufacturing process details of the Sponge Iron and Captive Power Plant (WHRB & AFBC) should be included.

15.  Data generated in the last three years i.e. air, water, raw material properties and analysis (major, trace and heavy metals), ground water table, seismic history, flood hazard history etc.

16.  Data on existing ambient air, stack emission, fugitive emissions data; water requirement and water balance cycle; generation, re-utilization and disposal of solid/ hazardous waste for the existing plant and predicted increase in pollution load due to proposed expansion should be incorporated.

17.  Point-wise compliance to the specific and general conditions stipulated in the environmental clearance, ‘Consent to Establish’ and ‘Consent to ‘Operate’ for the existing plant.

18.  Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall should be collected.

19.  Ambient air quality at 8 locations within the study area of 10 km., aerial coverage from project site with one AAQMS in downwind direction should be carried out.

20.  The suspended particulate matter present in the ambient air must be analyzed for the presence of poly-aromatic hydrocarbons (PAH), i.e. Benzene soluble fraction.  Chemical characterization of RSPM and incorporating of RSPM data.

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.

22.  Air quality modelling for steel plant for specific pollutants needs to be done.  Air pollution control devices installed and proposed for the control of emissions from all the sources should also be included. Action plan to follow National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 should be included.

23.  Ambient air quality monitoring modelling alongwith cumulative impact should be included for the day (24 hrs) for maximum GLC alongwith following :

                    i)      Emissions (g/second) with and without the air pollution control measures

                   ii)      Meteorological inputs (wind speed, m/s), wind direction, ambient air temperature, cloud cover, relative humidity & mixing height) on hourly basis

                 iii)      Model input options for terrain, plume rise, deposition etc.

                 iv)      Print-out of model input and output on hourly and daily average basis

                  v)      A graph of daily averaged concentration (MGLC scenario) with downwind distance at every 500 m interval covering the exact location of GLC.

                 vi)      Details of air pollution control methods used with percentage efficiency that are used for emission rate estimation with respect to each pollutant

               vii)      Applicable air quality standards as per LULC covered in the study area and % contribution of the proposed plant to the applicable Air quality standard. In case of expansion project, the contribution should be inclusive of both existing and expanded capacity.

              viii)      No. I-VII are to be repeated for fugitive emissions and any other source type relevant and used for industry

                 ix)      Graphs of monthly average daily concentration with down-wind distance

                  x)      Specify when and where the ambient air quality standards are exceeded either due to the proposed plant alone or when the plant contribution is added to the background air quality.

                 xi)      Fugitive dust protection or dust reduction technology for workers within 30 m of the plant active areas.

24.  Impact of the transport of the raw materials and end products on the surrounding environment should be assessed and provided.

25.  An action plan to control secondary fugitive emissions as per latest standards issued by the Ministry in May, 2008 and monitoring should be included.

26.  One season data for gaseous emissions other than monsoon season is necessary.

27.  Presence of aquifer/aquifers within 1 km of the project boundaries and management plan for recharging the aquifer should be included.

28.  Source of surface/ground water level, site (GPS), cation, anion (Ion Chromatograph), metal trace element (as above) chemical analysis for water to be used. If surface water is used from river, rainfall, discharge rate, quantity, drainage and distance from project site should also be included.

29.  Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management.

30.  Ground water modelling showing the pathways of the pollutants should be included

31.  Column leachate study for all types of stockpiles or waste disposal sites, at 20oC-50oC should be conducted and included.

32.  Action plan for rainwater harvesting measures at plant site should be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.  Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayat and Village Heads to augment the ground water level.

33.  Permission for the drawl of 220 m3/day ground water from the SGWB/CGWA and water balance data including quantity of effluent generated, recycled and reused and discharged is to be provided. Methods adopted/to be adopted for the water conservation should also be included.

34.  Surface water quality of nearby river (60 m upstream and downstream) and other surface drains at eight locations must be ascertained. 

35.  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.

36.  Provision of traps and treatment plants are to be made, if water is getting mixed with oil, grease and cleaning agents.

37.  If the water is mixed with solid particulates, proposal for sediment pond before further transport should be included. The sediment pond capacity should be 100 times the transport capacity.

38.  Wastewater characteristics (heavy metals, anions and cations, trace metals, PAH) from washed / beneficiated plants / washery.

39.  The pathways for pollution via seepages, evaporation, residual remains are to be studied for surface water (drainage, rivers, ponds, lakes), sub-surface and ground water with a monitoring and management plans.

40.  Action plan for solid/hazardous waste generation, storage, utilization and disposal particularly use of Char in FBC boiler should be included.

41.  A plan for the utilization of gases in the WHRB for generating power should be incorporated.

42.  Energy balance data for Sponge Iron and Captive Power Plant should be included.

43.  Disaster Management Plan including risk assessment and damage control needs to be addressed and included.

44.  Occupational health of the workers needs elaboration. Health effects of other metals used and health hazard plans based on monthly correlation of these metal related diseases and people affected and mitigation plans. Arsenicosis Management Plan, if Arsenic is present in ore, rock, coal, fly ash, water. Action Plan for protecting the workers against hazardous chemicals such as Sulphuric acid, pesticides, solvents etc.

45.  Occupational health of the workers needs elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring and periodical monitoring should be carried out. The detailed plan to carry out above mentioned activity should be mentioned. Acton plan for the green belt development plan in 33 % area should be included. The green belt should be around the project boundary and a scheme for greening of the traveling roads should also be incorporated. All rooftops/terraces should have some green cover.

46.  Detailed description of the flora and fauna (terrestrial and aquatic) should be given with special reference to rare, endemic and endangered species.

47.  At least 5 % of the total cost of the project should be earmarked towards the corporate social responsibility and item-wise details alongwith time bound action plan should be included. Socio-economic development activities need to be elaborated upon.

48.  A note on identification and implementation of Carbon Credit project.

49.  Total capital cost and recurring cost/annum for environmental pollution control measures should also be included.

50.  Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.

51.  Any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof should also be included.

52.  Action Plan for the implementation of the recommendations made for the Sponge and Captive Power Plants in the CREP guidelines must be prepared.

 

            The Expert Committee (Industry) recommended that the PAs may be communicated the above ‘TORs’ for the preparation of EIA/EMP.  As soon as the draft EIA/EMP report is prepared as per the ‘General Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006, the same may be submitted by the PAs to the Karnataka State Pollution Control Board (KSPCB) for conducting public hearing as per EIA Notification, 2006. On finalization of EIA/EMP prepared as per TORs and addressing and incorporating all concerns raised by public hearing / public consultation, the same should be submitted to the MOEF for prior environmental clearance.

 

 

4. 14        Expansion of Sponge Iron Plant (1,80,000 TPA to 4,00,000 TPA) and installation of Iron Ore Beneficiation Plant (0.6 MTPA) at Sy. No. 99, 100 & 225, Village Sidiginamola, District Bellary, Karnataka by M/s Janki Corp. Ltd. (TOR)

 

            The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP.  All the Sponge iron plants (>200 TPD) are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ capacity of the proposed sponge iron plant is 700 TPD (2x350 TPD) and appraised at the Central level.

