Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY-1) TO BE HELD DURING 7th–8th April, 2010

 

VENUE: Bhabha Hall, SCOPE CONVENTION CENTRE, Institutional Area, Lodhi Road, New Delhi

 

1.0          Opening Remarks of the Chairman

 

2.0              Confirmation of the Minutes of 8th Meeting of the Expert Appraisal Committee (Industry-1) held during 2nd–3rd March, 2010

 

3.0              Consideration of the Projects

 

7th April, 2010

4.0          New Proposals :

 

4.1          Modernization and expansion of Alumina Refinery (660 KTPA to 900 KTPA) and Smelter Plant (356 KTPA to 472 KTPA) at Renukoot, District Sonebhadra, Uttar Pradesh by M/s Hindalco Industries Ltd. (EC)

 

Project authorities vide their letter dated 6th April, 2010 informed to the Ministry that Renukoot is covered under CEPI 81.73 as per circular dated 13th January, 2010 and 15th March, 2010 and guidelines for the disposal of such proposals in the critically polluted area are yet to be prepared by the CPCB.  Therefore, PAs have requested to keep the proposal in pending till the guidelines are released by the CPCB.

 

Since Project authorities didn’t attend the meeting, it was decided that proposal should be considered afresh whenever guidelines are released by the CPCB or requested by the PAs.

 

 

4.2          Expansion of Alumina Refinery Plant (1.0 MTPA to 1.5 MTPA) and Captive Power Plant (75 MW to 90 MW) at Village Kansariguda, District Rayagada, Orissa by M/s Aditya Aluminium (A Division of Hindalco Industries Ltd.) (TOR to EC)

 

Project authorities vide their letter dated 6th April, 2010 informed to the Ministry that their Chief Executive Officer, who was supposed to attend the meeting, has suddenly became indisposed and have requested to defer the proposal for another date.

 

Since Project authorities didn’t attend the meeting, it was decided that proposal should be considered afresh as per the priority.

 

 

4.3          Expansion of capacities of Zinc (5,25,000 TPA to 5,50,000 TPA), Lead (95,000 TPA to 1,05,000 TPA) and other by-products through de-bottlenecking, improvement and modernization at Chanderia Lead Zinc Smelter, P.O. Putholi, Chittorgarh, Rajasthan by M/s Hindustan Zinc 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 91st Meeting of the Expert Appraisal Committee (Industry) held during 9th-11th February, 2009 for preparation of EIA/EMP. All the Zn smelter are listed at S.N. 3(a) under Primary Metallurgy Industry under Category ‘A’ and is appraised at the Central level.   

 

Additionally, PAs informed to the Committee that M/s Hindustan Zinc Ltd. have proposed for enhancing capacities of Zinc (5,25,000 TPA to 5,50,000 TPA), Lead (95,000 TPA to 1,05,000 TPA) and other by-products recoveries through de-bottlenecking and improvement/ modernization projects at Chanderia Lead Zinc Smelter, P.O. Putholi, Chittorgarh, Rajasthan and have proposed for the following items:

 

Products

Capacities

1. Enhancing the capacities of - Pyro Lead Zinc Smelter

375 to 790 TPA

2. Cadmium – Hydro Zinc Smelter-1

2,10,000 to 2,20,000 TPA

3. Hydro Zinc Smelter-2

2,10,000 to 2,25,000 TPA

4. Ausmelt Smelter (Refined lead)

60,000 to 70,000 TPA

5. Recovery of 1,600 TPA Cadmium & 400 TPA Copper in Hydro-1 and Hydro-2 by way of process improvements

-

6. Production of 80,000 TPA, CGG Alloy as a change in Product Mix (out of 4,45,000 TPA Zinc) Hydro-1 and Hydro-2

-

7.  DG sets

2x8 MW

 

PAs informed that following are the details of plants, EC accorded and public hearing held so far :

 

Plant

Main Products

Date of Public Hearing

Environmental Clearance (EC)

Pyro Lead Zinc Smelter

Zn: 1,05,000 TPA

Pb: 35,000 TPA

Not Applicable

J-11011/14/2009- IA II (I) dated 03.06.1983

Hydro Zinc smelter-1 with CPP

Zn: 1,70,000 TPA

CPP: 2x77 MW

8th June, 2003

J-11011/158/2009- IA II (I) dated 13.03.2004

Ausmelt Lead Smelter

Pb: 60,000 TPA

17th Nov., 2004

J-11011/17/2009- IA II (I) dated 03.08.2005

Hydro Zinc Smelter-2 with CPP De-bottlenecking of Hydro Zinc Smelter-1

Zn: 2,10,000 TPA

CPP: 100 MW

 

29th June, 2006

J-11011/279/2009- IA II (I) dated 06.12.2006

 

Following are the details of products from existing and proposed facilities:

 

S.

N.

Products/By-Products

Existing

(TPA)

Proposed

(TPA)

Total after expansion (TPA)

Products

1

Zinc (including CGG Alloy)

5,25,000

25,000

5,50,000

2

Lead

95,000

10,000

1,05,000

3

Power generation

254 MW

16 MW

(DG sets)

270 MW

By-products

1

Sulphuric Acid

8,04,490

0

8,04,490

2

Copper/Copper Sulphate

10,020

400

10,420

3

Cadmium

375

2,015

2,390

4

Silver

169

0

169

5

Low Grade Lead concentrate

30,000

30,000

60,000

6

Copper Cement

510

-510

0

7

Cadmium Sponge

680

-680

0

8

Lead Antimony Oxide

0

11,000

11,000

 

Now, PAs have informed that following will be the details of quantities of proposed project.:

 

S.N.

Nature of the project

Proposed Quantity (TPA)

Enhancing the capacities of

1

Zinc in Hydro –I

10,000

2

Zinc in Hydro-II

15,000

3

Refined Lead from Ausmelt (using old batteries and Lead secondaries)

10,000

Recovery by way of process improvement

4

Cadmium in Hydro-I and Hydro-II

1,600

5

Copper in Hydro –I and Hydro-II

400

6

Cadmium recovery in Pyro-Smelter

415

Change in Product Mix

 

7

Continuous Galvanizing Grade Alloy in Hydro –I and Hydro-II (out of 445,000 TPA Zinc)

80,000

Auxiliary projects

8

DG set

16 MW (8 MWx2)

9

Sewage Treatment Plant

1,000 m3/day

10

LCV Boiler

21 tonne steam per hour

 

PAs informed that following will be done during expansion:

 

·         Reducing waste generation :

Reduction in purification /enrichment /cobalt cake generation by 7320 TPA.

Reduction of HGP dust by 7500 TPA

Reduction in Antimony dross by 1500 TPA.

 

·         Conservation of natural resources

     By increasing copper recovery of 400 TPA

By increasing cadmium recovery of 2015 TPA

Saving of lead concentrate consumption by 7500 TPA

Saving of coal by 15,000 TPA.

 

·         Enhanced metal production about 6 % by

Improving metal recoveries, current efficiency, plant availability and metal efficiency.

Optimizing process parameters and utilizing design margins of equipments.

 

The process improvements will be carried out in the premises of existing pyro, ausmelt, hydro-1 and hydro-2 smelters. Total project area is 335.84 ha. and no land will be acquired  for the expansion project. No R & R is involved. Existing pyro plant exists since 1991.  Chittorgarh Fort is located at 6.5 km. ‘NOC’ is obtained from Department of Archaeology and Museum, Regional office, Udaipur vide letter dated 17th May, 2003 indicating that no impact is envisaged on historical and archaeological monuments from the proposed smelters and Power Plants. Point-wise compliance reports for the existing plants are submitted.  Era RF (9.0 km, NW), Kabra RF (6.0 km, NW), Gwalaji ka khera (5 km, WNW) and Chittorgarh RF (6.5 km, S) are located within 10 km radius of the project site. No significant impact was observed on Chittorgarh RF and other RFs. Air emissions will be monitored for air quality. Putholi village and Gujarat City are located at 1.0 & 9.0 km. respectively. Total cost of the proposed expansion is revised from Rs. 216.00 Crores to Rs. 228.00 Crores. Rs. 45.00 Crores and Rs. 0.50 Crores earmarked towards total capital cost and recurring cost/annum for environmental pollution control measures are revised to Rs. 36.15 Crores and Rs. 0.60 Crore respectively for the proposed project.

           

                        Lead zinc metallurgical Smelter process, HGP dust (15,360 TPA) from existing pyro plant, Lead rich dust (3,000 TPA) from other HZL plants; In Ausmelt Lead Metallurgical  smelter process, Lead secondaries (dross, ash, residues ) used Lead acid batteries scrap/plate (24,000 TPA); In Hydro Zinc Metallurgical Smelter–I process, Aluminium (300 TPA) and Calcine (18,000 TPA);  In Hydro Zinc Metallurgical Smelter–I process, Aluminium (300 TPA), Calcine (18,000 TPA), Copper Cadmium cake (13000 TPA) from hydro plant will be used as raw materials. 

                       

Pyrometallurgical smelter: Zinc and lead metals will be produced through this process involving Sinter, Imperial smelting Furnace (ISF) and Refineries.  Various steps involve will include : sintering of Pb-Zn concentrates and oxides in Sinter  machine, reduction of sinter to Pb bullion and furnace Zn in ISF; pyro-refining of furnace Zn to PW (Prime Western Brand) Zn (98.5%) purity) and SHG (Special high Grade) Zn (99.99% purity), pyro-refining of lead; recovery of  cadmium; recovery of Cu; Sulphuric acid productions and recovery of  silver. PAs informed that in pursuance of recommendation of SCMC, HGP (Hot Gas Precipitator) treatment plant will be modernized to treat HGP dust for recovering the valuable Cadmium metal from dust. The plant will generate lead sludge, which will be recycled as a raw feed in existing Ausmelt Lead Plant and Sinter plant. 

 

Pyro-metallurgical Lead Plant (Ausmelt) : CLZS will source Lead acid battery scrap / plates from domestic market and utilized advantageously in the existing sophisticated and eco-friendly Ausmelt Smelting technology with no sulphur burning and alongwith other Lead concentrate & oxidized raw feeds without any modification.  These Lead secondaries and used lead acid battery scrap/plates will be fed to the existing Ausmelt Lead Plant. The process will involve feed material handling system, ausmelt furnace, off gas handling system. H2SO4 plant (combined with sinter plant), refineries (combined with ISD lead refinery) oxygen plant, lead secondaries and used lead acid battery, batteries scrap/ plates from recyclers. Total refined lead production from existing Ausmelt Lead Smelter will increase from existing 60,000 TPA to 70,000 TPA. In this technology, smelting of Lead concentrate will be done directly to produce Lead bullion and slag and hence conventional sintering of Lead Concentrate can be avoided. A battery breaking unit for extracting the Lead secondaries from the scrap automobiles will be installed.

                       

                        Low calorific value (LCV) waste heat recovery boiler will be installed at ISF. LCV boiler will facilitate to burn the unused LCV & generate low pressure steam for the internal usages.

 

Hydrometallurgical Zinc Smelter (Hydro 1&2): The hydro-metallurgical smelter–I (hydro-I) was designed to produced 1,70,000 MT of refined zinc annually from Zinc concentrate. Further, it was debottlenecked to produced additional refined Zinc of 40,000 TPA, thus total of 2,10,000 TPA. The process selected for the zinc plant will be based on the conventional roast-leach-electro winning route. In Hydro-metallurgical smelter–II (Hydro-II), which is designed to produce 2,10,000 TA, recovery of Zinc and other by-product will be higher as well as special high grade quality Zinc will be produced. Continuous Galvanizing Grade (CGG) alloy will be produced as a change in product mix.  In the existing Hydro-II, it is also proposed to recover “Copper as Copper compound” from copper –Cadmium cake/residue generated from Hydro-II.  Cadmium sulphate solution will be produced in Hydro –II.

 

Captive Power Plant: 154 MW & 100 MW CPP based on pulverized fuel firing will be installed to control emissions within 50 mg/Nm3.  Fly ash will be collected in silos.  DG sets (2x8 MW) will also be installed.

           

PAs informed to the committee that pollutants will be in the form of particulate matter, lead, SO2 and acid mist.  Since most of the proposed activities will be carried out in the existing facilities, emissions will be routed through existing air pollution control systems / equipments.  At Ausmelt, PM and lead emissions will be limited to 150 mg/Nm3  and 10 mg/Nm3 respectively but Committee asked to control PM emissions within 100 mg/Nm3 being an old plant. Water sprinkling will be done for the de-dusting. In the proposed project, quantity of Hot Gas Precipitator (HGP) dust and Cadmium Copper Coke will be reduced due to use as raw feed in the copper and cadmium recovery plants. Electrostatic precipitator (ESP) will be provided to Captive Power Plant.  Dust suppression system to coke yard and pulse jet type bag filters will be provided to transfer points. Bag filters will be provided to Cadmium recovery plant, continuous galvanizing grade (CGG) alloy plant (Hydro-1 & 2), Zinc production plant (Hydro-1 & 2). Bag filter & water spraying facilities will be provided to Ausmelt Lead Smelter and Sinter Plant.  Dust extraction system consisting of ventury scrubber and bag filters will be provided to ISF and briquetting plant.  Fumes collected from Zinc plant in the form of Zn dust will be recycled to sinter plant. 

 

Ambient air quality monitoring was carried out 14 locations (8 permanent + 6 mobile locations) during November, 2008 and February, 2009.  One permanent on-line AAQMS is set up at Chittorgarh. Submitted data indicated 98 percentile of SPM (297.8 ug/m3), RPM (125.4 ug/m3), SO2 (56 ug/m3) and NOx (42.7 ug/m3) which are within permissible limit except RPM. Results of heavy metal analysis indicated 98tile value of Cd (0.3 ug/m3), Fe (1.02 ug/m3), Pb (0.8 ug/m3) and Zn (1.4 ug/m3). During presentation, PAs have informed the incremental value of SPM (2.92 ug/m3), SO2( 43.46 ug/m3) and NOx (37.91 ug/m3).  Incremental value of SPM (2.19 ug/m3), SO2 (1.36 ug/m3) and NOx (36.6 ug/m3). However, committee insisted to achieve RPM 100 ug/m3 and monitor all the parameters as per the new standards notified.  Tall stacks will be provided to all the plants.  Double conversion Double Absorption (DCDA) will be provided to acid plant attached to Pyro-smelter to achieve 2 kg of SO2/T of acid.  Column ventilation system will be provided to capture zinc dust. Acid mist emissions will be maintained within 50 mg/Nm3 by Tail gas treatment in Pyro plant. On-line SO2 analyser has been installed at Tail Gas Treatment (TGT) Stack.  This flue gas from Ausmelt furnace will be passed through ESP.  Bag filters will be provided to roaster with 50 mg/Nm3.  Fume extraction and bag filters are provided on the melting and casting operators of Zn Ingots and Zn powder to control emissions within 50 mg/Nm3. Stack of adequate height will be provided to DG sets. Water sprinklers will be provided to arrest dust in raw material handling and intermediate storage area. ESP alongwith stack of adequate height will be provided to CPP.  Bag filter will be installed with better quality cloth to have lower emissions and better efficiency. Adequate stack height of 30 m will be provided for the proposed 16 MW CPP. A continuous online monitoring system for stack emissions will be in place for online readings. 

  

Total water requirement from Gosunda Dam will be 34,900 m3/day (34,000 m3/day for existing and 900 m3/day for proposed expansion) but is reduced to 29,000 m3/day during presentation. Government of Rajasthan vide letter dated 19th November, 1994 allocated 1500 MCFT of water for HZL. Surface water quality monitoring results indicated BOD (2 mg/l to 5 mg/l), DO (3.2 to 4.8 mg/l), copper (0.2 to 0.6 mg/l), Zinc (3.0 to 7.0 mg/l) and presence of coliform (269–506). As per submitted EIA/EMP report, existing plant has 2 ETPs, each of capacities 8,400 m3/day and 4,200 m3/day.  Part of treated effluent will be processed through RO plant for recycling. The existing facility will be capable to utilize the additional effluent generated from post modernization.  All the effluent from the proposed units will treated in effluent treatment plant (ETP) followed by reverse osmosis (RO) plant. Garland drains with transfer pit is constructed to transfer the effluent, if any, to ETP.  The treated effluent will be used in the process, dust suppression and green belt development. Domestic sewage will be treated in septic tanks. Partial treated sewage from septic tanks will be treated in Sewage Treatment Plant (STP) and used for suitable purpose within the plant. No effluent will be discharged and ‘zero’ discharge will be adopted. Rain water harvesting structure will be installed

 

            ETP sludge will be partially recycled and surplus will be disposed off in existing SLF after stabilization.  Lead secondaries, used lead acid batteries scrap/plates, lead rich dust will be stored in closed shed with cement concerting flooring side walls and garland drains.  Dilute Sulphuric Acid (from used lead acid battery scrap/plates breaking unit) will be stored in existing acid storage tanks and will be confined in a place with acid proof filing.  Ausmelt slag and pyro-slag will be recycled/sent to slag yard. Metal will be recovered from Cobalt cake and then sent to SLF. In Hydro plants, spent catalyst will be sent to SLF after stabilization; Purification cake + Enriched cake + cobalt cake will be sent for metal recovery/SLF after stabilization; Cooler cake will be sent to SLF after stabilization; In Pyro-Ausmelt plants, Antimony dross will be partially recycled. ISF slag will be utilized by cement plants. Ausmelt Slag will be recycled/slag yard. Caustic soda will be sent to SLF after stabilization. Spent catalyst, cooler coke, ETP sludge, Anode mud, and Caustic slag will be stored in SLF at site.   Jarosite will be treated with lime and cement to produce jarofix and disposed off in lined facility. Mercury sludge will be stored at isolated places. ISF slag will be given to cement manufacturers. Fly ash from the CPP will be given to cement / brick manufacturers. Bottom ash will be stored in designated area as ash mound and will be used brick manufacture and road making. Municipal waste will be segregated into non-bio-degradable and bio-degradable and managed accordingly. The sludge from STP will be reused as manure for plantation. HGP dust will also be recycled after metal recovery. Waste oil will be sold to registered recyclers. Used oil (80KLA) will be sold to registered recyclers. STP sludge will be used as manure in plantation. Regular monitoring of the piezometric well around secured landfill is being carried out to ensure no any ground water contamination. 

  

Out of total 335.84 ha., 90.26 ha. (26.8%) is already developed as green belt and have proposed to develop in 33% area. Noise abatement measures are proposed in turbine, compressor blowers, crusher, ball mill, pre-heater, fans area. Acoustic enclosures and lagging will be provided to noise generating equipments. Personal Protective equipments will be provided to workers working in high noise generating equipment. Total power requirement will be 9.14 MW instead of 80 million kwh/annum earlier proposed and will be sourced from captive power plant (254 MW) backed with Ajmer Vidyut Vitran Nigam Limited (AVVNL).  HSD/LDO/LSHS/FO (2,400 MTPM) will be used as fuel.  CPP (154 MW & 100 MW) exists.

 

PAs requested for the exemption of the public hearing due to public hearing being already held in the past on 8th June, 2003, 17th November, 2004 and 29th June, 2006 while carrying out expansion of the project in the past while accorded environmental clearance vide letter dated 3rd June, 1983, 31st March, 2004, 3rd August, 2005 and 6th December, 2006 for the existing and expansion plants.  Following were highlighted for the exemtion from public hearing:

 

1.    Metal recovery from hazardous waste and converting hazardous waste to non-hazardous waste by recovery valuable Pb, Zn, Cd and recovering them into the smelter process for enhancing the capacities.

 

2.    In pursuance of recommendation of Hon’ble Supreme Court Monitoring Committee (SCMC), Hot Gas Precipitator (HGP) treatment plant will be modernized to treat HGP dust for recovering the valuable Cadmium metal from dust. The plant will generate lead sludge, which will be recycled as a raw feed in existing Ausmelt Lead Plant and Sinter plant.

 

3.    No additional Zinc concentrate will be used in the process leading to no change in Sulphur balance. Increase in metal production will be due to use of secondaries and de-bottlenecking.

 

4.    Proposed projects process will reuse waste generated from the existing plant process for extracting value added metals. This will reduce the net waste generation.

 

5.    The proposed projects are planned within the existing plant premises with special focus on environmental improvement projects such as in-house processing of hazardous waste, recovery of valuable metals, enabling recycling of hazardous waste, waste recovery and wastewater treatment will reduce the environmental pollution load. 

 

6.    The proposed project have no additional requirement of concentrate for smelting activities, instead scondaries will be used for Zinc and Lead production. Hence during operational condition, no increase of SO2 is envisaged.

 

7.    Slight increase in water requirement (900 m3/day) due to process improvement & metal recovery) but will be reused in the process and leading to ‘zero’ discharge.

 

8.    Solid wastes e.g. purification cake, cobalt cake, HGP dust, Antimony dross will be recycled for metal recovery thereby reducing net solid waste.

 

9.    There will be marginal increase in capacity of Zinc and lead metals and other valuable by products with no increase in pollution load.

 

10.  DG sets will be used for stand by arrangement only.

 

      After deliberations, the committee noted that proposal involves enhancement of capacities of different plants, recovery by process improvement, change in product mix and utilisation of waste heat etc.    Expansion of capacities of Zinc (5,25,000 TPA to 5,50,000 TPA), Lead (95,000 TPA to 1,05,000 TPA) and other by-products is very nominal  (Less than 10 %) and that too through de-bottlenecking, improvement and modernization and exempted from public hearing at the time of award of TORs. Therefore, Committee exempted the proposal from public hearing due to expansion of the project in the same campus and public hearing being held 3 times in the past u/s 7(ii) of EIA Notification, 2006.

 

After detailed deliberations, the Committee found the final EIA/EMP report adequate and suggested to stipulate following specific conditions alongwith other environmental conditions while considering for accord of environmental clearance:

 

i.              Satsfactory compliance to all the environmental conditions stipulated for the existing plant(s) by the Central/State Govt. in the environment clearances accorded so far should be ensured and regular reports submitted to the Ministry’s Regional Office at Lucknow.  The project proponent should obtain ‘Consent to Establish’ and ‘Consent to Operate’ from the Rajasthan State Pollution Control Board (RSPCB) and effectively implement all the conditions stipulated therein.

 

ii.             Comments, observations and recommendations of the Department of Archaeology and Museum, Regional office, Udaipur submitted vide letter dated 17th May, 2003 regarding impact on the Chittorgarh Fort located at 6.5 km from the proposed smelters and power plant should be implemented.

 

iii.            The company should install on-line stack emission monitoring equipments for continuous monitoring of SO2, NOX, SPM and O2 and all the pollution control measures should be inter-locked. Column ventilation system should be provided to capture zinc dust. On-line SO2 analyser should be installed at Tail Gas Treatment (TGT) Stack.  Electrostatic precipitator should be provided to Ausmelt furnace and captive power plant to control emissions within 50 mg/Nm3. Bag filters should be provided to roaster, Cadmium recovery plant, continuous galvanizing grade (CGG) alloy plant (Hydro-1 & 2), Zinc production plant (Hydro-1 & 2) to control emissions within 50 mg/Nm3. The low NOX burners should be installed to control the NOX emissions.

 

iv.           The critical parameters such as SPM, RSPM, NOX, SO2 and acid mist in the ambient air within the impact zone, peak particle velocity at 300 m distance or within the nearest habitation, whichever is closer should be monitored periodically.  Analysis reports for the ambient, stack and fugitive emission should be submitted to the Ministry’s Regional Office at Lucknow, CPCB and RSPCB.

 

v.            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.

 

vi.           As reflected in the EIA/EMP, Double Conversion Double Absorption (DCDA) should be provided to tha acid plant attached to Pyro-smelter to achieve 1.5 kg/ton of Sulphuric acid (H2SO4) produced.  Acid mist emissions from the stack should conform to the statutory limit of 50 mg/Nm3 by tail gas treatment in Pyro plant. Lead emissions should be within 10 mg/Nm3.  The company should ensure that SO2 emissions from the Zn and lead smelter plant are taken to existing sulphuric acid plant properly and converted to sulphuric acid.  The stack from the sulphuric acid plant should be provided with on-line stack emission monitoring equipment for continuous monitoring of SO2. and analysis reports submitted to the Ministry including its Regional Office at Lucknow, CPCB and RSPCB.

 

vii.          Fugitive dust emissions from all the sourcesincluding material handling areas and at various transfer points should be minimized by provision of dust suppression system. The trucks carrying concentrate should be fully covered.  The Company should improve overall house keeping by asphalting the internal roads and to reduce the generation of fugitive dust from vehicle movements.

 

viii.         Fugitive emissions, acid mist vapours, fumes and SO2 should be controlled and work environment monitored for prevailing contaminants regularly.  Fugitive dust emissions in the handling area and at various transfer points should be minimized by provision of dust suppression system. The Company should improve overall house keeping by asphalting the internal roads and to reduce the generation of fugitive dust from vehicle movements.

 

ix.           As proposed, total water requirement from Gosunda dam should not exceed 29,900 m3/day although Government of Rajasthan has allocated 1500 MCFT vide letter dated 19th November, 1994 and water should also be released from the Gosunda Dam for the use by the public as per the agreement signed.  It should be ensured that irrigation in the surrounding areas is not affected due to non-release of water by HZL. As reflected in the EIA/EMP, all the effluent should be treated in the effluent treatment plant (ETP) followed by reverse osmosis (RO) plant.  The water treated in RO Plant should be recycled in the process and rejects of RO plant should be evaporated in solar evaporation pond.  The RO rejects and ETP sludge should be sent to existing secured landfill.  All the treated effluent should be treated to conform to the prescribed standards for TDS, DO, pH and Total Suspended Solids (TSS) besides other relevant parameters and used in the process and/or for dust suppression and green belt development. No effluent should be discharged outside the premises and ‘zero’ discharge should be adopted.

 

x.            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.

 

xi.           Surface water quality of Gosunda dam and other surface drains at eight locations should be monitored regularly. Monitoring of water upstream and downstream of Jarosite pond secured landfill should be esured. Regular monitoring of the piezometric well around secured landfill should be carried out to ensure no ground water contamination.

 

xii.          In pursuance of recommendation of Hon’ble Supreme Court Monitoring Committee (SCMC), Hot Gas Precipitator (HGP) treatment plant should be modernized to treat HGP dust for recovering the valuable Cadmium metal from dust. All the lead sludge should be recycled as a raw feed in existing Ausmelt Lead Plant and Sinter plant.

 

xiii.         Jarosite should be treated by mixing lime and cement to produce Jarofix, a stable product. Jarosite should be treated with lime and cement to produce jarofix and disposed off in Jarofix disposal yard inside the plant premises. Cooler cake and part of lead silver residue should be neutralized and stabilized before disposal in secured landfill (SLF). Ausmelt slag and pyro-slag should be recycled back in the process and, if surplus, should be sold to authorized recyclers or disposed in SLF after neutralization. Metal should be recovered from Cobalt cake and then sent to SLF.  In Hydro Plants, spent catalyst should be sent to SLF after stabilization. Purification cake, Enriched cake, Cobalt cake should be sent for metal recovery/SLF after stabilization. Spent catalyst, cooler coke. ISF slag should be provided to cement manufacturers.  Mercury sludge should be stored at isolated places. The sludge from HGP dust should also be recycled after metal recovery. Waste/used oil should be provided to registered recyclers. STP sludge should be used as manure for plantation.

 

xiv.         As proposed, metal should be recovered from hazardous waste and converted hazardous waste into non-hazardous waste by recovery of Pb, Zn, Cd and converting them into the smelter process for enhancing the capacities.  All the other solid wastes viz. purification cake, cobalt cake, HGP dust, Antimony dross etc. should be recycled for metal recovery thereby reducing net solid waste.

 

xv.          Proper utilization of fly ash should be ensured as per Fly Ash Notification, 1999 and subsequent amendment in 2003 and 2010. All the fly ash should be provided to cement and brick manufacturers for further utilization in making Pozollona Portland Cement (PPC) and ‘Memorandum of Understanding’ should be submitted to the Ministry’s Regional Office at Lucknow.

 

xvi.         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 Lucknow, RSPCB and CPCB. 

 

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

 

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

 

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

 

xx.          All the recommendations made in Charter for Corporate Responsibility for Environment Protection (CREP) should be strictly followed. 

 

xxi.         Permission and recommendations of the State Forest Department regarding impact of the proposed expansion of the project on the surrounding reserve forests viz. Era RF (9.0 km, NW), Kabra RF (6.0 km, NW), Gwalaji ka khera (5 km, WNW) and Chittorgarh RF (6 km, S) located within 10 km. radius of the site should be included.

 

xxii.        Regular medical examination and health monitoring of all the employees for Lead (Pb) and Cadmium (Cd) should be carried out and if cases of presence of Lead (Pb) and Cadmium (Cd) are detected, necessary compensation should be arranged under the existing laws. A competent occupational health physician should be appointed to carry out medical surveillance. Occupational health of all the workers should be monitored for relevant parameters and records maintained for at least 40 years from the beginning of the employment or 15 years after the retirement or cessation of employment whichever is later.

 

xxiii.       All the recommendations made in Charter for Corporate Responsibility for Environment Protection (CREP) for Zinc smelters should be implemented.

 

xxiv.      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 Lucknow. Implementation of such program should be ensured accordingly in a time bound manner.

 

Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.4          Expansion of Steel Plant (6.8 MTPA to 9.7 MTPA, Crude Steel Production) at Tata Steel Works, Jamshedpur, District East Singhbhum, Jharkhand by M/s Tata Steel 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 Steel plants are kept at S.N. 3(a) under Category ‘A’ and are appraised at the Central level. 

 

M/s Tata Steels Ltd. have proposed for the expansion of Crude Steel Production (6.8 to 9.7 MTPA) at Tata Steel Works, Jamshedpur, District East Singhbhum, Jharkhand.  The project will be located within the existing campus of steel plant of M/s Tata Steel having an area 717 ha. No additional land will be required. Jora Pahar PF, Sand Pcha Rahar PF, Deluse RF are located within 10 km. radius. Environmental clearance for the undergoing expansions (5.0 to 6.8 MTPA) has been accorded vide letter no. J-11011/317/2006 IA(II)(I) dated 16th April, 2007.  Total land acquired is 5,094 ha.  Total cost of the project is revised in the EIA report from Rs. 9,006.00 Crores to Rs. 13,900.00 Crores and further to Rs. 14,800.00 Crores during presentation. Rs. 1,269.00 Crores and Rs. 30.00-40.00 Crores instead of Rs. 1,232.00 Crores and Rs. 40.00 Crores earlier proposed and further modified to Rs. 899.00 Crores, further revised to Rs. 2,107.00 Crores and Rs. 50-60 Crores vide e-mail dated 06.04.10 will be earmarked towards capital cost and recurring cost/annum for environmental pollution control measures. During presentation, PAs have confirmed that total cost earmarked for pollution mitigation measures is Rs 2107 Crores. Initially, PAs proposed for the following capacities:

 

S.N.

Plant / Product

Existing (6.8 MTPA)

Proposed (9.7 MTPA)

1.

Coke ovens

2.3

3.4

2.

Sinter Plant

7.6

8.0

3.

Pellet Plant

-

6.0

4.

Blast Furnaces

7.2

10.2

5.

Steel Making

6.8

9.7

6.

Long products

1.24

1.24

7.

Flat products

3.04

5.83

8.

Semis

2.32

2.37

 

Later on, PAs proposed following modifications :

 

      i.         Installation of Top Charge Battery (0.7 MTPA) at Jamshedpur instead of (0.35 MTPA) Top Charge Battery as a replacement of old Top Charge Battery # 3.

 

     ii.         Installation of new big Blast Furnace (‘I’ Blast Furnace) instead of upgrading old Blast Furnace as conceived earlier to augment the hot metal capacity.

 

The modifications led to changes in configuration as follows and the same is presented before the Committee during presentation :

 

S.N.

Plant / Product

Existing (6.8 MTPA)

Proposed (9.7 MTPA)

1.

Coke ovens

2.3

3.4

2.

Sinter Plant

7.6

8.0

3.

Pellet Plant

-

6.0

4.

Blast Furnace (Hot Metal)

7.2

10.55

5.

Steel Making (Crude Steel)

6.8

9.7

6.

Long products

1.24

1.24

7.

Flat products

3.04

5.83

8.