 

M/s Janki Corp. Ltd. have proposed for the expansion of sponge iron plant (1,80,000 TPA to 4,00,000 TPA) and installation of Iron Ore Beneficiation Plant (0.6 MTPA) at Sy. No. 99, 100 and 225, Village Sidiginamola, District Bellary, Karnataka. Total land acquired is   361.26 acres. Expansion of the project will be carried out in the existing premises.  No additional land will be required.  No sensitive areas are located within 15 km. radius of the project site.  Bellary city is at 12 km.  Total cost of the project is Rs. 99.50 Crores.  Rs. 4.00 Crores and Rs. 25.00 Lakhs are earmarked towards capital cost and revising cost/annum for environment pollution control measures.  Following facilities will be installed:

 

S.N.

Plant / facilities

Quantity (TPA)

Existing :

1

Sponge Iron Plant  (6x100 TPD)

1,80,000

2

Pellet Plant

6,00,000

3

Captive Power Plant : WHRB – 15 MW

                                    AFBC  – 9 MW

24 MW

Proposed :

2

Sponge Iron Plant (2x350 TPD)

2,20,000

3

Iron ore Beneficiation Plant

6,00,000

 

            Iron ore (3,20,000 TPA), Coal (1,90,000 TPA), Limestone (26,400 TPA) for the sponge iron plant and iron ore (0.7 MTPA) for the iron ore beneficiation plant will be used as raw materials.

           

Iron ore (-6mm) from raw material yard will be fed to the vibrating screen having water spray +1 mm fraction will be sent to storage.  -1 mm fraction alongwith water will be fed to drum scrubber and then to classifier.  +150 micron will be sent to product storage -150 mm will be thickened in hi-date thickener.  Raw material for sponge iron plant will be prepared in Crushers and screens and will be fed to rotary kiln and processing will be done in kiln and cooler system. Sponge iron being magnetic and char being non-magnetic will be separated in separate bins.

            Gaseous emissions will be generated from sponge iron plant.  The waste gases from the kiln will be passed through dust settling chamber (DSC) to settle the coarse dust particles and after burning chamber (ABC) to burn the CO.  Electrostatic Precipitator (ESP) will be provided to DRI kilns and cleaned gases will be let off through the ID fan and chimney (40m) into the atmosphere.

 

Total water requirement from Bellary Sewage Treatment Plant will be (36 m3/hr) 700 m3/day.  The effluent from the iron ore beneficiation plant will be treated in a thickener and thickened slurry will be filtered by horizontal belt filters.  The supernatant will be re-circulated and filter coke will be sold to brick manufacturer.  Service water will be passed through oil separator to remove oil content in the effluent.  Domestic effluent will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.

 

Dust collected from the ESP and bag filter will be sold to brick manufacture, fly ash (140 TPD sold to brick manufacture, coal char (300 TPD), Iron ore fines (11 TPD) and sponge iron fines (21 TPD) will be generated as solid waste.  Sludge (4,500 m3/m) will be disposed to brick manufacturers.  Spent oil (2.5 KLPA) will be disposed to authorized re-processors.

           

Out of 361.26 acres, green belt will be developed in 117.56 acres.  Power (3,500 KVA) will be sourced from GESCOM. Existing power requirement is 2,000 TPA.

           

            After detailed deliberations, the Expert Appraisal Committee (Industry) recommended the proposal for the preparation of EIA/EMP as per the following TORs:  

 

1.      A site location map on Indian map of 1:10, 00,000 scale followed by 1:50,000/1:25,000 scale on an A3/A2 sheet with at least next 10 Kms of terrains i.e. circle of 10 kms and further 10 kms on A3/A2 sheets with proper longitude/latitude/heights with min. 100/200 m. contours should be included. 3-D view i.e. DEM (Digital Elevation Model) for the area in 10 km radius from the proposal site.

2.      Present land use should be prepared based on satellite imagery. High-resolution satellite image data having 1m-5m spatial resolution like quickbird, Ikonos, IRS P-6 pan sharpened etc. for the 10Km radius area from proposed site. The same should be used for land used/land-cover mapping of the area.

3.      Location of national parks / wildlife sanctuary / reserve forests within 10 km. radius should specifically be mentioned. A map showing landuse / landcover, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc in 10 km of the project site.

4.      Actual land requirement, classification of land, acquisition status, rehabilitation and resettlement as per the policy of the Govt. of Karnataka should be incorporated.

5.      A list of industries containing name and type in 25 km radius should be incorporated.

6.      Project site layout plan showing raw materials, fly ash and other storage plans, bore well or water storage, aquifers (within 1 km.) dumping, waste disposal, green areas, water bodies, rivers/drainage passing through the project site should be included.

7.      List of raw material required and source alongwith mode of transportation should be included. All the trucks for raw material and finished product transportation must be “Environmentally Compliant”.

8.      Petrological and Chemical analysis and other chemical properties of raw materials used (with GPS location of source of raw material) i.e. ores, minerals, rock, soil, coal, iron, dolomite quartz etc. using high definition and precision instruments mentioning their detection range and methodology such Digital Analyzers, AAS with Graphite furnace, ICPMS, MICRO-WDXRF, EPMA, XRD, Nano studies or at least as per I30-10500 and WHO norms. These analysis should include trace element and metal studies like Cr (vi) Ni, Fe, As, Pb, Zn, Hg, Se, S etc.  Presence of radioactive elements (U, Th etc.).

9.      Petrography, grain size analysis and Major element analysis of raw material and soil from project site and raw material should be done on the same parameters along with analysis for SiO2, Al2O3, MgO, MnO, K2O, CaO, FeO, Fe2O3, P2O5, H2O, CO2.

10.  If the rocks, ores, raw material has trace elements their petrography, ore microscopy, XRD, elemental mapping EPMA, XRF is required to quantify the amount present in it and hence future risk involved while using it and management plan.

11.  Studies for fly ash, muck disposal, slurry, sludge material and solid waste generated should also be included, if the raw materials used has trace elements and a management plan.

12.  Manufacturing process details of the Sponge Iron and Iron Ore Beneficiation Plant should be included.

13.  Data generated in the last three years i.e. air, water, raw material properties and analysis (major, trace and heavy metals), ground water table, seismic history, flood hazard history etc.

14.  Data on existing ambient air, stack emission, fugitive emissions data; water requirement and water balance cycle; generation, re-utilization and disposal of solid/ hazardous waste for the existing plant and predicted increase in pollution load due to proposed expansion should be incorporated.

15.  Point-wise compliance to the specific and general conditions stipulated in the environmental clearance accorded by the SEIAA/SEAC, ‘Consent to Establish & Operation’ by the Karnataka SPCB for the existing plant. A copy of each should also be included

16.  Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall should be collected.

17.  Ambient air quality at 8 locations within the study area of 10 km., aerial coverage from project site with one AAQMS in downwind direction should be carried out.

18.  The suspended particulate matter present in the ambient air must be analyzed for the presence of poly-aromatic hydrocarbons (PAH), i.e. Benzene soluble fraction.  Chemical characterization of RSPM and incorporating of RSPM data.

19.  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.

20.  Air quality modelling for steel plant for specific pollutants needs to be done.  Air pollution control devices installed and proposed for the control of emissions from all the sources should also be included. Action plan to follow National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 should be included.