Semis

2.32

2.37

 

The Committee noted change in the capacities of coke oven, blast furnace and sinter plant for which TORs were awarded by the Ministry vide letter dated 9th January, 2008. There will be no change in final capacity of the Steel Plant (9.7 MTPA). After proposed expansion, the product-mix will be as under:

 

Plants

Present

Post 6.8 MTPA Growth plan (under construction) (MTPA)

Post 9.7 MTPA Expansion Project (MTPA)

Intermediate products

Hot Metal

5.3

7.2 ±5%

10.55 ±5%

Crude Steel

5.0

6.8 ±5%

9.7±5%

Saleable Products

Long Products

1.24

1.24 ±5%

1.24±5%

Flat products

2.90

3.04 ±5%

5.83±5%

Semis

0.63

2.32±5%

2.37 ±5%

 

PAs further informed that following will be done during the proposed expansion:

 

A.    New Production facilities under Expansion Project :

 

              i)    Coke Oven battery # 10 & 11 of capacity 0.7 MTPY each alongwith by-product recovery plant

             ii)    Pellet plant (PP) of capacity 6.0 MTPY

            iii)    Blast furnace ‘I’ of capacity 3.05 MTPY

           iv)    LD #3 Shop with crude steel production capacity 2.4 MTPY

            v)    Thin slab casting & rolling (TSCR) with production capacity of 2.34 MTPY hot strip coils

           vi)    Two (2) No. twin-shaft lime kiln of capacity 600 TPD each

 

  1. Units to be Upgraded :

 

i)          Augmentation of hot strip mill (HSM) from 3.10 to 3.55 MTPY

ii)         Enhancing LD#2 shop production by 0.5 MTPY

iii)        Upgrading blast furnaces ‘C’ from 0.23 to 0.70 MTPY hot metal production capacity

iv)       Increasing hot metal production from ‘F-H’ furnaces by 1.4 MTPY.

v)        Enhancing sinter production from SP#1-3 by an additional 0.1 MTPY

vi)       Suitable modifications in raw material & handling section (RMHS) for new as well as upgraded facilities

 

  1. Old Units to be closed down :

 

              i)    Blast furnace # ‘A-B’ and ‘D-E’ (4 Nos.)

             ii)    Top charge battery # 3

 

            Iron ore (1,318,000 TPM), Coking coal (402,200 TPM), Purchased coke and coke breeze (65,300 TPM), BF Injection coal (1,42,200 TPM), Anrgracite coal, Dunite / Pyroxinite and Limestone (2,34,600 TPM) will be used as raw materials.

 

Conventional BF–BOF route of steel making followed by thin slab casting and rolling will be used. No change will be made in the existing coke making facility and additional requirement will be sourced from Haldia Metcoke Plant in West Bengal and other.  No additional sinter plant will be installed. Iron ore fines will be used in BF in iron making in Pelletization Plant (6.0 MTPA).  After upgradation and modification, hot metal (10.2 MTPA) will be produced and steel production will be enhanced to 9.7 MTPA.  No other new mill except TSCR Mill will be installed.  Two lime calciners will be installed.

 

Ambient air quality monitoring has been carried out at 10 locations during the period January, 2008 to April, 2008 and the data submitted indicated SPM (94.71-420.8 µg/m3), RPM (45.6-166.9 µg/m3), SO2 (5.6-29.7µg/m3) and NOx (16.8-70.0 µg/m3) and are within the permissible limit except for RPM.  However, RPM values were found to be within 100 ug/m3 when data for one full year for the existing plant was collected and analyzed.  4.16.6 TSP (800–850 kg/h), SO2 (1700–1750 kg/hr.) and NOx (1800-1900 Kg/h) will be generated. Prediction of Ground Level Concentrations (GLC’s) due to proposed expansion has been made by Industrial Source Complex, Short Term (ISCST3) as per CPCB guidelines and the data submitted an indicated an incremental SPM of 0.465 µg/m3 from 39.0 µg/m3 to 39.465 µg/m3 which is well within the NAAQS norm.  Similarly, incremental SO2 and NOx emissions are 4.694 µg/m3 (8.0 µg/m3 to 12.694 µg/m3) and 15.35 µg/m3 (12.0 µg/m3 to 27.35 µg/m3) respectively. PAs have claimed that predicted PM10 value in Jamshedpur will be 66-92 µg/m3 by adopting stringent pollution control measure and traffic decongestion plan which will be within 100 µg/m3, SO2 and NOx values are predicted as 9-31 µg/m3 and 28-57 µg/m3 respectively.

 

Waste gas from the drying and grinding unit of pellet plant will be cleaned by bag filters. ESPs will be upgraded and bag filters will be provided to achieve particulate emissions <30 and 20 µg/m3 in existing and proposed units respectively.  PAs also informed that existing PM value is 495 kg/hr at 5.0 MTPY level and efforts will be made not to exceed 487 kg/hr at 9.7 MTPY production levels which will be lower than the existing value. Electrostatic precipitators (ESPs) will be provided at product pellet screening and handling section and induration furnace hood of pellet plant, cast house and stock of blast furnaces and LD#3 Shop. Land based fume extraction system has been considered for arresting fugitive emissions from coke oven battery # 10 and 11 during charging and pushing operations. The coke oven gas will be desulphurised by reduction of H2S content of coke oven gas in the by-product recovery section to below 500 mg/Nm3. NOx emissions will be controlled. Special features like on-main charging with high pressure liquor aspiration (HPLA) for extraction of oven gas, leak proof oven doors, hydraulic door and door frame cleaner, water sealed AP caps and charging & pusher side emission extractor device will be provided for the coke oven batteries to maintain VOC emissions are within permissible limit. Land based fume extraction system for pushing emission control from coke ovens will be provided. Bag house will be provided to Lime kilns. Dry fog dust suppression system / water sprinkling system will be provided in raw material handling areas to control fugitive dust emissions. Fugitive emission from different sources will be controlled by covered conveyors, water sprinkling in open yards and with dry fogging in the closed zones

 

PAs informed that Committee about the city road traffic decongestion plan with 2 new bridges over Subarnarekha and Kharkai Rivers and new ‘Western’, ‘Eastern’ and ‘East-West’ road corridors to divert heavy traffic through peripheral and to decongest the heart of the city and consequently reduce emission in the city.  98% and 70% inbound and out bound material movement will be done by railway wagons only to reduce dust emissions.  Road traffic in steel works will be reduced due to conveyor handling of bulk materials, centralized screening of iron ore, rationalization of weighing system, use of higher capacity vehicles etc. Mechanized vacuum cleaning of arterial roads will be carried out on regular basis to reduce dust emissions.  By product fuel gases such as coke oven gas, BF gas and LD gas will be reused in the plant itself.

           

Total water requirement from River Subarnarekha after expansion is revised from 120 MGD to 42 MGD but 73 MGD during presentation. However, water requirement after adopting air quenching in the coke ovens will be further reduced to 33.3 MGD. Additional water requirement for the expansion plant will be only 2.3 MGD.  Thus, total make up water requirement for the plant at 9.7 MGD will be 33.3 MGD.  All the waste water from various units will be pumped to the common effluent treatment  plant (CETP) for primary, secondary and tertiary treatment and recycled/reused for slag quenching, water sprinkling (dust suppression), dry fog operation, road cleaning and green belt development etc.  PAs claimed that water requirement will come down from 7.6 m3/Ton of crude steel at 6.8 MTPY to 5.7 m3/T at 9.7 MTPY stage.  Permission for the drawl of 227 MGD water is obtained vide letter dated 7.1.1992. The committee asked to explore air quenching instead of wet quenching.  PAs have agreed to adopt coke dry quenching in proposed new battery # 10 & 11 and 25 MW power will be recovered leading to CDM benefits to the tune of 300,000 CERs/annum.  Make up water requirement will be reduced by 300 m3/hr due to adoption of air quenching instead of wet quenching. Major part of the treated wastewater will be reused within the plant and balance treated wastewater will be discharged through the existing plant drain after meeting the statutory regulation. Closed loop circulation system using clarified water will be adopted to facilitate maximum recycling/reuse of water.  Waste water discharge will be reduced from 8.1 MGD to 1 MGD and efforts will be made to adopt ‘zero’ discharge. The phenolic effluent from the by-product recovery section of coke oven battery # 10 and 11 will be treated in either modified/new BOD plant. The treated wastewater will be either recycled or used for dust suppression, slag quenching and green belt development within the lease hold areaetc. No additional treated wastewater will be released out of the premises and Zero discharge will be adopted by recycling all the treated water in the plant itself. The Committee insisted for ‘zero’ discharge including from the existing plant. Wastewater containing suspended solids will be passed through clarifloculation plant to recover and reuse the clarified water for cooling or cleaning. Mill effluent containing oil and suspended solids will be passed through oil skimmers and filter press.

 

All the BF slag will be granulated and sold to the cement manufacturers for use in cement making.  MoUs are signed with M/s Lafarge, M/s Eco-cement & M/s ACC.  LD slag after metal recovery will be used within the steel plant in sinter plant, blast furnaces and LD convertor, aggregated making, road ballast making, soil conditioning etc. All the flue dust generated will be recycled within the plant to the extent of 84%. Mill scales after being treated for minimizing oil content, LD sludge and flue dust will be recycled back to the sinter plant. Lime fines are recycled back to sinter plants and refractory wastes are sold to outside agencies. The BF gas cleaning plant sludge is sold off for manufacturing briquettes which is used as fuel.

 

The hazardous solid wastes in the steel plant would comprise of coal tar sludge, BOD sludge and chrome sludge. The coal tar sludge and BOD sludge will be recycled for coke making by mixing with the coal charge before introducing the same into the ovens. Coal tar sludge would also find a good resale value in the market. Chromium sludge is being dumped 100% in a HDPE lined pit within the steel plant complex. Jugsalai muck dump (JMD) will be reclaimed in a time bound manner by covering the dump site with geo-netting and vegetation alongwith localized water harvesting.  Solid by-products will be temporarily stored in existing central slag granulation yard and waste recycling plant (WRP). PAs informed during presentation that M/s Tata Steel has already achieved 100 % utilization of all the other wastes and 100 % utilization is planned for BF slag and LD slag. The results of TCLP test indicate that the heavy metals are within the regulatory limits of USEPA.  

 

            Green belt exists in 32 % of total area (5,093 ha.) and will be developed in more than 33 %.  Peak power demand of 1068 MW instead of 1030 MW earlier proposed will be needed at 9.7 MTPA production stage and about 800 MW will be met from Damodar Valley Corporation and Jojobera thermal power station alongwith in-plant power availability of 231 MW. LPG (430 Kg/hr) or 11 TPD will be used as fuel.

 

CSR activities are covered in the city of Jamshedpur and more than 600 villages. Rs. 600.00 Crores are earmarked for next 5 years for education, health, medical, sports etc.

 

The Committee deliberated upon the issues raised during the Public Hearing / Public Consultation meeting conducted by the Jharkhand Pollution Control Board on 18th June, 2009.  The issues raised included increase in vehicular traffic and associated pollution problems, ground water depletion, inadequate drainage and sanitation facilities, delay in the progress of widening of roads and new bridge construction, rise in ambient temperature around the plant, conservation of natural resources like coal and iron ore, need for more social development works, jugsulai muck dump contributing to fugitive dust emissions and have satisfactorily been incorporated in the final EIA/EMP report.

 

After detailed deliberations, the committee desired submission of following information during 5th EAC(I) meeting held during November, 2009 alongwith the site visit by the sub-committee :

 

  1. Action plan for the use of air quenching in the coke oven plant instead of wet quenching.
  2. Actual water requirement from River Subarnarekha alongwith prior permission from the concerned department.
  3. A note on plant-wise wastewater treatment.
  4. Leachate study for the effluent generated and analysis.
  5. A note on slag disposal and TCLP analysis report.
  6. A note on topographic erosion.
  7. Reasons for further expansion of the steel plant at Jamshedpur when it is already too congested and not as a green field project in some other State.
  8. Impact of the existing plant on the Jamshedpur town. Can Jamshedpur town bear the load of 9.7 MTPA steel plant ?
  9. Reasons for not presenting before the committee as per TORs.

                       

            The sub-committee of EAC(I) comprising of Shri S. Raina, Vice Chairman; Prof. R. C. Gupta, Prof. Jayant Bhattacharya, Prof. C.S. Dubey, Members and Dr. V.P. Upadhyay, Regional Office, MoEF and Dr. P.B. Rastogi, Director, MoEF have visited the the site during 9-10th January, 2010 to asses the pollution control measures being adopted in the existing plant and suggest additional pollution control measures to be adopted.  The proposal was discussed with PAs in the light of site visit and additional information submitted.

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

 

1.    Compliance to all the specific and general conditions stipulated for the existing plant by the Central/State Govt. should be ensured and regular reports submitted to the Ministry and its Regional Office at Bhubaneswar.

 

2.    Efforts should be made to reduce RSPM levels in the ambient air and a time bound action plan should be submitted. On-line ambient air quality monitoring and continuous stack monitoring facilities for all the stacks should be provided and sufficient air pollution control devices viz. Electrostatic precipitator (ESP), bag house, gas cleaning plant, bag filters etc. should be provided to keep the emission levels below 50 mg/Nm3 by installing energy efficient technology. Low NOx burners should be installed to control NOx emissions.  

 

  1. All the standards prescribed for the coke oven plants should be followed as per the latest guidelines. Proper and full utilization of coke oven gases in power plant using heat recovery steam generators should be ensured and no flue gases should be discharged into the air. Sulphur should be recovered from the coke oven gases from new product plant.

 

  1. Only dry quenching method in the coke oven in new battery # 10 & 11 should be adopted.

 

  1. 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.

 

6.    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.

 

7.    As proposed, traffic decongestion plan should be implemented in a time bound manner to reduce emissions in the Jamshedpur city and separate budget should be allocated for implementiong the same.  Maximum inbound and out bound material movement should be done by railway wagons only to reduce dust emissions. Measures like covered conveyors for handling of bulk materials, centralized screening of iron ore, rationalization of weighing system, use of higher capacity vehicles etc. should be adopted to reduce dust emissions. Mechanized vacuum cleaning of arterial roads should be carried out on regular basis to further reduce dust emissions.

 

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

 

9.    As proposed, total water requirement from River Subarnarekha should be revised and reduced due to change from wet to dry quenching in coke oven plant.  Ctual water requirement should be informed to the Ministry and Regional Office at Bhubaneswar  and ‘permission’ for the drawl of requisite amount of water should be obtained from the concerned department. Closed circuit cooling system should be provided to reduce further water consumption. All the wastewater from various units should be treated in the effluent treatment plant (ETP) for primary, secondary and tertiary treatment. The phenolic effluent from the by-product recovery section of coke oven battery # 10 and 11 should be treated in BOD plant. The treated wastewater should be either recycled or used for dust suppression, slag quenching and green belt development etc. within the lease hold area.

 

  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. Continuous monitoring of Total Organic Compounds (TOC) in the wastewater treated in BOD plant from the coke oven plant should be done at the outlet of ETP (BOD plant). All the treated wastewater should be monitored for pH, BOD, COD, oil & grease, cyanide, phenolic compounds, Chromium+6 etc. besides other relevant parameters.

 

  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, Jharkhand SPCB and CPCB.

 

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

 

14.  As proposed, the water consumption should not exceed 5.7 m3/Ton of steel at 9.7 MTPHY stage.

 

15.  All the blast furnace (BF) slag should be granulated and provided to cement manufacturers for further utilization in cement making as per the MoUs signed with various companies.  LD slag after metal recovery should be used in sinter plant, blast furnaces and LD convertor, aggregates making, road ballast making, soil conditioning etc. All the flue dust generated should be recycled within the plant to the maximum extent. Mill scales, LD sludge, lime fines and flue dust should be recycled back to the sinter plant. The BF gas cleaning plant sludge should be used for manufacturing briquettes.

 

16.  As proposed, coal tar sludge and BOD sludge should be be recycled for coke making by mixing with the coal charge. Chromium sludge should be disposed in a HDPE lined secured landfill as per the CPCB guidelines within the complex. All the other solid waste including broken refractory mass should be properly disposed off in environment-friendly manner.

 

17.  As proposed, Jugsalai muck dump (JMD) should be reclaimed in a time bound manner by covering the dump site with geo-netting and vegetation alongwith localized water harvesting.

 

18.  All the 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 Chromium sludge and other hazardous substances recovered from the slag and output waste should be disposed off in secured landfill as per CPCB guidelines. 

 

19.  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 Bhubaneswar.

 

20.  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 Bhubaneswar, Jharkhand SPCB and CPCB. 

 

21.  A time bound action plan should be submitted to reduce solid waste, its proper utilization and disposal to the Ministry’s Regional Office at Bhubaneswar, Jharkhand SPCB and CPCB.

 

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

 

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

 

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

 

25.  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. Jora Pahar PF, Sand Pcha Rahar PF, Deluse RF located within 10 km radius of the project. Further, Conservation Plan for the conservation of wild fauna in consultation with the State Forest Department should be prepared and implemented.

 

26.  All the commitments made to the public during the Public Hearing / Public Consultation meeting held on 18th June, 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.

 

27.  At least 5 % of the total cost of the project i.e. Rs. 750.00 Crores 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.

 

Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.5          Integrated Steel Plant (0.14 Million TPA) alongwith Captive Power Plant (22 MW) at Jamadoba, Post Bankati, P.S. Kansa, District Burdwan, West Bengal by M/s Durgapur Ferro Alloys (P) 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 87th Meeting of the Expert Appraisal Committee (Industry) held during 25th- 26th November, 2008 for preparation of EIA/EMP.  All the Integrated Steel Plants have been kept in Category ‘A’ and have to be appraised by the Central Govt. 