21.  Ambient air quality monitoring modelling alongwith cumulative impact should be included for the day (24 hrs) for maximum GLC alongwith following :

                    i)      Emissions (g/second) with and without the air pollution control measures

                   ii)      Meteorological inputs (wind speed, m/s), wind direction, ambient air temperature, cloud cover, relative humidity & mixing height) on hourly basis

                 iii)      Model input options for terrain, plume rise, deposition etc.

                 iv)      Print-out of model input and output on hourly and daily average basis

                  v)      A graph of daily averaged concentration (MGLC scenario) with downwind distance at every 500 m interval covering the exact location of GLC.

                 vi)      Details of air pollution control methods used with percentage efficiency that are used for emission rate estimation with respect to each pollutant

               vii)      Applicable air quality standards as per LULC covered in the study area and % contribution of the proposed plant to the applicable Air quality standard. In case of expansion project, the contribution should be inclusive of both existing and expanded capacity.

              viii)      No. I-VII are to be repeated for fugitive emissions and any other source type relevant and used for industry

                 ix)      Graphs of monthly average daily concentration with down-wind distance

                  x)      Specify when and where the ambient air quality standards are exceeded either due to the proposed plant alone or when the plant contribution is added to the background air quality.

                 xi)      Fugitive dust protection or dust reduction technology for workers within 30 m of the plant active areas.

22.  Impact of the transport of the raw materials and end products on the surrounding environment should be assessed and provided.

23.  An action plan to control secondary fugitive emissions as per latest standards issued by the Ministry in May, 2008 and monitoring should be included.

24.  One season data for gaseous emissions other than monsoon season is necessary.

25.  Presence of aquifer/aquifers within 1 km of the project boundaries and management plan for recharging the aquifer should be included.

26.  Source of surface/ground water level, site (GPS), cation, anion (Ion Chromatograph), metal trace element (as above) chemical analysis for water to be used. If surface water is used from river, rainfall, discharge rate, quantity, drainage and distance from project site should also be included.

27.  Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management.

28.  Ground water modelling showing the pathways of the pollutants should be included

29.  Column leachate study for all types of stockpiles or waste disposal sites, at 20oC-50oC should be conducted and included.

30.  Action plan for rainwater harvesting measures at plant site should be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.  Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayat and Village Heads to augment the ground water level.

31.  Permission for the drawl of 700 m3/day water from Bellary Sewage Treatment Plant from the concerned authority and water balance data including quantity of effluent generated, recycled and reused and discharged is to be provided. Methods adopted/to be adopted for the water conservation should also be included.

32.  Surface water quality of nearby river (60 m upstream and downstream) and other surface drains at eight locations must be ascertained. 

33.  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.

34.  Provision of traps and treatment plants are to be made, if water is getting mixed with oil, grease and cleaning agents.

35.  If the water is mixed with solid particulates, proposal for sediment pond before further transport should be included. The sediment pond capacity should be 100 times the transport capacity.

36.  Wastewater characteristics (heavy metals, anions and cations, trace metals, PAH) from washed / beneficiated plants / washery.

37.  The pathways for pollution via seepages, evaporation, residual remains are to be studied for surface water (drainage, rivers, ponds, lakes), sub-surface and ground water with a monitoring and management plans.

38.  Action plan for solid/hazardous waste generation, storage, utilization and disposal particularly use of Char in FBC boiler should be included.

39.  A plan for the utilization of gases in the existing WHRB for generating power should be incorporated.

40.  Energy balance data for Sponge Iron and Captive Power Plant should be included.

41.  Disaster Management Plan including risk assessment and damage control needs to be addressed and included.

42.  Occupational health of the workers needs elaboration. Health effects of other metals used and health hazard plans based on monthly correlation of these metal related diseases and people affected and mitigation plans. Arsenicosis Management Plan, if Arsenic is present in ore, rock, coal, fly ash, water. Action Plan for protecting the workers against hazardous chemicals such as Sulphuric acid, pesticides, solvents etc.

43.  Occupational health of the workers needs elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring and periodical monitoring should be carried out. The detailed plan to carry out above mentioned activity should be mentioned. Acton plan for the green belt development plan in 33 % area should be included. The green belt should be around the project boundary and a scheme for greening of the traveling roads should also be incorporated. All rooftops/terraces should have some green cover.

44.  Detailed description of the flora and fauna (terrestrial and aquatic) should be given with special reference to rare, endemic and endangered species.

45.  At least 5 % of the total cost of the project should be earmarked towards the corporate social responsibility and item-wise details alongwith time bound action plan should be included. Socio-economic development activities need to be elaborated upon.

46.  A note on identification and implementation of Carbon Credit project.

47.  Total capital cost and recurring cost/annum for environmental pollution control measures should also be included.

48.  Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.

49.  Any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof should also be included.

50.  Action Plan for the implementation of the recommendations made for the Sponge and Captive Power Plants in the CREP guidelines must be prepared.

 

PAs requested for the exemption for public hearing due to expansion in the existing plant in the same campus. The Expert Committee (Industry) didn’t agree for the same since installation of 2x350 TPD Sponge Iron Plant and Iron Ore Beneficiation Plant (6 MTPA) is a major expansion.

 

The committee recommended that the PAs may be communicated the above ‘TORs’ for the preparation of EIA/EMP. As soon as the draft EIA/EMP report is prepared as per the ‘General Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006, the same may be submitted by the PAs to the Karnataka State Pollution Control Board (KSPCB) for conducting public hearing as per EIA Notification, 2006. On finalization of EIA/EMP prepared as per TORs and addressing and incorporating all concerns raised by public hearing / public consultation, the same should be submitted to the MOEF for prior environmental clearance. 

  

 

4. 15        Expansion of Ferro Alloy Plant near Village Manesamudram, Mandal Hindupur, District Ananthapur, Andhra Pradesh by M/s M.B. Smelters Pvt. Ltd. (TOR)

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Ferro Alloy Plants are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ and appraised at the Central level.

 

            M/s M.B. Smelters Pvt. Ltd. have proposed for the expansion of Ferro Alloy Plant near Village Manesamudram, Mandal Hindupur, District Ananthapur, Andhra Pradesh.  Total project area is 32.36 acres and is already acquired.  Additional 118.32 acres land is procured from APIIC and a copy of the allotment letter is submitted. Total land acquired is 32.36 acres. No national parks, wild life sanctuary are located within 10 km radius. Errakonda reserve forest is located at 9.0 km within 10 km of the project site. No rehabilitation and resettlement is involved. Penneru Uttara Pinakini River and Errakonda RF is located within 10 km.  Karnataka State boundary is at 9 km.  Nearest village Manesamudram is at 1.1 km.  Total cost of the project is Rs.  120.00 Crores.   Rs. 8.50 Crores and Rs. 0.75 Crores/annum are earmarked towards total capital cost and recurring cost/annum for environmental pollution control measures.

 

Existing facilities include submerged ore furnace of 1x1.5 and 1x1.0 MVA capacity. The existing ferro alloy plant is of 2.5 MVA and 47.5 MVA will be added in the proposed expansion. Hence, total capacity of the ferro alloy plant after expansion will be 50 MVA. Existing plant was established in 1987 and no environment clearance was required.  Following are the details of the proposed and facilities and products:

             

Phase

Smelting Facility

Ferro Alloy / Product

Quantity (TPA)

A.

Existing :

I

1x1.5 MVA

1x1 MVA

Ferro-Manganese

Silico-Manganese

 

4,270

2,445

B.