 

            Additionally, PAs informed to the Committee that M/s Durgapur Ferro Alloys Pvt. Ltd. have proposed for the Integrated Steel Plant  (0.14 Million TPA) alongwith Captive Power Plant (22 MW) at Jamadoba, Post Bankati, P.S. Kansa, District Burdwan, West Bengal. PAs confirmed that total area acquired is 44 acres. No National Park/Wild life sanctuary/Reserve Forest is located within 10 Km radius of the project. Project cost is enhanced from Rs. 198.00 Crores to Rs. 270.00 Crores. Rs. 11.00 Crores instead of 8.00 Crores and Rs. 1.20 Crores instead of Rs. 0.90 Crores is earmarked towards total capital cost and recurring cost/annum towards environmental pollution control measures. River Ajay is flowing at 7 Km. No national park, biosphere reserve, historical sites and sea/estuaries etc. within the 10 km. The Committee noted that In EIA/EMP, manufacturing capacity of the proposed project has been modified as Sponge iron (from 3,00,000 TPA to 1,20,000 TPA), Steel Billets (3,29,000 TPA to 1,45,000 TPA), Rolling mill (3,24,000 TPA to 1,40,000 TPA),  WHRB captive power (8 MW), AFBC CPP (16 MW to 14 MW) and no Oxygen plant.  Following facilities will be installed:

 

Unit

Originally planned capacity

Modified capacity

DRI Kiln

3,00,000 TPA

1,20.000 TPA

SMS

3,29,000 TPA

1,45,000 TPA

Rolling Mill

3,24,000 TPA

1,40,000 TPA

CPP - FBC

16 MW

14 MW

CPP - WHRB

Pre-heating kiln planned

8 MW

Oxygen Plant

30 TPD

Not required.

           

Iron ore for DRI, DRI Coal, Dolomite, Pig Iron, Coal fines, Char from FBC and burnt lime will be used as raw materials. 

 

DRI-EAF/IF-LRF-CCM-Rolling Mill route will be adopted. PAs confirmed that no blast furnace will be installed.  Direct reduction method with pre-heating using sensible heat of kiln flue gas will be used to manufacture sponge iron.  This will reduce fuel consumption and will increase operating performance & productivity. Hence, waste heat recovery boiler was not proposed initially but now have proposed. Steel Melting Shop will consist of IF, LRF and CCM.  Sponge iron will be melted in EAF.  LRF will be provided for refining and super heating the hot metal. Steel billets will be manufactured using DRI-EAF-CCM and DRI-IF-CCM route.  Rolling mill will be installed to manufacture TMT bars and structural.  CFBC-CPP (16 MW) will be installed.

 

The sized iron ore, DRI grade coal charged into  the rotary kiln and will be rapidly heated up by the combustion of coal volatiles released in the charge using the under bed air injector system. The reduction of iron ore in the solid state will follow at about 1000OC with CO generated from the coal, converting the iron into metallic iron. Small quantities of dolomite / limestone will be added to entrap Sulphur from coal.  To prevent the re-oxidation of the sponge iron produced from the kiln, a rotary cooler will be used, which will indirectly cool down the products. The sponge iron and char will be separated magnetically.  In the manufacturing of sponge iron through conventional DRI process, only 45 % of the input heat energy will be utilized in the heating and reduction of iron ore.  Further, heat of the kiln flue gas from ABC will be utilized in waste heat recovery boilers.  The steam produced will be utilized for captive power generation in the CPP.  Rolling mill will be used for manufacturing TMT bars and light and medium structural. Two turbo generators of 12 MW capacity each (common for WHRB & FBC) will be installed.

 

PAs informed to the Committee that ambient air quality monitoring has carried out at 11 locations during November, 2007 to February 2008 and submitted data indicated range of SPM levels (88.3–149.9 ug/m3), RPM (30.1–69.8 ug/m3), SO2 (5.6–9.6 ug/m3) and NOx (5.8–10.2 ug/m3).  98 percentile value of SPM (148.6 ug/m3), RPM (68.5 ug/m3), SO2 (9.3 ug/m3) and NOx (9.7 ug/m3) are within permissible limit. Incremental value of SPM (14.08 ug/m3), SO2 (20.44 ug/m3) and NOx (4.38 ug/m3).

 

PAs informed to the Committee that ESP will be provided to CPP-FBC to control gaseous emissions within 100 mg/Nm3 but Committee insisted for 50 mg/Nm3.   WHRB will be installed to use gases for pre-heating. Dust settling chamber (DSC) will be installed for settling of coarse particles. Flue gas from After burning chamber (ABC) will be utilized by waste heat recovery boilers and ESP with stack will be provided to bring down the SPM levels below permissible level. Pulse jet bag filter will be installed at coal crushing section, iron ore crushing section, stock house and stock silo, cooler discharge area and intermediate storage and product house. The pulse type bag filter with stack will also be provided in steel melting furnace.  Fume extraction and bag filters will be provided to extract fumes for IF & LRF.  The gas cleaning system will consist of water cooled duct, gas cooler, bag house, ID fan and stack. Ventilation system will be provided to CCM. Dust extraction system comprising of pulse jet type bag filter will be installed in ladle furnace–gas cleaning plant. Limestone dosing along with coal will be fed to control SO2 emissions. Regular water sprinkling will be carried out to minimize the fugitive dust emissions during transportation.

 

Condenser will be provided to separate steam condensate from billet casting unit and spend gas let out through stack.

   

Total water requirement will be ssourced from River Ajaya only and is reduced from 3,370 m3/day to 2,110 m3/day and have applied for the permission for the drawl of water. No ground water will be used.  Closed circuit re-circulation system will be installed to minimize water consumption.  DM Plant will be installed to meeting boiler and cooling water requirement.  Oil and gas will be separated from the rolling mill and wastewater will be recycled and reused.  All the effluent will be treated and reused for dust suppression, ash handling and green belt development.  No effluent will be discharged and ‘zero’ discharge will be adopted. Domestic effluent will be treated in STP.   

 

Coal fines and DRI char will be used in FBC boiler.  SMS scrap will be recycled and reused in the process.  Bottom ash will be used in road making and land filling.  Iron ore fines will be sold to sinter and pelletization unit. Fly ash will be used as per plan. Kiln dust, kiln accretions and Mill scale will be used for land filling.  SMS slag will be dumped in earmarked area.

 

Out of 44 acres, green belt will be developed in 14 acres. Out of total 36 MW power requirement, 16 MW will be used from Captive Power Plant.  20 MW will be sourced from grid.  LDO will be used for SMS, CCM, DRI, CPP and lime plant. In EIA/EMP, power requirement is reduced to 25 MW out of which 22 MW will be generated and 3 MW will be purchased.  The annual requirement of FO/LDO will be 10,000 KL.

 

            The Committee deliberated upon the issues raised during the Public Hearing / Public Consultation meeting conducted by the West Bengal Pollution Control Board on 30th July, 2009 and issues raised including employment generation, pollution control system, abstraction of make up water, green belt development, afforestation plan, corporate social responsibility etc have satisfactorily been incorporated in the final EIA/EMP report.

 

            After deliberating on the facts presented before the Committee (Industry), the Committee had no objection regarding reduction in the quantity since pollution load will also decrease accordingly. However, at the same time, it is observed that manufacturing capacity of the different plants proposed earlier has been modified and change in configuration will lead to changes in the cost, raw material requirement, process details, air pollution control measures, water requirement, wastewater treatment system, solid/hazardous waste management, disposal, reutilization, budget allocation for the CSR activities for the proposed activities has to be revised according to the new facilities proposed.  

 

            Keeping bove mentioned facts in mind, the Committee deferred the proposal and asked PAs to submit the revised proposal including EIA/EMP using the same base line data.

 

Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.6          Expansion of Steel Plant at Plot No. 97 & 98, J. P. Durgah Road, Kottur Industrial Area, Village & Mandal Kottur, District Mahaboobnagar, Andhra Pradesh by M/s Vinayak Steels Limited (Unit-II) (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 1st Meeting of the Expert Appraisal Committee (Industry) held during 20th-21st July, 2009 for preparation of EIA/EMP.  All the steel Plants have been kept at S. N. 3(a) under primary metallurgical industry under category ‘A’ and is appraised at Central level.

 

Additionally, PAs informed to the Committee that M/s Vinayak Steels Limited (Unit-II) have proposed to expand its Steel Plant at Plot No. 97 & 98, J. P. Durgah Road, Kottur Industrial Area, Village and Mandal Kottur, District Mahaboobnagar, Andhra Pradesh. Total private land acquired is 8 acres. No R & R is involved. A copy of the Gazette Notification issued by the Govt. of Andhra Pradesh indicating location of Village and Mandal Kottur inside the notified industrial area as per G.O. No. 49 dated 3rd February, 1992 is submitted.  ‘Consent for Establishment (CFE)’ for the existing plant is issued by the APPCB vide Order No. 229-MHB/APPCB/ZO-HYD/CFE/2009-175 dated 29th May, 2009.  An open jungle is located at a distance of 8 km from the project site. Thimapur (2 km N), Palmalkul (4 km NE), Chinnatupra (4.5 km E), Kottur Thanda (2 km S), Fatimapur (2 km NW) are located within 10 km radius of the project site. Nearest habitation is at a distance of about 1 km. No national parks, wildlife sanctuaries and bird sanctuaries are located within 10 km radius. Total cost of the proposed expansion will be Rs. 30.00 Crores. Rs. 2.00 Crores and Rs. 0.20 Crores will be earmarked towards total capital cost and recurring cost/annum for environmental pollution control measures. Now, PAs have enhanced the amount for environmental pollution control measures to Rs. 3.00 Crores. No litigation/court case is in pending against the project. Following are the details of existing and proposed facilities:

 

S.N.

Facility

Product

Capacity

Existing :

1

Induction Furnace

Ingots/Billets

33,000 TPA

(4.5 TPH)

2

Rolling mill

MS Bars/Structures

49,500 TPA

(150 TPD)

Proposed :

1

Induction Furnace

4 crucibles with 2 in stand-by

Ingots/Billets

72,000 TPA

(2x12 TPC)

2

Ferro Alloy Plant

Ferro Manganese

/ Ferro Silicon

42,000 TPA

(2x12 MVA)

 

Sponge iron (57,024 TPA), steel scrap (17,424 TPA), pig Iron (16,632 TPA) will be used in induction furnace. M.S. Ingots/billets (79,200 TPA) in rolling mill and quartz / Manganese ore (12,000 TPA), charcoal (9,000 TPA), mill scales (2,400 TPA), electrode paste (450 TPA), casting sheets (42 TPA) and M.S. rods (300 TPA) will be used as raw materials in Ferro Alloy Plant. PAs have confirmed that no Ferro Chrome will be manufactured. 

 

            Manganese ore (48,000 TPA), Coke (11,400 TPA), Dolomite (8,400 TPA) will be used as raw materials for Fe-Mn. Quartz (51,000 TPA), Coke (18,000 TPA), Mill scale (13,800 TPA) will be used as raw materials for Fe-Si.

 

            PAs informed to the Committee that Ferro alloy will be melted in open submerged electric arc furnace at about 1400oC–1600oC.  The raw materials will be thoroughly mixed in the proper proportion before being charged into furnace through skip, Telfer hoist and charging chute. The charge will be stocked manually near to electrodes on furnace top.  As the charge will enter the smelting zone, the alloy will be formed by chemical reactions of the oxides and the reductant, being heavy, gradually settles at the bottom. The furnace will be tapped at regular intervals. The tap hole will be opened by oxygen lancing pipe and after tapping is completed, it will be closed by clay plugs. The liquid ferro alloy will be collected and cast in dressed sand beds. After solidification the cake will be broken manually to required lump size. 

           

            Scrap/sponge iron, fluxes, ferro alloys will be melted in an Induction furnace at 1650oC. When the total charge is melted into hot liquid metal then the metallurgy of steel in terms of carbon, phosphorus content, alloy elements etc will be controlled at this stage. Based upon the composition of molten steel, additives will be added to get the requisite composition and grade of steel. For production of ingots the molten material will be poured into the molds to produce ingots.  The molten material will be poured into ladle and then transported to continuous casting machine by help of overhead cranes. The ladle will be placed over the continuous casting machine to cast the molten steel into required size of billets.  Billets will be fed to pre-heated furnace to produce M.S. bars and structures.

 

PAs informed to the committee that the baseline data was collected to obtain ‘Consent for Establishment (CFE)’ from Andhra Pradesh Pollution Control Board. CFE was granted by APPCB, Hyderabad.  The ambient air quality data collected at 8 locations during the period December, 2008–February, 2009 indicated average value of SPM (106.9-162.8 µg/m3), RPM (30.2-50.8 µg/m3), SO2 (12.2-16 µg/m3) and NOx (15-19.4 µg/m3) which are within the permissible limit. 98tile value of SPM (56.3 ug/m3), RSPM (25.8 ug/m3), SO2 (17.2 ug/m3) and NOx(23.1 ug/m3).  The submitted data indicated the incremental SPM (1.25 µg/m3), SO2 (0.30  µg/m3) and NOX (0.48 µg/m3).

 

In induction furnace, fumes will be extracted through revolving hood and then cleaned by passing through bag filter, which will be finally discharged into atmosphere through 30 m high chimney.  The final emissions from chimney of Induction melting furnace will be Hydro-carbon (5 mg/m3), SPM (< 50 mg/m3), SO2 (< 10 mg/m3) and NOx (< 5 mg/m3).  In ferro alloy plant, reverse air/pulse jet bag filter with ID fan, spark arrestor and furnace hood will be provided and clean gas will be let out to atmosphere through 30 m high chimney. 

 

Total ground water requirement will be 195 m3/day and permission will be obtained from Ground Water Department through Commissioner of Industries after getting environment clearance. No process effluent will be generated as cooling water will be re-circulated. Acidic and alkaline effluents from DM plant will be neutralized in neutralization tank. Service water will be passed through an oil separator to remove the oil content in the effluent. All these effluent streams will be mixed in holding tank alongwith cooling tower blow down. Treated effluent will be recycled into DRI plant and remaining water will be used for dust suppression and for green belt development. However, domestic effluent will be treated in septic tank followed by soak pit. Treated effluent will be treated will be used for gardening purpose. Roof top rain water harvesting structures will be constructed.

           

            Slag will be generated from Induction Furnace. Fe-Mn slag and Fe-Si slag will be generated from submerged arc furnace. IF slag will be used for landfill in low lying areas.  Mill scale from the rolling mill will be sold into the market. Scrap will be reused in the plant. No Ferro chrome will be manufactured. 

 

Green belt will be developed in 2.64 acres land (33%) of total plant area.  Ear plugs will be provided to workers working in noise prone areas. Acoustic enclosures will be provided to noise generating equipment. Total power requirement from APCPDCL will be 27 MVA.  Charcoal (9,000 TPA) will be used in arc furnace. A DG set (1250 KVA) running on Diesel will be installed for lighting purpose.

 

After deliberating on the facts presented before the Expert Appraisal Committee (Industry), the Committee noted that no public hearing/consultation is required due to project being located in notified Kottur industrial area as per Section (iii), Stage (3), Para (i)(b) of EIA Notification, 2006. The Committee found the final EIA/EMP report adequate and suggested to stipulate following specific conditions alongwith other environmental conditions while considering for accord of environmental clearance

 

  1. All the conditions stipulated for the existing plant by the Central/State Govt. should be implemented and report submitted to the Ministry’s Regional Office at Bangalore, APPCB and CPCB.

 

  1. Continuous monitoring facilities for all the stacks and sufficient air pollution control equipments viz. fume extraction system with bag filters, I D fan, spark arrestor and stack of adequate height should be provided to control emissions below 50 mg/Nm3. 

 

  1. 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.

 

  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 195 m3/day ground water from CGWA/SGWB 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 Bangalore, APPCB 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. 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.  Otherwise, hazardous substances should be recovered from the slag and output waste and be disposed in secured landfill as per CPCB guidelines. All the slag should be disposed off in environment-friendly manner.

 

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

 

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

 

13.  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, APPCB and CPCB. 

 

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

 

  1. A Risk and Disaster Management Plan should be prepared and a copy submitted to the Ministry’s Regional Office at Bangalore, APPCB 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 steel plants should be strictly implemented.

 

  1. 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 shall be taken to prevent impact of particulate emissions / fugitive emissions, if any from the proposed plant on the surrounding forests located at 8 km from the proposed the project site. Further, Conservation Plan for the conservation of wild fauna in consultation with the State Forest Department should be prepared and implemented.

 

19.   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.

 

Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.7          Integrated Steel Plant (2.0 MTPA), Cement Plant (1.4 MTPA) and Captive Power Plant (230 MW) at Village Danapur, Taluk Hospet, District Bellary, Karnataka by M/s B.M.M. Ispat Ltd. (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 82nd Meeting of the Expert Appraisal Committee (Industry) held during 10th to 12th June, 2008 for preparation of EIA/EMP.  All the Integrated Steel Plants (2.0 MTPA), Cement Plant (1.40 MTPA) and Captive Power Plants (230 MW) are listed at S.N. 3(a), 3(b) and I(d) and  under Category ‘A’ and are appraised at the Central level. Since capacity of proposed steel plant (2.0 MTPA), Cement Plant (1.4 MTPA) and CPP (230 MW) is more than the prescribed capacity, proposal is appraised at the Central level.