Proposed :

I

2x2 MVA

2x9 MVA

1x2 MVA

Ferro-Manganese & Silico-Manganese

 

Low carbon Ferro Manganese 

64,000

 

4,500

II

1x9 MVA

1x16.5 MVA

Ferro-Manganese & Silico-Manganese

Ferro Silicon & Silicon metal

Slag wool from waste slag 

25,200

14,200

20,000

TOTAL

50 MVA  

      

Following will be manufactured:

 

Ferro Alloy / Product

Quantity (TPA)

Manganese-based

89,600

Silicon-based

14,200

Low Carbon

4,500

Slag Wool

20,000

 

            Mn Ore (2,01,600 TPA), quartz (58,600 TPA), met coke/coal (44,800 TPA), fluxes (dolomite / lime 35,840 TPA), pet coke/wood charcoal (17,076 TPA), Aluminium scrap (1,350 TPA), Calcium Fluoraspar will be used as raw materials.

 

            Silico-Manganese/Ferro Manganese & Ferro-Silicon/Silicon metal will be manufactured in submerged arc furnaces using Manganese ore, coke/coal, quartz etc. as raw materials at 1400-15000C.  Liquid ferro alloy and slag will be tapped, separated in cast iron pan and send mould respectively.  Slag will be sent to slag dump and then used for different purposes.

            Fume extraction system with bag filters will be provided to submerged arc furnace to control emissions within 100 mg/Nm3 but committee insisted for 50 mg/Nm3. All roads will be asphalted to prevent fugitive dust emanation.

 

Total ground water requirement from bore wells will be 200 m3/day. Closed circuit cooling system will be adopted in submerged arc furnace. The treated effluent will be used for ash conditioning, dust suppression and green belt development.   Service water will be passed through oil separator to remove oil content in the effluent.  Domestic effluent will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.

  

            Slag generated from Silico-Manganese will be utilized for road work / own landfill / convert to slag wool or disposed off as per APPCB norms.  Ferro-Manganese slag will be used for the production of Silico-Manganese.

 

Action plan for development of green belt in 33% area is submitted. The ambient noise level will be greater that 75 dB(A) during day time and less than 70 dB(A) during night time. Power (50 MVA) will be supplied by APCPDCL.  Total men power requirement will be 300 personnel. No litigation/court case in pending against the proposal

           

After deliberating on the facts presented before the Expert Appraisal Committee (Industry), the committee recommended the proposal for the preparation of EIA/EMP as per the following TORs:

 

1.      A site location map on Indian map of 1:10, 00,000 scale followed by 1:50,000/1:25,000 scale on an A3/A2 sheet with at least next 10 Kms of terrains i.e. circle of 10 kms and further 10 kms on A3/A2 sheets with proper longitude/latitude/heights with min. 100/200 m. contours should be included. 3-D view i.e. DEM (Digital Elevation Model) for the area in 10 km radius from the proposal site.

2.      Present land use should be prepared based on satellite imagery. High-resolution satellite image data having 1m-5m spatial resolution like quickbird, Ikonos, IRS P-6 pan sharpened etc. for the 10Km radius area from proposed site. The same should be used for land used/land-cover mapping of the area.

3.      Location of national parks / wildlife sanctuary / reserve forests within 10 km. radius should specifically be mentioned. A map showing landuse/landcover, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc in 10 km of the project site.

4.      Project site layout plan showing raw materials and other storage plans, bore well or water storage, aquifers (within 1 km.) dumping, waste disposal, green areas, water bodies, rivers/drainage passing through the project site should be included.

5.      Details and classification of total land (identified and acquired) should be included.

6.      Proposal should be submitted to the Ministry for environment clearance only after acquiring total land. Necessary documents indicating acquisition of land should be included.

7.      Rehabilitation & Resettlement (R & R) should be as per policy of the State Govt. and a detailed action plan should be included.

8.      Permission and approval for the use of forest land and recommendations of the State Forest Department regarding impact of proposed expansion on the surrounding reserve forests, if applicable, should be included.

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.

11.  List of raw material required and source alongwith mode of transportation should be included. All the trucks for raw material and finished product transportation must be “Environmentally Compliant”.

12.  Petrological and Chemical analysis and other chemical properties of raw materials used (with GPS location of source of raw material) i.e. ores, minerals, rock, soil, coal, iron, dolomite quartz etc. using high definition and precision instruments mentioning their detection range and methodology such Digital Analyzers, AAS with Graphite furnace, ICPMS, MICRO-WDXRF, EPMA, XRD, Nano studies or at least as per I30-10500 and WHO norms. These analysis should include trace element and metal studies like Cr (vi) Ni, Fe, As, Pb, Zn, Hg, Se, S etc.  Presence of radioactive elements (U, Th etc.).

13.  Petrography, grain size analysis and Major element analysis of raw material and soil from project site and raw material should be done on the same parameters along with analysis for SiO2, Al2O3, MgO, MnO, K2O, CaO, FeO, Fe2O3, P2O5, H2O, CO2.

14.  If the rocks, ores, raw material has trace elements their petrography, ore microscopy, XRD, elemental mapping EPMA, XRF is required to quantify the amount present in it and hence future risk involved while using it and management plan.

15.  Studies for slag, muck disposal, slurry, sludge material and solid waste generated should also be included, if the raw materials used has trace elements and a management plan.

16.  Commitment that instead of char from local sources, petro coke will be used as fuel should be included.

17.  Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall is necessary.

18.  Mass balance for the raw material and products should be included.

19.  Energy balance data for all the components of ferro alloy plant should be incorporated.

20.  Design details of Ferro Alloy Plant (Submerged Arc Furnace) and manufacturing process details should be included.

21.  Data generated in the last three years i.e. air, water, raw material properties and analysis (major, trace and heavy metals), ground water table, seismic history, flood hazard history etc.

22.  Data on existing ambient air, stack emission, fugitive emissions data; water requirement and water balance cycle; generation, re-utilization and disposal of solid/ hazardous waste for the existing plant and predicted increase in pollution load (GLCs) due to proposed expansion should be incorporated.

23.  Point-wise compliance to the specific and general conditions stipulated in the ‘Consent to Establish & Operate’ for the existing plant.

24.  Ambient air quality at 8 locations within the study area of 10 km., aerial coverage from project site with one AAQMS in downwind direction should be carried out.

25.  The suspended particulate matter present in the ambient air must be analyzed for the presence of poly-aromatic hydrocarbons (PAH), i.e. Benzene soluble fraction. Chemical characterization of RSPM and incorporating of RSPM data.

26.  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.

27.  Air quality modelling for ferro alloy plant for specific pollutants needs to be done.  APCS for the control of emissions should also be included to control emissions within 50 mg/Nm3.

28.  Action plan to follow National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 should be included.

29.  Ambient air quality monitoring modeling alongwith cumulative impact should be included for the day (24 hrs) for maximum GLC alongwith following :

i.         Emissions (g/second) with and without the air pollution control measures

ii.       Meteorological inputs (wind speed, m/s), wind direction, ambient air temperature, cloud cover, relative humidity & mixing height) on hourly basis

iii.      Model input options for terrain, plume rise, deposition etc.

iv.     Print-out of model input and output on hourly and daily average basis

v.       A graph of daily averaged concentration (MGLC scenario) with downwind distance at every 500 m interval covering the exact location of GLC.

vi.     Details of air pollution control methods used with percentage efficiency that are used for emission rate estimation with respect to each pollutant

vii.    Applicable air quality standards as per LULC covered in the study area and % contribution of the proposed plant to the applicable Air quality standard. In case of expansion project, the contribution should be inclusive of both existing and expanded capacity.

viii.  No. I-VII are to be repeated for fugitive emissions and any other source type relevant and used for industry

ix.     Graphs of monthly average daily concentration with down-wind distance

x.       Specify when and where the ambient air quality standards are exceeded either due to the proposed plant alone or when the plant contribution is added to the background air quality.

xi.     Fugitive dust protection or dust reduction technology for workers within 30 m of the plant active areas.