 

            Additionally, PAs informed to the Committee that M/s BMM Ispat Ltd. have proposed for the Integrated Steel Plant (2.0 MTPA), Cement Plant (1.4 MTPA) and Captive Power Plant (230 MW) at Village Danapur, Taluk Hospet, District Bellary, Karnataka. Total land requirement will be 1,429 hectares. During presentation, PAs informed that out of 785 ha. private land, 321.72 ha. land is acquired.  PAs informed that 643.35 ha. Govt. land is also in possession. No National Park and Wildlife sanctuary is located within 10 Km radius of the project. Gunda RF, Nandibanda RF and Ramgad RF are located at 4 Km, 7 Km and 4 Km respectively. The committee was surprised when PAs confirmed that Hospet RF (4 Km) and Sandur RF (4 Km) earlier informed are not located within 10 Km radius of the project. Dhanpura Village is at 2.0 Km. Surface water bodies are TB Dam (5 km), Danayankere (1 km), Gunda K ere (0.5 Km).  A railway line is passing through the proposed site and Southern Western Railway, Hubli, Karnataka has issued ‘No Objection’ for the construction of Steel plant subject to leaving 30 meters from the railway boundary vide their letter no. H/W.280/II/NOC/DRG dated 28th January, 2008. Total cost of the project is Rs. 6,233.70 Crores instead of Rs. 6,151.30 Crores.  Rs. 625.00 Crores and Rs. 26.50 Crores are earmarked towards environment pollution control measures. During presentation, it was informed that capital cost towards pollution control measures is Rs. 412.00 Crores and 42.25 Crores for recurring cost per annum. In EIA/EMP report, manufacturing capacity of Iron ore benefeciation plant and DRI plant is enhanced from 3.20 to 3.40 MTPA and 0.64 MTPA to 0.70 MTPA respectively.  Following will be manufactured:

 

S.N.

Items

Capacity

1

Iron ore beneficiation plant

3.40 MTPA

2

Palletizing Plant

1.20 MTPA

3

DR Plant

0.70 MTPA

4

Coke Oven

0.80 MTPA

5

Sinter Plant

2.50 MTPA

6

Blast furnace

1.70 MTPA

7

EAF & BOF Steel making

2.30 MTPA

8

Continuous casting machines

                                 Slab Caster

                                 Billet Caster

 

1.10 MTPA

1.10 MTPA

9

Rolling mills  :

               Hot strip mill

               Structurals/wire rods

 

1.00 MTPA

1.00 MTPA

10

Oxygen Plant

2x500 TPD

11

Calcining

1,080 TPD

12

Cement Plant

1.40 MTPA

13

Power Plant

230 MW

 

Following will be saleable products :

 

S.N.

Products

Capacity

1

HR Coil

1.00 MTPA

2

Structurals / wire rods

1.00 MTPA

3

Cement

1.40 MTPA

 

            Low grade iron ore (4.4 MTPA), Iron ore lumps / Pellets (0.4 MTPA), Lime stone (0.5 MTPA), Dolomite (0.35 MTPA), Quartzite (0.12 MTPA), Coking coal (0.92 MTPA), Non-coking coal (1.2 MTPA), Bentonite (0.008 MTPA) Clinker (0.7 MTPA) and Gypsum (0.04 MTPA) will be used as raw material. PAs informed that environment clearance for the captive mines (3.6 MTPA) has already been accorded and coal will be sourced from Indonesia.  Quantity of raw materials has been modified as Iron ore pellets (0.31 MTA), Non-coking coal (1.11 MTA), Limestone (0.53 MTA), Dolomite (0.34 MTA), Quartzite (0.13 MTA) and Clinker (0.73 MTA).  PAs informed to the Committee that coal will be sourced from Indonesia.

 

            PAs informed to the Committee that Low-grade iron ore will be beneficiated in beneficiation plant. The fine-grained concentrate will be agglomerated into pellets and used for making sinter for feeding the blast furnace.  Non-recovery type of the coke oven will be installed to produce coke from imported coking coal to supply coke to BF and Coke breeze to sinter plant.  Pellets will be used for the production of DRI in rotary kilns and DRI will be used for steel making in EAF.  EAF and BOF will be used for the production of hot metal.  Liquid steel will be cast into slabs or billets   in continuous casting machines and rolled into desired shape in the rolling mill to produce 1.0 MTPA hot rolled coils, 1.0 MTPA light structures/wire rods.  CPP will be installed to use heat in the off gases from DR kilns and coke oven.  Rolled products and cement will be final products. Solid waste (granulated slag from BF) will be utilized for cement manufacturing.  Clinker, gypsum and slag will be used to manufacture Portland slag cement.

 

            Ambient air quality monitoring was carried out at 10 location during winter season (December, 2006–February, 2007) and summer season (March–May 2007). PAs informed during presentation that value of SPM (102-172 µg/m3), RPM (38-68 µg/m3), SO2 (7-16 µg/m3) and NOx (10.0–28.0 µg/m3). The incremental SPM (61.37 µg/m3), RPM (21.46 µg/m3), SO2 (61.37 µg/m3) and NOX (41.63 µg/m3). Submitted data indicated average value of SPM (96.8-159.2 µg/m3), RPM (34.8-58.9 µg/m3), SO2 (6.2-12 µg/m3) and NOx (8.3–24.2 µg/m3) which are within the permissible limit. 98tile value of SPM (182 µg/m3), RPM (69 µg/m3), SO2 (16 µg/m3) and NOx (28 µg/m3). The submitted data indicated the incremental SPM (75.44 µg/m3), RPM (30.22 µg/m3), SO2 (56.4 µg/m3) and NOX (41.81 µg/m3).

 

            Electrostatic precipitator will be provided to sponge Iron plants, iron ore pelletising plant and power plant to clean process gas from the grate unit and cooler exhaust stacks or discharging clean gases to control dust emissions within 50 mg/Nm3. ESP will also be provided to sinter plant to control emissions within 50 mg/Nm3.  Dust extraction system at coal crushing unit, material transfer points etc. and dust extraction system with bag filters will be provided to DR plant, BF plant and coke plant to control dust emissions within 50 mg/Nm3.  Dust catcher and ventury scrubbers will provided to steel melting shop to clean BOF gas and Bag filters will be provided to clean EAF gases within 50 mg/Nm3. Energy recovery from top blast furnace (BF) gas will be done to reduce green house gases. Dust extraction system will be provided to the Iron ore beneficiation plant to collect the dust in ore handling points and then cleaned in wet scrubbers.   The exhaust gas from the process will be cleaned in ESPs.  The clean air will be let out into the atmosphere through stack.  The dust collected in bag filters and ESP will be recycled in the process. 

 

PAs informed during presentation that total water requirement from Tungabhadra river will be 100 MLD instead of 90 MLD (1,20,460 m3/hr) and also instead of earlier proposed from Tungbhadra Dam and ground water. Now, no ground water will be abstracted. ‘Permission’ for the drawl of 100 MLD from Tungbhadra Dam has been accorded by the Tungbhadra Board vide letter no. CI/312/SPI/2008 dated 21st October, 2008.  Each main production unit will have its plant, which will be provided with thickeners, both to concentrate slurry and tailings to recover water and reduce fresh water requirement.  The palletizing plant, DR plant, sinter plant, BF plant, steel making units and rolling mills have cooling towers in respective units to cool the water used for gas/equipment cooling before it is recycled. Thickeners will be provided to recover clear water from the tailings of the beneficiation plant. No effluent will be discharged outside the premises and ‘zero’ discharge will be adopted. Separate guard ponds for major production units will be designed with HDPE lining. Settling tanks and thickeners will be provided to recover clear water from tailings, continuous casting machines shop, rolling mills. Slime pond for tailing sludge. Sanitary waste generated from all sections of the steel plant will be collected from a closed drain and treated by fluidized aerobic biological treatment. The treated water will be utilized for green belt development.  Rainwater harvesting will be installed in the proposed plant.

Flue dust from ESP from pellet plant will be collected and recycled into the sintering plant. In sponge iron plant, sludge from dust settling chamber/wet scrubber, dust from de-dusting system, fines, char, fly ash  from heat exchanger and ESP will also be generated. In blast furnace, sinter BF return will be recycled back into sinter plant and BF slag will be sent for production of cement. In steel melting shops, slag will be sent for designed landfill, flue dust from bag filter will be sent for sinter plant. Mill scale will be returned to sinter plant. Scrap will be reused. In rolling mill, scrap will be reused. Scale & muck will be recycled in sinter plant, In coke oven plant, coke breeze will be recycled to coke oven and dust from filter bag will be utilized in cement manufacturing. Dust from ESP will be reused in cement plant. Fly ash and bottom ash will be generated from captive power plant. A copy of the MOU is submitted from M/s BMM Cements Ltd. indicating use of entire quantity of fly ash generated by the captive power plant (230 MW). Waste oil and lead acid batteries will be provided to registered recyclers / reprocessors.

 

PAs informed during presentation that green belt will be developed in 472 ha. out of total 1,429 ha. instead of  220 ha (33 %) out of total 660 ha proposed earlier. Total power requirement of the proposed plant will be 230 MW, which will be sourced from captive sources taking support of state electricity grid.  Coking coal (9,24,000 TPA) in coke oven and non-coking coal (1,189,000 TPA) in pellet plant, DR Plant, BF Plant, power plant and CPP will be used as fuel.

 

The Committee deliberated upon the issues raised during the Public Hearing/Public Consultation meeting conducted by the Karnataka Pollution Control Board on 17th September, 2009 and issues raised including pollution control, land acquisition, development works, employment generation, safety etc. have satisfactorily been incorporated in the final EIA/EMP report.

           

After detailed deliberations, the Committee found the final EIA/EMP report adequate and suggested to stipulate following specific conditions alongwith other environmental conditions while considering for accord of environmental clearance :

 

1.    All the recommendations of the Southern Western Railway, Hubli, Karnataka mentioned in the ‘No Objection’ for the construction of proposed steel plant vide letter no. H/W.280/II/NOC/DRG dated 28th January, 2008 should be strictly implemented and report submitted to the Ministry and its Regional Office at Bangalore.

 

2.    No land should be acquired next to Railway line. No part of the steel plant including cement plant or dump yard should be installed across the Railway line. Instead, vacant land should be used for the development of green belt. A commitment in this regard alongwith revised layout plan should be submitted to the Ministry’s Regional Office at Bangalore.

 

3.    Efforts should be made to reduce RSPM levels in the ambient air and a time bound action plan should be submitted. On line ambient air quality monitoring and continuous stack monitoring facilities for all the stacks should be provided and sufficient air pollution control devices viz. Electrostatic precipitator (ESP), gas cleaning plant, dust capture, ventury scrubber, bag filters etc. should be provided to keep the emission levels below 50 mg/Nm3 by installing energy efficient technology.  

 

  1. An action plan should be prepared and submitted to the Ministry’s Regional Office at Bangalore for the control of SO2 emissions from the captive power plant.

 

  1. All the standards prescribed for the coke oven plants should be followed as per the latest guidelines. Proper and full utilization of coke oven gases in power plant using heat recovery steam generators should be ensured and no flue gases should be discharged into the air.

 

  1. Only dry quenching method in the coke oven should be adopted and water requirement should be reduced accordingly.

 

  1. 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.

 

8.    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.

 

9.    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.

 

10.  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.

 

11.  Total water requirement from Tungabhadra dam should not exceed 95.3 MLD due to adoption of dry quenching in the coke oven plant and air cooled condensers although ‘permission’ from the State Govt is obtained for 100 MLD vide letter no. CI/312/SPI/2008 dated 21st October, 2008. As proposed, no ground water should be used. Air cooled condensers and closed circuit cooling system should be provided to further reduce water consumption and water requirement should be further reduced accordingly and should inform to the Ministry and its Regonal Office at Bangalore.

 

  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 Bangalore, KSPCB and CPCB.

 

14.  All the wastewater from the different plants should be treated in effluent treatment plant. All the treated wastewater should be monitored for pH, BOD, COD, oil & grease, cyanide, phenolic compounds, Chromium+6 etc. besides other relevant parameters.

 

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

 

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

 

17.  Coal and coke fines should be recycled and reused in the process.  Flue dust from ESPs, sinter BF return, mill scale & muck should be collected and recycled into the sintering plant. Scrap should be reused. Coke breeze should be recycled to coke oven.  All the bag filter dust, raw meal dust, coal dust, clinker dust and cement dust from pollution control devices of the cement plant should be recycled and reused in the process and used for cement manufacturing. Spent oil and batteries should be sold to authorized recyclers / reprocessors only. 

 

18.  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 blast furnace (BF) slag should be granulated. BF slag and dust from ESP, bag filters etc. should be provided to cement manufacturers for further utilization. SMS slag should also be properly utilized. Tailings from the beneficiation plant should be disposed off properly in the tailing dam only.  All the other solid waste including broken refractory mass should be properly disposed off in environment-friendly manner.

 

19.  All the 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. 

 

20.  Proper utilization of fly ash should be ensured as per Fly Ash Notification, 1999 and subsequent amendment in 2003 and 2010. All the fly ash from the captive power plant should be used maximum in making Pozollona Portland Cement (PPC) in the proposed cement plant.

 

21.  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, KSPCB and CPCB. 

 

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

 

23.  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, KSPCB and CPCB within 3 months of issue of environment clearance letter.

 

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

 

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

 

26.  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. RF (4 Km), Nandibanda RF (4 Km) and Sandur RF (4 Km) located within 10 km radius of the project. Further, Conservation Plan for the conservation of wild fauna in consultation with the State Forest Department should be prepared and implemented.

 

27.  All the commitments made to the public during the Public Hearing / Public Consultation meeting held on 17th September, 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.

 

28.  At least 5 % of the total cost of the project i.e. Rs. 310.00 Crores 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.

 

29.  Rehabilitation and Resettlement Plan for the project affected population including tibals as per the policy of the State Govt. in consultation with the State Govt. of Karnataka should be implemented. Compensation paid in any case should not be less than the norms prescribed under the National Resettlement and Rehabilitation Policy, 2007.

 

Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.8          Expansion of Sponge Iron Plant (30,000 TPA to 1,50,000 TPA), Ferro Alloy Plant (2x5 MVA, 16,041 TPA) and Captive Power Plant (WHRB & AFBC 12 MW) at Dejuri, Deucha, P.O. Unra, Jambedia, P.S. Barjora, District Bankura, West Bengal by M/s Sen Ferro Alloys Private Ltd. (TOR to 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 sponge iron plants with ³ 200 TPD capacity have been kept at S.N. 3(a) under Category ‘A’ and have to be appraised at the Central level.

 

Additionally, PAs informed to the Committee that M/s Sen Ferro Alloys Private Ltd. initially proposed for the expansion of Sponge Iron Plant (30,000 TPA to 1,50,000 TPA), Ferro Alloy Plant (2x5 MVA, 16,041 TPA) and Captive Power Plant (WHRB & AFBC, 12 MW) at Dejuri, Deucha, P.O. Unra, Jambedia, P.S. Barjora, District Bankura, West Bengal. However, during submission of EIA/EMP, it is informed that ferro alloy plant will be replaced by Induction Furnace (72,000 TPA). Perusal of the EIA/EMP report indicated that ferro alloy is also mentioned at several places which need to be clarified.  Capacity of the sponge iron plant is reduced from 250 TPD to 200 TPD.  AFBC is now proposed but capacity of the WHRB & AFBC has to be ascertained. Proposed expansion will be within the existing plant premises of 14.5 acres which is revised to 13.5 acres land in EIA/EMP report. Initially, it was mentioned that total land is 30 acres, of which 8 acres land is already purchased and 5.45 acres is leased from Govt. of West Bengal.  Vacant land of 13.5 acres in the existing premises will be used for proposed expansion project. A copy of ‘Consent to Operate‘ for existing sponge iron plant (50 TPD) accorded by West Bengal Pollution Control Board vide dated 22.02.2007 is submitted. No national Park/wild life sanctuary/reserve forest is located within 10 km radius of the project site. Beliator protected forest is around 1 km from the project site. Damodar river flows at a distance of 7 km from the project site. Durgapur town is 12 km way from the proposed site. Total cost of the proposed expansion is Rs. 9,354.43 Lakhs. Rs. 935.44 Lakhs and Rs. 74.84 Lakhs will be earmarked towards total capital cost and recurring cost/annum for environmental pollution control measures. Following will be manufactured :

 

S.

N.