30.  Impact of the transport of the raw materials and end products on the surrounding environment should be assessed and provided.

31.  One season data for gaseous emissions other than monsoon season is necessary.

32.  An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008.

33.  Presence of aquifer/aquifers within 1 km of the project boundaries and management plan for recharging the aquifer should be included.

34.  Source of surface/ground water level, site (GPS), cation, anion (Ion Chromatograph), metal trace element (as above) chemical analysis for water to be used. If surface water is used from river, rainfall, discharge rate, quantity, drainage and distance from project site should also be included.

35.  Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management.

36.  Ground water modelling showing the pathways of the pollutants should be included

37.  Column leachate study for all types of stockpiles or waste disposal sites, at 20oC-50oC should be conducted and included.

38.  ‘Permission’ for the drawl of 200 m3/day ground water from bore wells should be included. Water balance cycle data including quantity of effluent generated, recycled and reused and discharged is to be provided. Methods adopted/to be adopted for the water conservation should be included.

39.  A note on the impact of drawl of water on the nearby River during lean season.

40.  Action plan for rainwater harvesting measures at plant site should be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.  Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayat and Village Heads to augment the ground water level.

41.  Surface water quality of nearby River (60 m upstream and downstream) and other surface drains at eight locations must be ascertained. 

42.  If the site is within 10 km radius of any major river, Flood Hazard Zonation Mapping is required at 1:5000 to 1;10,000 scale indicating the peak and lean river discharge as well as flood occurrence frequency.

43.  A note on treatment of wastewater from different plants, recycle and reuse for different purposes should be included.

44.  Provision of traps and treatment plants are to be made, if water is getting mixed with oil, grease and cleaning agents.

45.  If the water is mixed with solid particulates, proposal for sediment pond before further transport should be included. The sediment pond capacity should be 100 times the transport capacity.

46.  Wastewater characteristics (heavy metals, anions and cations, trace metals, PAH) from all sources should be included.

47.  The pathways for pollution via seepages, evaporation, residual remains are to be studied for surface water (drainage, rivers, ponds, lakes), sub-surface and ground water with a monitoring and management plans.

48.  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.

49.  Geotechnical data by a bore hole of upto 40 mts. in every One sq. km area such as ground water level, SPTN values, soil fineness, geology, shear wave velocity etc. for liquefaction studies and to assess future Seismic Hazard and Earthquake Risk Management in the area.

50.  Action plan for solid/hazardous waste generation, storage, utilization and disposal particularly slag from all the sources should also be included. 

51.  Identification and details of land to be used for all type of slag disposal in the secured land fill as per CPCB guidelines should be included.

52.  All stock piles will have to be on top of a stable liner to avoid leaching of materials to ground water.

53.  End use of solid waste and its composition should be covered.  Toxic metal content in the waste material and its composition should also be incorporated particularly of slag.

54.  Provision of Toxic Chemical Leachability Potential (TCLP) test for the slag and its end use should be included. 

55.  Commitment that no Ferro chrome will be manufactured without prior approval of the Ministry.

56.  Acton plan for the green belt development plan in 33 % area should be included. The green belt should be around the project boundary and a scheme for greening of the traveling roads should also be incorporated. All rooftops/terraces should have some green cover.

57.  Detailed description of the flora and fauna (terrestrial and aquatic) should be given with special reference to rare, endemic and endangered species.

58.  Disaster Management Plan including risk assessment and damage control needs to be addressed and included.

59.  Occupational health of the workers needs elaboration. Health effects of other metals used and health hazard plans based on monthly correlation of these metal related diseases and people affected and mitigation plans. Arsenicosis Management Planif Arsenic is present in ore, rock, coal, fly ash, water. Action Plan for protecting the workers against hazardous chemicals such as Sulphuric acid, pesticides, solvents etc.

60.  Occupational health of the workers needs elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring and periodical monitoring should be carried out. The detailed plan to carry out above mentioned activity should be mentioned.

61.  At least 5 % of the total cost of the project should be earmarked towards the corporate social responsibility and item-wise details alongwith time bound action plan should be included. Socio-economic development activities need to be elaborated upon.

62.  Plan for the implementation of the recommendations made for the ferro alloy plants in the CREP guidelines must be prepared.

63.  Total capital cost and recurring cost/annum for environmental pollution control measures should also be included.

64.  Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.

65.  Any litigation pending against the project and / or any direction / order passed by any Court of Law against the project, if so, details thereof.

 

            The Expert Committee (Industry) decided that PAs may be communicated the above ‘TORs’ for the preparation of EIA/EMP.  As soon as the draft EIA/EMP report is prepared as per the ‘General Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006, the same may be submitted by the PAs to the Andhra Pradesh Pollution Control Board (APPCB) for conducting public hearing as per EIA Notification, 2006. On finalization of EIA/EMP prepared as per TORs addressing all concerns set out in EIA/EMP should be submitted to the MOEF for prior environmental clearance.

 

 

4. 16        Expansion of Ferro Alloy Plant (10,500 TPA to 15,000 TPA) or Pig Iron (25,000 TPA) at 567B, 568 and 553/B, Urla Industrial Area, Urla, District Raipur, Chhattisgarh by M/s Hira Ferro Alloys Ltd. (Unit-1) (TOR)   

 

 The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Ferro Alloy Plants are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ and appraised at the Central level.

 

M/s Hira Ferro Alloys Ltd. (Unit-1) have proposed for the expansion of Ferro Alloy Plant (10,500 TPA to 15,000 TPA) or Pig Iron (25,000 TPA) at 567B, 568 and 553/B, Urla Industrial Area, Urla, District Raipur, Chhattisgarh.  It is noted that no coal based units are proposed which are otherwise banned by the State Govt. in the Urla. Existing project area is 6,050 m2 and expansion will be carried out on additional 3,717 m2 allotted by CSIDC vide letter No. 6794 dated 14th October, 2009. No national parks/wild life sanctuary/reserve forests located within 10 km radius.  Total land acquired is 9,767 m2.  Total cost of the project is Rs. 13.25 Crores.  Rs 75.00 Lakhs and Rs. 21.50 Lakhs are earmarked towards capital cost and recurring cost/annum for environmental pollution control measures. A copy of ‘Environment Clearance’ and ‘Consent to Establish’ for the existing plant alongwith point-wise compliance report is submitted.

 

Mn and Iron ores, quartz and coke will be used as raw materials.  Manganese ore and Iron will be used as submerged ore furnace charge.  Coke will be used as reductant and quartz as additional agent. The raw material will be charged in the furnace and smelted at 1700-18000C furnace. The alloy and slag will be tapped at regular intervals. Pig iron will also be manufactured in submerged arc furnace.  Iron ore will be the base material required for Pig Iron manufacturing. Coke will be used as reductant and limestone as flux.  The raw materials will be charged into SAF and smelted.  Iron and slag will be tapped at regular intervals.

           

Bag filters will be provided to control emissions from ferro alloy/pig iron plant within 50 mg/ Nm3.  Total water requirement from CSID supply for the existing and expansion will be 50 m3/day.  Permission for the drawl of 50 m3/day from CSIDC from the Competent authority is obtained. No additional water will be required.  Water will be re-circulated in cooling tower.  The treated effluent will be used for dust suppression and green belt development. Service water will be passed through oil separator to remove oil content in the effluent.  Domestic effluent will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted. Silico-Manganese slag (32,045 MTPA) or Pig iron slag (8,950 MTPA) will be used for filling low-lying areas and kiln preparation. The slag generated from the production of Ferro-Manganese will be utilized for production of Silico-Manganese.

 

            Out of total 9,767 m2, green belt will be developed in 3,305 m2.  Power (10 MW) will be sourced from M/s Hira Ferro Alloys Ltd., Unit-II. No litigation/court case is in pending against the proposal/land.

 

After deliberations, the committee felt that pig iron manufacturing will not only be a costly affair but also environment-unfriendly since it will use lot of electric energy. Project may not be viable too.  Therefore, it was suggested to reconsider manufacture of pig iron through the route proposed but committee rejected manufacturing pig iron through the route proposed. 

 

The Committee also noted that proposed location viz. Raipur is listed at S.N. 63 in the list of Comprehensive Environmental Pollution Index in the Office Memorandum dated 13th January, 2010. PAs were asked to clarify why the proposal should be considered when it is located in the Urla critically polluted area and no information regarding existing SPM, RPM, SO2 and NOx is submitted. 

 

Keeping above mentioned facts in mind, the committee desired that a revised proposal without pig iron plant through proposed route and with breakup of ferro alloy to be manufactured should be submitted alongwith ambient air quality data for the proposed location viz. ambient air quality data generated by the PAs, approved laboratory, CECB and zonal office of the CPCB to take a decision regarding setting of the project in the critically polluted area.  A certificate from the CECB should also be included certifying no increase in pollution load, if any, due to installation of proposed project.

 

The committee differed the proposal and asked PAs to submit the revised proposal alongwith above mentioned additional information for consideration of the proposal for ‘TORs’. The proposal will be considered afresh on priority as and when submitted to the Ministry.

 

 

4. 17        Ferro Alloy Plant (75,000 TPA) at Sy. No. 281, 284, 288, 289, 290 at Village Garbam, District  Vizianangaram, Andhra Pradesh by M/s Sharp Ferro Alloys Limited (TOR)

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Ferro Alloy Plants are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ and appraised at the Central level. 

 

            M/s Sharp Ferro Alloys Limited have proposed for the Ferro Alloy Plant (75,000 TPA) at Sy. No. 281, 284, 288, 289, 290 at Village Garbam, District Vizianangaram, Andhra Pradesh. Out of total 20 acres land, 17.18 acres private land is already purchased. No rehabilitation and resettlement is involved. No national parks/wild life sanctuary/reserve forests are located within 10 km radius. Garbham village is located at 2.5 km and Chipurupalli at 3.4 km.  Total cost of the project is 56.00 Crores. Rs. 500.00 Lakhs and Rs. 20.00 Lakhs are earmarked towards total capital cost and recurring cost/annum respectively for environmental pollution control measures. Submerged area furnaces (5x9 MVA) will be installed. During discussion, PAs informed that following High Carbon Ferro Alloys will be manufactured :

 

1.      H.C. Ferro-Manganese           =          15,000 to 20,000 TPA

2.      H.C. Siloco-Manganese          =          30,000 to 40,000 TPA

3.      H.C. Ferro Chrome                 =          15,000 TPA

 

            Mn ore (16,345 MTPA), Chromite ore (875 MTPA), coal (6076.875 MTPA) will be used as raw materials.  Coal will be used as reducing agent.  Quartz, dolomite will be used as de-sulphurising agents (Flexes).  Beneficiation process will be adopted to increase metal content in lean ores – Beneficiated concentrates of ore will be reduced by Carbon (Coke). Raw materials will be smelted at 1500-18000C. Liquid ferro alloys and slag will be trapped separately. No charcoal will be used as reductant

           

Bag filter system with spark arrestor, ducting, valves, ID fans will be provided to control emissions from furnace. The clean gas will be released to the atmosphere by the ID fans through chimney. Dust suppression system will be provided to control dust emission.

 

Total ground water requirement from bore wells will be 50 m3/day and will apply for the permission. The treated effluent will be used for ash conditioning, dust suppression and green belt development. Service water will be passed through oil separator to remove oil content in the effluent.  Domestic effluent will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.

 

            Fe-Mn slag will be used for manufacture of Si-Mn. Si-Mn slag will be used in low lying area inside and outside the plant and also sold through vendors.  Ferro chrome slag will be provided to APPCB approved vendors and temporarily stored inside the factory premises in pucca pits leading to no seepage on contamination.  Waste/used/spent oil and used batteries will be sold to authorized recyclers / re-processors.

           

Green belt will be developed in 33% area. Power (20 MVA in first phase) will be sourced from A.P. Eastern Power Distribution Co. Ltd. (APEPDCL). PAs confirmed that no litigation/court case in pending against the proposal.

 

After deliberating on the facts presented before the Expert Appraisal Committee (Industry), the committee recommended the proposal for the preparation of EIA/EMP as per the following TORs:

 

1.      Exact quantity of the product to be manufactured and raw material used.

2.      A site location map on Indian map of 1:10, 00,000 scale followed by 1:50,000/1:25,000 scale on an A3/A2 sheet with at least next 10 Kms of terrains i.e. circle of 10 kms and further 10 kms on A3/A2 sheets with proper longitude/latitude/heights with min. 100/200 m. contours should be included. 3-D view i.e. DEM (Digital Elevation Model) for the area in 10 km radius from the proposal site.

3.      Present land use should be prepared based on satellite imagery. High-resolution satellite image data having 1m-5m spatial resolution like quickbird, Ikonos, IRS P-6 pan sharpened etc. for the 10Km radius area from proposed site. The same should be used for land used/land-cover mapping of the area.

4.      Location of national parks / wildlife sanctuary / reserve forests within 10 km. radius should specifically be mentioned. A map showing landuse/landcover, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc in 10 km of the project site.

5.      Project site layout plan showing raw materials and other storage plans, bore well or water storage, aquifers (within 1 km.) dumping, waste disposal, green areas, water bodies, rivers/drainage passing through the project site should be included.

6.      Details and classification of total land (identified and acquired) should be included.

7.      Proposal should be submitted to the Ministry for environment clearance only after acquiring total land. Necessary documents indicating acquisition of land should be included.

8.      Rehabilitation & Resettlement (R & R) should be as per policy of the State Govt. and a detailed action plan should be included.

9.      Permission and approval for the use of forest land and recommendations of the State Forest Department regarding impact of proposed expansion on the surrounding reserve forests,if applicable, should be included.

10.  A list of industries containing name and type in 25 km radius should be incorporated.

11.  Residential colony should be located in upwind direction.

12.  List of raw material required and source alongwith mode of transportation should be included. All the trucks for raw material and finished product transportation must be “Environmentally Compliant”.