Facility

Existing Capacity

Proposed Capacity

Total production after expansion

1

Sponge Iron Plant

30,000 MTPA

(1x50 TPD)

1,20,000 MTPA

(2x100 TPD)

1,50,000 MTPA

2

Ferro Alloy plant

 

 

Replaced by Induction Furnace

-

16,041 MTPA

(2x 5 MVA)

 

72,000 TPA

(2x15.0 TPA)

16,041 MTPA

 

 

72,000 TPA

3

Power Plant

AFBC                  

WHRB

-

 

12 MW

 

 

 

Raw materials required for Sponge Iron plant will be Iron ore (1,00,000 TPA), Non-coking coal (90,000 TPA) and Dolomite (1,000 TPA). Manganese ore lumps (1.6 TPA), Quartzite (0.3 TPA), Dolomite (0.2 TPA) will be used in the Ferro alloy plant. ??

 

Crushed Iron ore and coal alongwith limestone will be charged into the Rotary Kiln. Iron ore will be preheated and reduced in the Rotary Kiln and then passes to a Rotary cooler where it is cooled.  The cooled material will then be fed to product separation system where residual char, ash and spent limestone waste products will be magnetically removed from Sponge iron. Waste gas from Sponge Iron plant will be used for power generation using WHRB as well as AFBC.

 

Ferro alloy production will involve melting and reduction of Manganese ore with coal/coke in a submersible arc furnace (SAF). The molten alloy will be poured into a mould with the help of a ladle and cooled. Silico-Manganese manufacture will involve simultaneous reduction of Manganese and Silicon at 1500oC from Manganese silicates, slag, ore and quartzite. Basic raw materials mixed with suitable reducers and fluxes are charged into the SAF.  On reaching a temperature of 500C various chemical reactions starts and smelted Ferro-Manganese and slag at about 14000C are collected at the bottom of furnace. Molten alloy and slag will be periodically tapped. The slag and metal will be cast separately in cake form and transferred to metal and slag yard for separating, sizing and packing for dispatching them to the customer.

 

Scrap will be melted in an Induction furnace at 1650oC. When the total charge is melted into hot liquid metal then the metallurgy of steel in terms of carbon, phosphorus content, alloy elements etc will be controlled at this stage. Based upon the composition of molten steel, additives will be added to get the requisite composition and grade of steel. For production of ingots the molten material will be poured into the moulds to produce ingots. 

 

PAs informed to the Commttee that ambient air quality data collected at 8 locations during the period February, 2009–March, 2009 indicated average value of SPM (187.56-339 µg/m3), RPM (60-109.56 µg/m3), SO2 (9-14.25 µg/m3) and NOx (33.31-49.81 µg/m3). 98tile value of SPM (391.9 µg/m3), RPM (131.93 µg/m3), SO2 (17.4 µg/m3) and NOx (53.4 µg/m3).  The submitted data indicated the incremental PM (14.65 µg/m3), SO2 (7.429µg/m3) and NOX (2.55 µg/m3) which are within permissible limit except RPM. However, increment value for RPM is not estimated.

 

In the existing plant, bag filters are installed at coal crusher, Cooler discharge tunnel, Product house & Stock house. Emissions from sponge Iron will be prevented by installation of ESP, bag filters/water cooled heat exchanger/spark arrester/ID fan connected to stack of adequate height. Hot gases from sponge Iron kiln will be successively passed through Dust Settling Chamber (DSC), After Burning Chamber (ABC) and then cleaned in ESP before being let off to the atmosphere through the chimney. Fume extraction system with bag filters will be provided to ferro alloy plant. Dust suppression will be carried out by sprinkling water on the raw material stockpiles etc. Dust extraction system comprising of bag filters, hood and stack of adequate height will be provided at material transfer points to control fugitive emissions. ESP will be installed between WHRB and stack to control dust emissions below 100 mg/Nm3.

 

In EIA/EMP, PAs have mentioned that fugitive dust emissions due to iron ore fines, coal fines and dolomites fines from the stock pile of raw materials and fines dump in the open area will be controlled by dust suppression (DS) system by water sprinkling and also dry fog suppression system.  Dust particulate load in Direct Reduction Unit will be brought down by the ECS to meet the permissible limit of 50 mg/m3 and clean gas will be discharged into atmosphere through 35 m high stack. ESP and RCC stack of 50 m height will be provided in the captive power plant (WHRB and AFBC) to meet the limit of 50 mg/m3. Bag filter will be provided in the product house, raw material handling area, cooler discharge, induction furnace, ferro alloy & SAF. 

 

Total water requirement from Damodar River will be 250 KLD and have applied for the permission for drawing the water to SWID & WBPHED.  No industrial effluent will be discharged and ‘zero’ discharge will be adopted. Domestic effluent will be discharged through soak pit, septic tank to Panchayat drain.  Waste effluents generated from demineralization plant will be sent to neutralization pit.  Rain water harvesting is proposed.

 

Char generated from sponge Iron plant will be used in Power Plant. Ferro-Manganese slag will be used in the manufacture of Silico-Manganese. Silico-Manganese slag will be used for land filling, road construction and local industrial area. Sludge from raw water treatment will be used as manure. Bed ash in slurry form will be collected in ash dyke.

 

Green belt will be developed in 3.3 acres (33.0%). Noise will be controlled by providing acoustic enclosures for DG sets and other noise generating equipments. Power requirement will be met from the proposed Captive Power Plant (12MW). 1x125 KVA and 1x250 KVA of DG sets for existing plant and 2 Nos. of  DG sets for proposed expansion project will be used for power back up. Fuel oil (LDO, 1.5 KLD) will be required for kiln start-up and intermittent firing. 

           

      After detailed deliberations, the Expert Appraisal Committee (Industry) deliberated upon the issues raised during the Public Hearing/Public Consultation meeting conducted by the West Bengal Pollution Control Board on 23rd November, 2009 like impact of water pollution, impact of air pollution on public health, plantation, medical facilities, environmental compliance, monitoring etc. have satisfactorily been incorporated in the final EIA/EMP report.  However, the Committee found the EIA/EMP report incomplete and inadequate and asked PAs to revise the Form I, Prefeasibility Report and EIA/EMP report incorporating the following :

 

1.   Ferro alloy plant (16,041 MTPA, 2x 5 MVA) is proposed in the EIA/EMP report which is to be replaced by Induction Furnace (72,000 TPA). However, it is observed in the EIA/EMP report that ferro alloy is mentioned at several places which needs to be corrected.  Accordinly, configuration in the table needs to be changed.

2.    No AFBC plant is proposed for the utilization of char generated from the sponge iron plant. Only WHRB is proposed to make use of gases from the DRI plant. Commitment that WHRB & AFBC of adequate capacity will be installed. Total power to be generated from AFBC and WHRB in MW should be submitted.

1.    Actual source of the water, reassessment of the water requirement and permission for the drawl of water.

2.    Hydrology study of the area.

3.    Action plan for the green belt development in 33 % area.

4.    Action plan and item-wise details alongwith time frame for allocating and using 5 % of the total cost of the project towards implementing corporate social responsibility.  Socio-economic development activities need to be elaborated upon.

5.    Allocation of seperate budget for implementing the issues raised during the public hearing.

 

The information incorporated in the final EIA/EMP report will be discussed in the EAC(I) meeting as soon as submitted by calling PAs. The proposal is differed till then.

 

Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.9          Ferro Alloy Plant (3x9 MVA) at Sy. No. 31-1, 2, 3, 32-1A, 2B, 37-2, 38-1, 2 & 48-1 Village Gollapuram, Mandal Hindupuram, District Anantapuram, Andhra Pradesh by M/s Oswal Smelters Private Limited (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 87th Meeting of the Expert Appraisal Committee (Industry) held during 25th-26th November, 2008 for preparation of EIA/EMP.  All the Ferro Alloy Plants are kept under Primary Metallurgy Industry in Category ‘A’ and appraised at the Central level. 

 

               Additionally, PAs informed to the Committee that M/s Oswal Smelters Private Limited has proposed to set up a Ferro Alloy Plant at Survey No. 31-1, 2, 3, 32-1A, 2B, 37-2, 38-1,2 & 48-1, Village Gollapuram, Mandal Hindupuram, District Anantapuram, A. P.  Total land acquired for the proposed plant is 29.82 acres. No national park and wild life sanctuary is located within 10 km radius of the project site. Narsimhapur Reserve Forest is located at 8.5 km but during presentation, PAs informed that it is located at 13.5 km. Inter-state border is at a distance of 6 km from the proposed site. Ramachandrapuram is located at distance of 9 km from the proposed site. Gollapuram Guddampalli, Melya, Jogireddipalli villages are located near the project site.  Total cost of the project is Rs. 56.03 Crores. Rs. 3.00 Crores and Rs. 0.72 Crores instead of Rs. 4.50 Crores and Rs. 2.10 Crores earlier proposed will be earmarked towards total capital cost and recurring cost/annum for environmental pollution control measures. Following are the details of facilities and products from the proposed plant:

           

S.N

Facility

Plant configuration

Products and production capacities

1

Submerged arc furnace

3x9 MVA

Ferro Silicon -           19,000 MTPA (or)

Silico Manganese -   42,750 MTPA (or)

Ferro Manganese -   55,000 MTPA (or)

Ferro Chrome -               42,750 MTPA

 

Ferro alloys production will be direct reduction of respective metal ores with the help of Carbon as reducing agent and electricity as heat source. Ferro alloys will be smelted at about 1350oC-1500oC in a conventional, open Submerged Electric Arc Furnace (SEAF).   

 

            Manganese ore, Chrome ore, quartz, Manganese slag, pet coke, reductants and electrode paste, casing sheet, M.S. round, lancing pipe, Oxygen will be the raw materials required. The product will be selected as per the market demand. Therefore, total production quantities will vary depending upon product in process.

           

            PAs informed to the Commttee that ambient air quality monitoring has been carried out at 9 locations during the period March, 2008 to May, 2008 and the data submitted indicated SPM (78.4-99.6 µg/m3), RPM (23.6-30.1 µg/m3), SO2 (6.7-9.6 µg/m3) and NOx (8.1-10.8 µg/m3) and are within the permissible limit. Prediction of Ground Level Concentrations (GLC’s) due to proposed project has been made by Industrial Source Complex, Short Term (ISCST3) as per CPCB guidelines and the data submitted an indicated an incremental SPM of 1.2 µg/m3 from 99.6 µg/m3 to 100.8 µg/m3 which are well within the NAAQS norm.  Similarly, incremental PM10 is 1.2 µg/m3 (30.1 µg/m3 to 31.3 µg/m3) and incremental SO2 and NOx emissions are 1.9 µg/m3 (9.6 µg/m3 to 11.5 µg/m3) and 1.6 µg/m3 (10.8 µg/m3 to 12.4 µg/m3) respectively.

 

Fume extraction system with bag filters will be provided to control the primary and secondary emissions from submerged arc furnaces and will be discharged through stack of 30 m height to control outlet dust emissions within 100 mg/Nm3 but committee asked to achieve 50 mg/Nm3. Dust suppression system will be provided at unloading areas to prevent the fugitive dust emissions. Dust during material handling will be controlled by water spraying. Dust curtains will be provided all around the work area to prevent the dust emission during construction. Water spraying will be done to prevent the dust emission due to vehicular movement. 

 

Total ground water requirement is 94 m3/day and application seeking permission for the drawing water has been submitted to State Ground Water Department. Closed circuit cooling system will be adopted. No wastewater will be generated from process and cooling as closed circuit cooling system will be adopted. Sanitary wastewater will be treated in Septic tank followed by soak pit. PAs informed during presentation that rain water harvesting will be constructed.

 

Silico-Manganese slag will be used for road construction. Ferro-Manganese slag will be used in the manufacture of Silico-Manganese. Ferro-Silicon slag will be used in cast iron foundries. PAs informed during presentation that Ferro-Chrome slag will be processed for Chrome recovery in the Ferro Chrome recovery plant and Chromium will be recovered by crushing, screening, coarse and fine jigging. TCLP test will be performed and then slag will be disposed in a secured land fill.

 

Extensive green belt will be developed in 10 acres out of total 29 acres within the plant premises.  Noise will be controlled within permissible limits as per OSHA/MOEF guidelines. Ear plugs will be provided to workers who work near noise generating equipment.  Power requirement of 8000 KVA for the 1st Unit will be supplied by A.P. Transco.  DG set (250 KVA) will be installed to meet the power requirement in case of emergency.

           

The Committee deliberated upon the issues raised during the Public Hearing / Public Consultation meeting conducted by the Andhra Pradesh Pollution Control Board on 12th August, 2009 have satisfactorily been incorporated in the final EIA/EMP report and  the issues raised include employment, pollution control measures, socio-economic development activities like road development, temple development etc.  

           

            After detailed deliberations, the Committee found the final EIA/EMP report adequate and suggested to stipulate following specific conditions alongwith other environmental conditions while considering for accord of environmental clearance :

 

  1. Continuous monitoring facilities for all the stacks and sufficient air pollution control equipments viz. fume extraction system with bag filters, I D fan and stack of adequate height to submerged arc furnace to control emissions below 50 mg/Nm3. Monitoring of total Chromium (Cr) and Carbon monoxide (CO) should also be ensured.  Standards for Nickel (Ni), Chromium (Cr) and Lead (Pb) should be within permissible limit.

 

  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 94 m3/day ground water from the State Ground Water Board/Central Ground Water Authority should be obtained. Closed circuit cooling system should be adopted to recycle/reuse water to reduce water consumption.

 

  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.

 

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

 

  1. Chrome recovery plant should be installed to recover Chromium through jizzing process.  Discharge from metal recovery plant should be monitored for the Chromium content and maintained within the permissible limit before recycling and reuse. Slag tailing should be dumped in own premises in secured land fill as per CPCB guidelines after recovery of the metal. Used oils/lubricants should be sold to authorized recyclers / reprocessors.     

 

  1. Slag produced in Ferro-Manganese (Fe-Mn) production should be used in manufacture Silico-Manganese (Si-Mn). As proposed, Ferro-Silicon slag should be provided to cast iron foundries for further utilization.

 

  1. Chromate slag should be used for road making only after passing through Toxic Chemical Leachability Potential (TCLP) test. Otherwise, Ferro chrome should be recovered from the slag and output waste should be disposed in secured landfill as per CPCB guidelines.

 

  1. Product fines, flue dust should not be dumped anywhere but reused in the process. SAF slag should not be dumped but efforts should be made to reuse in environment-friendly manner.

 

  1. 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, APPCB and CPCB.

 

  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 chrome units should be strictly implemented. 

 

  1. 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. Narsimhapur RF located within 15 km from the project site. Further, Conservation Plan for the conservation of wild fauna in consultation with the State Forest Department should be prepared and implemented.

 

  1. All the commitments made to the public during the Public Hearing/Public Consultation meeting held on 12th 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.

 

  1. At least 5 % of the total cost of the project (Rs. 2.80 Crores) 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.

 

Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.10       Alumina Refinery Complex (0.7 MTPA) alongwith Co-generation  Power Plant (30 MW) at Village Rambu, Talaanchalbadi, Baraja, Raikona, Lekhpai, Mandaput, Deulaguma, Sariguma, Balapai, Kaskadango, Dumapai, Lamberi  Tehsil & District Rayagada, Orissa by M/s RSB Metaltech 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 Alumina Refinery Plants are listed at S.N. 3(a) Primary Metallurgical Industries under Category ‘A’ and appraised at the Centre level.

     

M/s RSB Metaltech Pvt. Ltd have proposed for setting up of Alumina Refinery Complex (0.7 MTPA) alongwith Co-generation Power Plant (30 MW) at Village Rambu, Talaanchalbadi, Baraja, Raikona, Lekhpai, Mandaput, Deulaguma, Sariguma, Balapai, Kaskadango, Dumapai, Lamberi  Tehsil & District Rayagada, Orissa. Total land requirement of the project will be 1516.6 Acres. PAs have submitted a copy of MoU signed with Govt. of Orissa on 19th December, 2009 for setting up of Alumina Refinery Complex (0.7 MTPA) alongwith Co-generation  Power Plant (30 MW).  Orissa Industrial Infrastructure Development Corporation (IDCO) is the nodal agency for procuring land for the project. IPICOL has recommended for acquiring 3062.90 acre (1516.60 acre = 99.92 acre forest land; 794.33 acre leasable; 97.99 gochar; 524.36 private land) for Alumina refinery at Raigarh in favour of M/s RSB Metaltech Pvt. Ltd. vide lketter dated 24th September, 2009. PAs have deposited Rs. 2,04,66.800 to IDCO vide letter dated 25th November, 2009 and land acquisition is under process. PAs also confirmed that 76.5 acre private land from the private owners is already purchased and details of Mauza, Khata and Plot Nos. alongwith agreements signed are submitted.  Total project cost is Rs. 3,160.81 Crores. Rs. 277.29 Crores and Rs. 4.72 Crores are the capital and recurring cost towards environment and protection measures. PAs informed during presentation, Rs. 299.79 Crores and Rs. 5.64 Crores are earmarked towards capital and recurring cost/annum for environmental protection measures. Following are the details of proposed production capacity & facilities to be created:

S. N.

Units

Production Capacity

1

Alumina Smelter

0.7 Million TPA

2

Co-generation plant

30 MW

3

To lay a conveyor of 12 km long to bring the bauxite from mine to the plant

4

To lay a pipeline of 18 Km to meet the water requirement.