13.  Petrological and Chemical analysis and other chemical properties of raw materials used (with GPS location of source of raw material) i.e. ores, minerals, rock, soil, coal, iron, dolomite quartz etc. using high definition and precision instruments mentioning their detection range and methodology such Digital Analyzers, AAS with Graphite furnace, ICPMS, MICRO-WDXRF, EPMA, XRD, Nano studies or at least as per I30-10500 and WHO norms. These analysis should include trace element and metal studies like Cr (vi) Ni, Fe, As, Pb, Zn, Hg, Se, S etc.  Presence of radioactive elements (U, Th etc.).

14.  Petrography, grain size analysis and Major element analysis of raw material and soil from project site and raw material should be done on the same parameters along with analysis for SiO2, Al2O3, MgO, MnO, K2O, CaO, FeO, Fe2O3, P2O5, H2O, CO2.

15.  If the rocks, ores, raw material has trace elements their petrography, ore microscopy, XRD, elemental mapping EPMA, XRF is required to quantify the amount present in it and hence future risk involved while using it and management plan.

16.  Studies for slag, muck disposal, slurry, sludge material and solid waste generated should also be included, if the raw materials used has trace elements and a management plan.

17.  Commitment that instead of char from local sources, petro coke will be used as fuel should be included.

18.  Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall is necessary.

19.  Mass balance for the raw material and products should be included.

20.  Energy balance data for all the components of ferro alloy plant should be incorporated.

21.  Design details of Ferro Alloy Plant including Submerged Arc Furnace and Captive Power Plant and manufacturing process details should be included.

22.  Data generated in the last three years i.e. air, water, raw material properties and analysis (major, trace and heavy metals), ground water table, seismic history, flood hazard history etc.

23.  Data on existing ambient air, stack emission, fugitive emissions data; water requirement and water balance cycle; generation, re-utilization and disposal of solid/hazardous waste for the existing plant and predicted increase in pollution load (GLCs) due to proposed expansion should be incorporated.

24.  Ambient air quality at 8 locations within the study area of 10 km., aerial coverage from project site with one AAQMS in downwind direction should be carried out.

25.  The suspended particulate matter present in the ambient air must be analyzed for the presence of poly-aromatic hydrocarbons (PAH), i.e. Benzene soluble fraction. Chemical characterization of RSPM and incorporating of RSPM data.

26.  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.

27.  Air quality modelling for ferro alloy plant for specific pollutants needs to be done.  APCS for the control of emissions should also be included to control emissions within 50 mg/Nm3.

28.  Action plan to follow National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009 should be included.

29.  Ambient air quality monitoring modeling alongwith cumulative impact should be included for the day (24 hrs) for maximum GLC alongwith following :

i.         Emissions (g/second) with and without the air pollution control measures

ii.       Meteorological inputs (wind speed, m/s), wind direction, ambient air temperature, cloud cover, relative humidity & mixing height) on hourly basis

iii.      Model input options for terrain, plume rise, deposition etc.

iv.     Print-out of model input and output on hourly and daily average basis

v.       A graph of daily averaged concentration (MGLC scenario) with downwind distance at every 500 m interval covering the exact location of GLC.

vi.     Details of air pollution control methods used with percentage efficiency that are used for emission rate estimation with respect to each pollutant

vii.    Applicable air quality standards as per LULC covered in the study area and % contribution of the proposed plant to the applicable Air quality standard. In case of expansion project, the contribution should be inclusive of both existing and expanded capacity.

viii.  No. I-VII are to be repeated for fugitive emissions and any other source type relevant and used for industry

ix.     Graphs of monthly average daily concentration with down-wind distance

x.       Specify when and where the ambient air quality standards are exceeded either due to the proposed plant alone or when the plant contribution is added to the background air quality.

xi.     Fugitive dust protection or dust reduction technology for workers within 30 m of the plant active areas.

30.  Impact of the transport of the raw materials and end products on the surrounding environment should be assessed and provided.

31.  One season data for gaseous emissions other than monsoon season is necessary.

32.  An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008.

33.  Presence of aquifer/aquifers within 1 km of the project boundaries and management plan for recharging the aquifer should be included.

34.  Source of surface/ground water level, site (GPS), cation, anion (Ion Chromatograph), metal trace element (as above) chemical analysis for water to be used. If surface water is used from river, rainfall, discharge rate, quantity, drainage and distance from project site should also be included.

35.  Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management.

36.  Ground water modeling showing the pathways of the pollutants should be included

37.  Column leachate study for all types of stockpiles or waste disposal sites, at 20oC-50oC should be conducted and included.

38.  ‘Permission’ for the drawl of 50 m3/day water from bore wells should be included. Water balance cycle data including quantity of effluent generated, recycled and reused and discharged is to be provided. Methods adopted/to be adopted for the water conservation should be included.

39.  A note on the impact of drawl of water on the nearby River during lean season.

40.  Action plan for rainwater harvesting measures at plant site should be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.  Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayat and Village Heads to augment the ground water level.

41.  Surface water quality of nearby River (60 m upstream and downstream) and other surface drains at eight locations must be ascertained. 

42.  If the site is within 10 km radius of any major river, Flood Hazard Zonation Mapping is required at 1:5000 to 1;10,000 scale indicating the peak and lean river discharge as well as flood occurrence frequency.

43.  A note on treatment of wastewater from different plants, recycle and reuse for different purposes should be included.

44.  Provision of traps and treatment plants are to be made, if water is getting mixed with oil, grease and cleaning agents.

45.  If the water is mixed with solid particulates, proposal for sediment pond before further transport should be included. The sediment pond capacity should be 100 times the transport capacity.

46.  Wastewater characteristics (heavy metals, anions and cations, trace metals, PAH) from all sources should be included.

47.  The pathways for pollution via seepages, evaporation, residual remains are to be studied for surface water (drainage, rivers, ponds, lakes), sub-surface and ground water with a monitoring and management plans.

48.  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.

49.  Geotechnical data by a bore hole of upto 40 mts. in every One sq. km area such as ground water level, SPTN values, soil fineness, geology, shear wave velocity etc. for liquefaction studies and to assess future Seismic Hazard and Earthquake Risk Management in the area.

50.  Action plan for solid/hazardous waste generation, storage, utilization and disposal particularly slag from all the sources should also be included. 

51.  Identification and details of land to be used for all type of slag disposal in the secured land fill as per CPCB guidelines should be included.

52.  All stock piles will have to be on top of a stable liner to avoid leaching of materials to ground water.

53.  End use of solid waste and its composition should be covered.  Toxic metal content in the waste material and its composition should also be incorporated particularly of slag.

54.  Provision of Toxic Chemical Leachability Potential (TCLP) test for the slag and its end use should be included. 

55.  Design details of the secured land fill for the disposal of Ferro chrome slag as per CPCB guideline should be included.

56.  Acton plan for the green belt development plan in 33 % area should be included. The green belt should be around the project boundary and a scheme for greening of the traveling roads should also be incorporated. All rooftops/terraces should have some green cover.

57.  Detailed description of the flora and fauna (terrestrial and aquatic) should be given with special reference to rare, endemic and endangered species.

58.  Disaster Management Plan including risk assessment and damage control needs to be addressed and included.

59.  Occupational health of the workers needs elaboration. Health effects of other metals used and health hazard plans based on monthly correlation of these metal related diseases and people affected and mitigation plans. Arsenicosis Management Planif Arsenic is present in ore, rock, coal, fly ash, water. Action Plan for protecting the workers against hazardous chemicals such as Sulphuric acid, pesticides, solvents etc.