5

To lay railway line of about 5 km for coal & alumina transport.

5

To set up a full fledged township to provide the residential facility to its employees.

 

Bauxite (21,00,000 MTA), caustic soda (35,000 MTA), lime (21,000 MTA), fuel oil (56,000 KLPA), coal (3,85,000 MTA), synthetic flocculant (196 MTA) and CGM (154 MTA) will be used as raw materials. 

ESP will be installed to control air emissions. 150 m high stack will be provided in co-generation plant. 120 m high stack will be provided in Calciner. Bag filters will be used at transfer point. Dust suppression will be by dry fog/water sprinkler.

Water requirement from River Sankhesu will be 12,252 m3/day. Wastewater will be generated from various units including nitric acid stream, Sulphuric acid stream, cooling blow downstream, oil storage area stream, sanitary waste stream and miscellaneous stream. Effluent treatment plant (ETP) will be installed for treatment of trade effluent. Neutralization pond will be created for DM plant effluent and cooling tower/boiler blow down. Sewage treatment plant (STP) will be installed for treatment of domestic sewage.  Treated effluents will be recycled for dust suppression & for use in ash slurry making. Plant will be designed for ‘zero’ discharge. High mud density technology will be used for minimizing washwater usage. Acidic effluent (from cleaning) will be sent to red mud pond for self neutralization. Excess water will be drained to mud storage area and reused in plant.  

Solid waste will be generated as thickened slurry from mud disposal area, coal ash slurry from steam plant and lime grit from lime slacker. Red mud will be disposed of by thickened slurry disposal system to a disposal area. The coal ash generated in the co-generation plant will be used for various construction purposes and unutilized ash will be disposed off to ash disposal area. Other solid waste such as lime grit and solid residue from effluent treatment facility will be utilized for preparing dykes in the red mud disposal area. New HRD/DCW technology giving high density mud for reduced load for mud storage will be adopted. Pressure digestion for high extraction efficiency method will be adopted to reduce mud generation. Thickened slurry disposal (61%) of red mud storage will lead to less land usage.  The coal earmarked for co-generation plant is mainly of grade “F”, which has about 40-45 % ash content.

Green belt will be developed in 33% area. Enclosures will be provided at blowers/compressors and noise prone equipments to reduce noise transmission. Silencer will be provided in noise generating machines to control noise pollution. Ear muff/plugs will be provided for employees.

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

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

2.        Actual land requirement, classification of land, acquisition status, item-wise break up of land requirement and its availability to be furnished. Land requirement for the project to be optimized.

3.        Permission from the tribals, if tribal land has also to be acquired alongwith details of the compensation plan.

4.        Rehabilitation and resettlement as per the policy of the Govt. of Orissa should be incorporated. Detailed R & R plan shall be prepared taking into account the socio-economic status of the area, homestead oustees, land oustees, landless laboureres.

5.        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.

6.        Permission and recommendations of the State Forest Department regarding impact of proposed expansion on the surrounding 8 reserve and 4 protected forests, if any, located within 10 km radius of the project site should be included.

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

8.        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. A photograph of the site should also be included.

9.        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.

10.      Location of any National Park, Wildlife Sanctuary, Elephant / Tiger Reserve (existing as well as proposed), Migratory routes, if any, within 10 km of the project site should specifically be mentioned and marked on the map duly authenticated by the Chief Wildlife Warden.

11.      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.

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

13.      Residential colony should be located in upwind direction.

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

15.      Status of environment clearance of the mine from where bauxite ore will be sourced. A copy of environment clearance should be included.

16.      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..

17.      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.

18.      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.

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

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

21.      A note on comparison of various technology available for the manufacturing Aluminium and adoption of best technology available. Manufacturing process details for Aluminium Refinery and Captive Power Plant should be included.

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

23.      Energy balance data for all the components of Aluminium refinery including proposed power plant should be incorporated.

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

25.    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.

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 Aluminium refinery including proposed power 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 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.

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. Incorporation of water harvesting plan for the project is necessary, if source of water is bore well.

41.      Permission for the drawl of 12,252 m3/day from River Sankhesu 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.

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 all the solid/hazardous waste including red mud, fly ash etc. should be included. 

53.      Details of evacuation of ash, details regarding ash pond impermeability and details of the lining etc. needs to be addressed.

54.      Generation and utilization of red mud have to be set out. Red mud pond should be as per the CPCB Guidelines with garland drains with at least 10 years capacity. Details for land availability, structure of pond, lining as per CPCB guidelines should be included. Possibility for re-utilization of red mud should also be explored and an action plan included.

55.      Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase.

56.      All stock piles will have to be on top of a stable liner to avoid leaching of materials to ground water. Details of secured land fill as per CPCB guidelines should also be included.

57.      Coordinates of the plant site as well as red and ash pond with topo sheet should be included.

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 traveling 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.  In case of any scheduled fauna, conservation plan should be provided.

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 and action plan for protecting the workers against hazardous chemicals such as Sulphuric acid, pesticides, solvents etc. should be included

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 should be included.

64.      Socio-economic development activities need to be elaborated upon. Measures of socio economic influence to the local community proposed to be provided by project proponent. As far as possible, quantitative dimension should be given. Socio-economic development activities need to be elaborated upon.

65.      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.

66.      Impact of the project on local infrastructure of the area such as road network and whether any additional infrastructure would need to be constructed and the agency responsible for the same with time frame. 

67.      An Action Plan for the implementation of the recommendations made for the Alumina Refinery and Captive Power Plant in the CREP guidelines must be prepared.

68.      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. 

69.     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.

 

            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 Orissa State Pollution Control Board (OSPCB) 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.

 

Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.11       Integrated Aluminium Complex (Aluminium Smelter, 0.175 MTPA) and Captive Power Plant (4x120 MW) at Village Markata, Kadua, Mahupal, Bhagirathpur Sajan, Samatangi, Manjakana, Malapura, Balabhadrapurpatna, Analabareni, Tehsil Kamakhyanagar District Dhenkanal, Orissa by M/s RSB Metaltech 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 Alumina Smelters are listed at S.N. 3(a) Primary Metallurgical Industries under Category ‘A’ and appraised at the Centre level.

 

M/s RSB Metaltech Pvt. Ltd have proposed Integrated Aluminium Complex (Aluminium Smelter, 0.175 MTPA) and Captive Power Plant (4x120 MW) at Village Markata, Kadua, Mahupal, Bhagirathpur Sajan, Samatangi, Manjakana, Malapura, Balabhadrapurpatna, Analabareni, Tehsil Kamakhyanagar District Dhenkanal, Orissa. Total land requirement of the project will be 1546.3 acres. PAs vide their letter dated 1st April, 2010 have informed that 47.970 acre private land from the private persons is already purchased. Details of Mauza, Khata and Plot Nos. alongwith agreements signed are submitted. PAs have also submitted a copy of MoU signed with Govt. of Orissa on 19th December, 2009 for setting up of Alumina Smelter.  Orissa Industrial Infrastructure Development Corporation (IDCO) is the nodal agency for procuring land for the project.  IPICOL has recommended for acquiring 1546.30 acre for smelter and CPP at Dhankanal in favour of M/s RSB Metaltech Pvt. Ltd. PAs have deposited Rs. 1,05,47,900 to IDCO vide letter dated 23rd November, 2009.  Out of total 1546.3 acres, 427.62 acre is the forest land and IDCO has requested PAs to submit FDP for the forest land vide letter dated 2nd February, 2010.  Land acquisition at Dhenkanal is still under progress. Nearest village is Biladihi (0.3 Km). Nearest town is Kamakhyanagar (5.6 Km). 13 Reserve forests are located within 10 kms. Project site falls under seismic zone–II. No protected area/national parks/ sanctuaries are located within 15 km. Total project cost is Rs. 6180.98 Crores. Rs. 355.5 Crores and Rs. 8.89 Crores are the capital and recurring cost towards environment and protection measures. PAs informed during presentation, Rs. 477.5 Crores and Rs. 10.77 Crores are the capital and recurring cost towards environment and protection measures. Following are the details of proposed production capacity & facilities to be created:

S. N.

Units

Production Capacity

1

Aluminium Smelter

0.175 Million TPA

2

CPP

4x120 MW

3

Rail link of about 5 km length to plant site from proposed Kamakhyanagar

4

To lay a pipeline of 18 Km to meet the water requirement.

5

To set up a full fledged township to provide the residential facility to its employees.

 

C.P. Coke (62,000 TPA), Alumina (336,000 TPA), Pitch (11,000 TPA), Aluminium Fluoride (3,000 TPA), Fuel Oil (8750 KLA), LDO (1750 KLA) will be used as raw materials. Coal (27,60,000 TPA), Fuel oil (21,900 KLA) will be used as raw materials for CPP.

State of the art Pre-braked Technology from GAMI, China will be used. 

PAs wanted to present ambient air quality data and incorporate in the EIA/EMP but committee didn’t agree for incorporation in the EIA/EMP since no ‘TORs’ have been issued by the Ministry so far.  ESP will be installed as pollution control device. Highly efficient bag filters will be used in FTP and GTC to remove suspended particulates below 100 mg/m3 but committee insisted for 50 mg/m3. Particulate matter emissions from anode brake oven will be controlled below 50 mg/m3 as per CREP guidelines. Twin flue stack (220 m high) to captive power plant and 50 m high stack will be provided to bake oven. Stack (80 m.) will be provided in gas treatment centre. Truck mounted heavy suction arrangement will be provided for dust extraction system. Hooded cells will be used to reduce fugitive emissions. Advance dry scrubbing system will be used in FTP. Computerized fire control system will be provided in baking furnace. Fluoride emissions will be kept below 0.8 kg/ton of Aluminium production. Hyper Dense phase system will be provided for dust free transfer for Alumina.  Raw material handling section will be provided with dust suppression (DS)dust extraction (DE) systems.

Total ground water requirement from bore wells and River Brahmani will be 15 m3/hr and 3,280 m3/hr. respectively. PAs conveyed that permission for the drawl of ground water is obtained vide letter dated 25th & 30th June, 2009. Full fledge water treatment plant with adequate sludge removing arrangement will be installed. Effluent treatment plant will be installed for the treatment of trade effluent. Neutralization pond will be created for DM plant effluent and cooling tower/boiler blow down. Sewage treatment plant will be installed for treatment of domestic sewage. Plant will be operated on ‘zero’ discharge. Separate storm water drains and rainwater harvesting facilities will be provided. Storm water during rainy season will be collected in guard pond and will be monitored for fluoride level and if required will be treated for fluoride removal through de-fluorination unit.  Oil and Grease removal will be provided.

Fly ash (8,28,550 TPA) / bottom ash (1,56,950 TPA) will be collected in dry form. For emergency storage, the ash will be disposed of using high concentration slurry disposal (HCD) system in an earmarked area of 118.608 acres. Spent Pot lines (2,900 TPA) and Dross (700 TPA) from cast house will be generated as solid waste from smelter. Spent pot lining material shall be stored properly as per standard practice till suitable disposal. Sludge of WTP (250 TPA) and STP (20 TPA) will be used as manure for green belt development. Sludge from FTP will be sent to secured landfill. Piezo-wells around the SPL storage to monitor the ground water quality.  Anode butts will be recycled in anode plant. Used batteries will be returned to suppliers. Used oil will be sold only to authorized recyclers. Alumunium dross will be sold to authorized secondary metal processing units.

Green belt will be developed in 33% area. Enclosures will be provided at blowers/compressors and noise prone equipments to reduce noise transmission. Silencer will be provided in noise generating machines to control noise pollution. Ear muff/plugs will be provided for employees.

            After detailed deliberation and considering the above aspects, the Expert Appraisal Committee (Industry) recommended the proposal for the preparation of EIA/EMP as per the following TORs :

 

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

2.      Approval for the use of 427.62 acre forest land and recommendations of the State Forest Department regarding impact of proposed expansion on the surrounding 13 reserve forests, if applicable, should be included.

3.      The earlier questionnaire for industry sectors should be submitted while submitting EIA/EMP.

4.      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.

5.     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.

6.      Details and classification of total land (identified and acquired) should be included. Details of land required, acquired and the ownership of the land.

7.      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.

8.      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.

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

17.    Manufacturing process details for the Aluminium Smelter Plant including Captive Power Plant should be included. A chapter on the best available technology available alongwith the reasons for the selection of the same may be included.

18.    Reasons for proposing Captive Power Plant (480 MW) when actual power requirement is 360 MW only.

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

20.    Energy balance data for all the components of Aluminium Smelter Plant including proposed 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.    Air quality modelling for Aluminium Smelter and Power Plant for specific pollutants like PAH and Fluoride and location of one ambient air quality monitoring station in downwind direction is necessary. Stack emissions from all the sources should be within 50 mg/Nm3.

23.    A detailed note on impact of Fluoride emissions on surrounding environment including flora and fauna and Fluoride balance alngwith the mitigation measures proposed.

24.    Impact of SO2 emissions on surrounding environment and Sulphur balance is needed.

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.    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) Above points 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.  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 lke proposed preventive methods, control and monitoring etc. 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.  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.

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

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

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

39.  Permission for the drawl of 3,280 m3/hr water from River Brahmani 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 be included.

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

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 washed/beneficiated plants/washery.

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 disposal/utilization of spent pot lining and fly ash as per Fly Ash Notification should be included. Copies of MOU regarding utilization of ash should also be included.

51.  Action Plan for the linkages/agreements with time frame for disposal of fly ash, spent

a.    pot line etc. should be included.

52.  Details and design of secured land fill as per CPCB guidelines should be incorporated.

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.

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

55.  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.

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

57.  Impact of the project on local infrastructure of the area such as road network and whether any additional infrastructure would need to be constructed and the agency responsible for the same with time frame.

58.  Risk assessment and damage control needs to be addressed alongwith action plan.

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

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

63.  Total capital cost and recurring cost/annum for environmental pollution control measures.

64.  Socio-economic development activities need to be elaborated upon. Measures of socio economic influence to the local community proposed to be provided by project proponent. As far as possible, quantitative dimension should be given. Socio-economic development activities need to be elaborated upon.

65.  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.

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

67.  Detailed Environment management Plan (EMP) with specific reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure should be provided.

68.  EMP should include the concept of waste-minimisation, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.

69.  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. 

70.  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.

 

The Committee after detailed discussion decided that after incorporating above mentioned TORs in the EIA/EMP report may be submitted by the PAs to the Orissa Pollution Control Board (OPCB) for conducting public consultation / public hearing as per EIA Notification, 2006. A letter should be written to the OPCB to conduct public hearing/consultation within stipulated time frame. After incorporating the issues raised in the public hearing meeting in the EIA/EMP report, the company should submit the final EIA/EMP report and other requisite documents for obtaining environmental clearance from the Ministry.

Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.12       Expansion of Steel Complex by installing DRI Plant (3x500 TPD, 0.45 MTPA), Iron Ore Beneficiation Plant (0.6 TPA) and Captive Power Plant (50 MW; 30 MW WHRB and 20 MW CFBC) at Plot No. G1, Mangalpur Industrial Area, Village Mangalpur, P.O. Baktarnagar, P.S. Raniganj, District Burdwan, West Bengal by M/s Jai Balaji Industries 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 Steel Plants are listed at S.N. 3(a) under Primary Metallurgical Industries under Category ‘A’ and appraised at the Central level.

 

           M/s Jai Balaji Industries Limited have proposed for the expansion of Steel Complex by installing DRI Plant (3x500 TPD, 0.45 MTPA), Iron Ore Beneficiation Plant (0.6 TPA) and Captive Power Plant (50 MW; 30 MW WHRB and 20 MW CFBC) at Plot No. G1, Mangalpur Industrial Area, Village Mangalpur, P.O. Baktarnagar, P.S. Raniganj, District Burdwan, West Bengal. PAs have confirmed that proposed plant is located at 22 km. from the Durgapur critically polluted area and is not covered under CEPI dated 13th January, 2010. PAs vide e-mail dated 24th March, 2010 informed that capacity of Iron Ore Beneficiation Plant will now be 0.6 MTPA instead of 1.0 MTPA.   Total project area earlier proposed as 194.12 acres is reduced to 121.62 acres out of which 92.91 acre is already acquired and 10.21 acres land is yet to be acquired from Asansol Durgapur Development Authority (ADDA).  Damodar and Ajay River is at 5 km and 14.5 km respectively. Several school and colleges are located within 10 km radius.  Proposed plant will be closer to Raniganj coal field. No reserve / protected forest / wildlife sanctuary is located within 10 km area. Total cost of the project is Rs. 397.00 Crores. Rs. 40.00 Crores and Rs. 4.00 Crores are earmarked towards capital cost and recurring cost for environmental protection measures. Project site falls under seismic zone II.  No litigation is pending against the project. Following are the details of the existing and proposed facilities and products to be manufactured:

 

S.