60.  Occupational health of the workers needs elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring and periodical monitoring should be carried out. The detailed plan to carry out above mentioned activity should be mentioned.

61.  At least 5 % of the total cost of the project should be earmarked towards the corporate social responsibility and item-wise details alongwith time bound action plan should be included. Socio-economic development activities need to be elaborated upon.

62.  Plan for the implementation of the recommendations made for the ferro alloy plants and steel melting shop in the CREP guidelines must be prepared.

63.  Total capital cost and recurring cost/annum for environmental pollution control measures should also be included.

64.  Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.

65.  Any litigation pending against the project and / or any direction / order passed by any Court of Law against the project, if so, details thereof.

 

            The Expert Committee (Industry) decided that PAs may be communicated the above ‘TORs’ for the preparation of EIA/EMP.  As soon as the draft EIA/EMP report is prepared as per the ‘General Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006, the same may be submitted by the PAs to the Andhra Pradesh Pollution Control Board (APPCB) for conducting public hearing as per EIA Notification, 2006. On finalization of EIA/EMP prepared as per TORs addressing all concerns set out in EIA/EMP should be submitted to the MOEF for prior environmental clearance.

 

 

4. 18        Expansion of Ferro Alloy Plant (10,000 TPA to 13,000 TPA) at Plot No. 201, 202, 224-D, Sector-C, Urla Industrial Area, Tehsil & District Raipur, Chhattisgarh by M/s Deepak Ferro Alloys Limited (TOR)              

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Ferro Alloy Plants are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ and appraised at the Central level.

 

            M/s Deepak Ferro Alloys Limited have proposed for the expansion of Ferro Alloy plant (10,000 TPA to 13,000 TPA) at Plot No. 201, 202, 224-D, Sector-C, Urla Industrial Area, Tehsil and District Raipur, Chhattisgarh.  It is noted that no coal based units are proposed which are otherwise banned by the State Govt. Total project area is 4.60 acres.  Raipur is at 7.4 km.  Total cost of the project for expansion is Rs. 3.00 Crores.  Following are the details of existing and proposed products to be manufactured:

 

Existing

Proposed

Total

Submerged arc furnace

1x7 MVA or

10,000 TPA

 

1x3  MVA or

3,000 TPA

 

 

13,000 TPA

 

            Mn ore, dolomite, mill scales, coke, electrode paste will be used as raw materials.  Raw materials will be charged into submerged arc furnace for smelting.  Coke coal be used as reductant and quartz as an addition agent. The alloy and slag produced in the furnace will be tapped at regular intervals.

            Fume extraction system with bag filters will be provided to control emissions from submerged ore furnace cleaned gases after pollution control equipments will be let out into the atmosphere through stacks of adequate height.  Dust suppression and water sprinkling system in unloading areas and other areas will be provided to control dust emissions.

Total water requirement from Chhattisgarh State Industrial Development Corporation Limited (CSIDCL) will be 7 m3/day.  No effluent will be generated due to use of closed circuit cooling system. The treated effluent will be used for dust suppression and green belt development.  Service water will be passed through oil separator to remove oil content in the effluent.  Sanitary waste water will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.

  

            Ferro-Manganese will be used as raw material for manufacture of Silico-Manganese.  Stag from Silico-Manganese will be used in road construction. Waste / used / spent oil and used batteries will be sold to authorized recyclers / reprocessors.

 

Green belt will be developed in 33 % area. Noise will be controlled with <75 d(B) of during day time and , 70 d B(A) during night time as per MoEF Notification dated 14th February, 2000. Power will be sourced from Chhattisgarh SEB grid.

 

The Committee noted that proposed location viz. Raipur is listed at S.N. 63 in the list of Comprehensive Environmental Pollution Index in the Office Memorandum dated 13th January, 2010. PAs were asked to clarify why the proposal should be considered when it is located in the Raipur critically polluted area and no information regarding existing SPM, RPM, SO2 and NOx is submitted. 

 

Keeping above mentioned facts in mind, the committee desired that the proposal should be submitted alongwith ambient air quality data for the proposed location viz. ambient air quality data generated by the PAs and also from the approved laboratory, CECB and zonal office of the CPCB to take a decision regarding setting of the project in the critically polluted area.  A ‘certificate’ from the CECB should also be included certifying no increase in pollution load, if any, due to installation of proposed project.

The committee differed the proposal and asked PAs to submit the revised proposal alongwith above mentioned additional information for consideration of the proposal for ‘TORs’. The proposal will be considered afresh on priority as and when submitted to the Ministry.

 

4. 19        Ferro Alloy Plant (2x9 MVA; 30,000 TPA) at Village Taraimal, Tehsil Tamnar, District Raigarh, Chhattisgarh by M/s Sumit Ispat Private Limited (TOR)

 

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken alongwith the draft Term of References for the preparation of EIA/EMP. All the Ferro Alloy Plants are listed at S.N. 3(a) under Primary Metallurgy Industries under Category ‘A’ and appraised at the Central level. 

 

            M/s Sumit Ispat Private Limited have proposed for the Ferro Alloy Plant (2x9MVA; 30,000 TPA) at Village Taraimal, Tehsil Tamnar, District Raigarh, Chhattisgarh. Total land acquired is 14.2 acres. No rehabilitation and resettlement is involved. No national parks and wild life sanctuary are located within 10 km radius. Three reserve forests (RF) viz. Taraimal RF, Samaruma RF, Urdana RF and 7 Protected Forests namely Amaghat PF, Pajhar PF, Punjipathara PF, Lakha PF, Dungapani PF, Barkachhar PF, Kharidungri PF are located within 10 KM radius of the project site. Permission from State Forest Department regarding the impact of the proposed plant on the surrounding reserve forests is under process. Total cost of the project is Rs. 25.00 Crores.  Rs 4.04 Crore and Rs. 41.00 Lakhs are earmarked towards total capital cost and recurring cost/annum respectively for environmental pollution control measures.  Si-Mn (15,000 TPA) and Fe-Mn (15,000 TPA) will be manufactured.  No ferro-chrome will be manufactured.  Following facilities will be installed and products manufactured:

 

S.N.

Facility

Details

Quantity (TPA)

1

2x9 MVA, Submerged arc furnace

Ferro Silicon

12,780 TPA

2

Silicon Mangnese

26,620 TPA

3

Ferro Manganese

37,080 TPA

 

Manganese ore (60,300 TPA), quartz (7,500 TPA), coke (21,000 TPA), electrode paste (1,050 TPA) and slag (2,400 TPA) will be used as raw materials.   Manganese ore with other additions quartz, coke etc. will be smelted in submerged arc furnace for the production of ferro alloy.  The raw materials will be charged into furnace.  The alloy and slag produced in furnace will be tapped at regular intervals. Coke will be used as reductant. PAs clarified that no rolling mill is proposed and “flue gas from reheating furnace……….”  at S.N. 5.1 in Form-I is wrongly mentioned.

           

Fume extraction system with bag filters will be provided to control emission from furnace.  Cleaned gas after pollution controlling equipments will be let out into the atmosphere through stack of appropriate height. Dust emissions will be controlled by water spraying generated due to vehicular movement. 

Total ground water requirement from bore wells will be 45 m3/day and have applied to the CGWA/SGWB for the permission.  The ground water table in area is 10 m.  No effluent will be generated from the ferro alloy slant due to adoption of closed circuit cooling system. The trea