N.

Facilities

Existing

Capacity

Project Under

Construction

Proposed

Capacity

Ultimate

Capacity

1.

DRI Plant

1,05,000 TPA

(7x50 TPD)

-

4,50,000 TPA

(3x500 TPD)

5,55,000 TPA

2.

Coal Washery

1,08,000 TPA

1,08,000 TPA

-

2,16,000 TPA

3.

Iron Ore Beneficiation Plant

-

-

 

0.60 MTPA

4.

Iron Ore Pellet Plant

 

6,00,000 TPA

-

6,00,000 TPA

5.

Steel Melt Shop (4x15 T Induction Furnace)

-

2,37,600 TPA

-

2,37,600 TPA

 

6.

Ferro Alloys

30,156 TPA

(2x7 MVA SAF)

 

-

-

30,156 TPA

 

7.

Captive Power Plant

18.3 MW

-

50 MW

(30 MW WHRB + 20 MW CFBC)

68.3 MW

 

During presentation, PAs have informed following will be installed:

 

S.

N.

Facilities

Existing

Capacity

Project Under

Construction

Proposed

Capacity

Ultimate

Capacity

1.

DRI Plant

0.105MTPA

(7x50 TPD)

-

0.45 MTPA

(3x500 TPD)

0.555 MTPA

2.

Coal Washery

0.108M MTPA

0.108 MTPA

-

0.216 MTPA

3.

Iron Ore Beneficiation Plant

-

-

0.60 MTPA

0.60 MTPA

4.

Iron Ore Pellet Plant

 

0.60 MTPA

 

0.60 MTPA

5.

Steel Melt Shop (4x15 T Induction Furnace)

-

0.198 MTPA

 

0.198 MTA

6.

Ferro Alloys

 0.02952 MTPA

-

 

0.02952 MTPA

7.

Captive Power Plant

18.3 MW

-

50 MW

(30 MW WHRB + 20 MW CFBC)

68.3 MW

 

            Iron ore pellets/lump ( 6,75,000 TPA), non-coking coal (5,40,000 TPA), dolomite (7,000 TPA) will be used as raw materials in DRI plant. Iron ore fines (9,25,000 TPA) will be used raw material in iron beneficiation plant. Coal washery middlings (84,000 TPA), dolochar (1,89,000 TPA) and coal fines (12,107 TPA) will be used as raw material in captive power plant. 

           

Sponge iron will be manufactured in DRI kiln. The sponge iron and char will be separated as metallic and non-metallic material. Iron ore will be beneficiated from low grade iron ore fines -10 mm to +65% iron in iron ore beneficiation plant suitable for the production of pellets and will be transported to pellet plant. Wet high intensity magnetic separation (WHISMS)/High gradient magnetic separation (HGMS) unit, hydro-cyclone, thickener for tails, thickener for concentrate, process water storage tank will be installed. CPP (WHRB) will be based on flue gases from DRI and CFBC based on coal washing rejects, dolochar/char and coal.

            Hot gases from DRI plant will be used in waste heat recovery boiler (WHRB) to generate power.  Electrostatic precipitators (ESP) with particulate emission less than 100 mg/m3 will be provided to DRI plant and CFBC plant but committee insisted for 50 mg/m3.  Hot gases will pass through after burning chamber (ABC) and dust settling chamber (DSC) and used for generating power through WHRB.  Bag filters will be provided to raw material handling system of DRI plant and power plant and product handling area during discharge and intermediate and product bins. Adequate dust extraction/suppression system will be installed at locations near dust generation. Water sprinkling will be done to control fugitive emissions during handling of different raw materials and end products.  Dust extraction system will be provided to conveyor/transfer points of Iron ore beneficiation plant. Bag filters will be provided in raw material handling system for power plant. Boiler flue gases and DRI kiln off gases will be passed through ESP. 

Total water requirement from Asansol Durgapur Development Authority for the expansion programme will be 1,650 m3/day instead of 2,030 m3/day.  The tail fraction from the beneficiation plant will be pumped to the tailing pond.  Water recovery will be done from tailing dam and from pellet plant.  In iron ore beneficiation plant, the clear water from the pond will be re-circulated for further use. 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. The entire treated wastewater will be reused in the proposed Iron ore beneficiation plant and existing coal washery. 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 in CFBC boiler. Dust from DRI plant will pass through WHRB. ETP sludge, flue dust will be stored in ash disposal area. Fly ash will be sold to nearby cement/brick manufacturing plants and bottom ash will be disposed off in abandoned mines. Tailings from IOB will be dumped in the tailing pond and finally disposed off in the abandoned mines. Waste/used/spent oil and used batteries will be sold to authorized recyclers/re-processors.

  

            40.19 acres out of total 121.62 acre is earmarked for green belt development (33.04%). As per presentation made, power requirement will be 68.3 MW, which will be sourced from captive power plant. Power required will be sourced from captive power plant (reduced to 13 MW from 50 MW).  One DG set (1x1500 KVA) will be installed.

 

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.        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.

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

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

4.        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. A photograph of the site should also be included.

5.        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.

6.        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.

7.        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.

8.        Details and classification of total land (identified and acquired) 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, analysis of all the raw materials 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.      Action plan for excavation and muck disposal 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 environmental clearance and ‘NOC’ from the WBPCB 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 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.

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 modeling 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. Incorporation of water harvesting plan for the project is necessary, if source of water is bore well.

42.      Permission for the drawl of 1,650 m3/day ground water from bore well from the ADDA 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, tailings, char 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.      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 and action plan for protecting the workers against hazardous chemicals such as Sulphuric acid, pesticides, solvents etc. should be included

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 should be included.

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 with financial budget for complying with the commitments made. 

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 should also be included.

 

In addition to the above, information on the following may also be incorporated in the EIA report.

 

1.         Is the project intended to have CDM-intent? 

(i)      If not, then why?

(ii)     If yes, then :

 

(a)      Has PIN (Project Idea Note) {or PCN (Project Concept Note)} submitted to the ‘NCA’ (National CDM Authority) in the MoEF?

(b)      If not, then by when is that expected?

(c)      Has PDD (Project Design Document) been prepared?

(d)      What is the ‘Carbon intensity’ from your electricity generation projected (i.e. CO2 Tons/MWH or Kg/KWH)

(e)      Amount of CO2 in Tons/year expected to be reduced from the baseline data available on the CEA’s web-site (www.cea.nic.in)

 

2.   Notwithstanding 1(i) above, data on (d) & (e) above to be worked out and reported. 

 

            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.                                                                                                                                                           

         Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.13       Coke Oven Plant (2,37,600 TPA), Coal Washery (66,000 TPA), Coal Beneficiation Plant (Slurry Washery; 5,28,000 TPA) and Captive Power Plant (WHRB, 6 MW) at Plot No. 116-178, 179(Part)-189, 205-211, 294-331, 332(part), 333(Part), 334-360, 466-500, Village Hirodih, P.S. Jainagar, District Kodarma, Jharkhand by M/s Jupiter 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 coke oven plants (2,37,600), coal washery (66,000 TPA) and captive power plant (6 MW) are listed at S.N. 4(b) and 2(a) under Category ‘B’ and appraised at the Central level due to absence of SEIAA/SEAC in the State of Jharkhand. 

 

           M/s Jupiter Ispat Private Limited have proposed for the Coke Oven Plant (2,37,600 TPA), Coal Washery (66,000 TPA), Coal Beneficiation Plant (Slurry Washery; 5,28,000 TPA) and Captive Power Plant (WHRB, 6 MW) at Plot No. 116-178, 179(Part)-189, 205-211, 294-331, 332(part), 333(Part), 334-360, 466-500, Village Hirodih, P.S. Jainagar, District Kodarma, Jharkhand.  PAs confirmed that the project is not located in a notified industrial area and is 60 km from the critically/severely polluted area. The land is acquired on lease from M/s Jupiter Spun Pipe Company Private Limited.  Total project area is 345 acres and proposed plant will be set up in 40 acres.  Kodarma town is at 1.85 km. Forest is located at 3.5 km (NW-NE). PAs have informed that no nation park/wild life sanctuary/reserve forest is located within 10 Km.  Dam is located at Kodarma (11.5 km, SW).  Total cost of the project is Rs. 88.65 Crores. Rs. 360.00 Lakhs and Rs. 29.00 Lakhs are earmarked towards capital cost and recurring cost against pollution control measures. Following will be manufactured:

 

S.N.

Facilities / Products

Quantity (TPD / TPA)

1.

LAM Coke

720 /  (2,37,600)

2.

Coal Washery

200 / (66,000)

3.

Slurry Washery

1,600 /28,000)

4.

WHR Power Plant

6 MW

           

Out of 200 TPD raw coal, 120 TPD washed coal, 40 TPD middlings and 40 TPD rejects will be produced in coal washery.  In slurry washery (coal beneficiation plant) out of 1600 TPD raw coal, 800 TPD washed coal and 800 TPD rejects will be generated.  Coal (66,000 TPA), slack coal (5,28,000 TPA) will be used as raw materials.

 

           PAs informed to the Commttee that high ash coal will be converted to low ash coal in coal washery.  Washed coal from washery will be put inside the Bee Hive coke oven (non-recovery type) for carbonization.  Coal will be burnt for manufacturing low ash coke.  After processing coke will be taken out and water quenched for cooling. However, the committee didn’t agree for the same and asked PAs to adopt air quenching. Hydro flotation and forth rotation method will be adopted in coal washery. Washery will include crushing, screening and HM cyclone process will be adopted including jiggling process. The thickened slurry will be dewatered in multi-roll-ball process filter. Captive power plant (WHRB) will be installed to make use of flue gases generated from the coke oven. Low ash metallurgical coke manufactured will be used in iron steel industry and also as a fuel in cupola and open hearth furnace.

            Particulate matter will increase due to grinding and burning process.  Down draft system with ventury scrubber will be installed in coke ovens and bag filters in crushing and handling areas of washery section to control particulate matters within 100 mg/Nm3 but committee asked to achieve 50 mg/Nm3. Non-recovery type of coke oven will be provided with external recuperator system to recover sensible heat from outgoing flue gases before escaping from the chimney and used in power generation through WHRB.  Water scrubber system will be provided to condense the tarry material.  Poly-aromatic hydrocarbon (PAH) will be burnt in the coke oven itself.  Dedusting system and water sprinkler will be provided to control fugitive emissions.

Total ground water requirement from bore wells was proposed 623 m3/day but has to be reduced due to adoption of air quenching of hot coke. Permission for ground water drawl is yet to be obtained.  No liquid effluent will be generated and discharged due to adoption of closed loop system. Only make up water will be fed into the plant.  Anionic and cationic flocculants from coal washery will be used in thickener and belt press to facilitate settling and dewatering process.  The discharge of the belt press will be dumped on the ground.  The treated effluent will be used for ash conditioning, dust suppression and green belt development.  After wet quenching, wastewater will be drained to a settling tank and reused for quenching itself using a closed circuit system.  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. 

 

            Coal washery rejects (830 TPD) will be sold to briquette / red bricks manufacturing plant.  Solid waste from APCD will be partly recycled to the process and balance will be used for land filling.  Middlings (16,500 TPA) will be sold to FBC power plant.   Waste / used / spent oil and used batteries will be sold to authorized recyclers / re-processors.

 

            Green belt will be developed in 15.30 acres out of total 40 acres.  Power (60 MW) will be sourced from captive power plant and USEB.  D.G. sets (1x500 KVA and 1x200 KVA) will be installed for emergency use.

 

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. Photograph of the site should also be included.

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 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.    Site-specific micro-meteorological data including inversion height and mixing height should be incorporated.

7.    Permission and recommendations of the State Forest Department regarding impact of proposed expansion on the surrounding reserve forest located at 3.5 km should be included.

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

9.    Residential colony should be located in upwind direction.

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

11.  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.).

12.  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.

13.  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.

14.  Studies for coal washery rejects, middlings, 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.

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

16.  A chapter on type and full details of coke oven plant including process details, charging, heat transfer, discharge, occupational hazards, mitigation measures proposed, pollution control methods and justification for installing non-recovery/recovery type of coke oven should be included.

17.  A brief description of the coal washery and coal beneficiation plant, the technology used, the annual throughput for the past three years, the source of coal, the list of clients to whom the washed coal is to be supplied, the mode of transport of incoming unwashed coal and the outgoing washed coal. Specific pollution control and mitigative measures for the entire process.

18.  Feasibility of using BARC technology on dry process with minimal dust pollution may be looked at as examined.

19.  Commitment that no water quenching will be used and details of air quenching methods to be adopted should be included.

20.  Details of sources of coal, coal linkages and possible recipients of washed coal should be incorporated. A clear mention of movement of raw coal and washed coal from the source and to the last target by road and railway and calculation of the quantity and number of trucks should be mentioned.

21.  Impacts of mineral transportation - the entire sequence of mineral production, transportation, handling, transfer and storage of mineral and waste, if any, and their impacts on air quality should be shown in a flow chart with the specific points where fugitive emissions can arise and the specific pollution control/mitigative measures proposed to be put in place.

22.  Details of various facilities to be provided for the personnel involved in mineral transportation in terms of parking, rest areas, canteen, and effluents/pollution load from these activities.  Examine whether existing roads are adequate to take care of the additional load of mineral [and OB ]transportation, their impacts. Details of workshop, if any, and treatment of workshop effluents.

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

24.  Plan for utilization of coke oven gases in power plant (WHRB) and commitment for no discharge of gases into the air should be included. Details of the utilisation of power generated should be incorporated.

25.  Mass balance of coke oven gases should be incorporated.

26.  Energy balance for the coke oven should be included.

27.  Air quality modelling for the coke plant/power plant and air pollution control system proposed for plant to achieve 50 mg/Nm3 should be included.

28.  Ambient air monitoring should include HC, CO alongwith SPM, RSPM, SO2, NOX and VOCs.

29.  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.

30.  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. Location of one AAQMS in downwind direction should be included.

31.  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.

32.  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.

29.  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.

30.  Sources of secondary fugitive emissions, its control and monitoring as per the CPCB guidelines should be included.

31.  One-month data for gaseous emissions other than monsoon season should be included.

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.  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.

36.  Presence of an aquifer/aquifers 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.  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.

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

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

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

42.  Actual requirement of water after adoption of air quenching and permission for the drawl of water 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.

43.  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.

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

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

46.  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.

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

48.  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.

49.  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.

50.  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.

51.  Solid waste generation, storage, utilization and disposal should be included particularly related to the coal washery rejects and middlings. ‘MOU’ signed, if coal washery rejects and middlings are to be supplied to briquette plants and power plants respectively.

52.  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.

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

54.  Socio-economic development activities need to be elaborated upon.

55.  Risk assessment and damage control needs to be addressed.

56.  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.

57.  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.

58.  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.

59.  Compliance to the recommendations mentioned in the CREP guidelines should be included.

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

61.  Detailed Environment management Plant (EMP) with specific reference to air pollution control system, water management, monitoring frequency, responsibility and time bound implementation plan.

62.  EMP should include the concept of waste-minimization, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.

63.  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.

64.  A tabular chart for the compliance of TOR should be provided with EIA/EMP.

 

            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  Jharkhand State Pollution Control Board (JSPCB) 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.

 

                        Minutes approved by the Chairman on 27th April, 2010

 

MINUTES FOR 9th MEETING OF THE RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 7th–8th April, 2010

 

7th April, 2010

4.0     New Proposals :

 

4.14       Expansion of Rolling Mill (TMT Bars 2,00,000 to 3,90,000 TPA) at Adityapur Industrial Area, Gamharia, Seraikela, Kharsawan, Jharkhand by M/s Beekay Steel Industries 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 Rolling Mill Plants are listed at S.N. 3(a) II under Secondary Metallurgical Industries under Category ‘B’ and appraised at the Central level due to non-existent of SEIAA/SEAC in Jharkhand State. The proposed unit is located in Saraikela, Jharkhand and is listed at S.N. 64 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 Saraikela critically polluted area and no information regarding existing SPM, RPM, SO2 and NOx is submitted. PAs have clarified that proposed expansion project is located at 27.12 km from the Saraikela, Jharkhand and a map is submitted accordingly. 

 

           M/s Beekay Steel Industries Ltd. have proposed for the expansion of Rolling Mill (TMT Bars 2,00,000 to 3,90,000 TPA) at Adityapur Industrial Area, Gamharia, Seraikela, Kharsawan, Jharkhand.  “Consent to Establish” has been accorded by the JSPCB.  Total land acquired is 12 acres. A copy of Notification issued by the Govt. of Bihar indicating Adityapur Industrial area as notified industrial area vide notification dated 11th December, 1994 is submitted. Uperabera village is at 0.5 km. Jamshedpur town is at 10 km. Existing plant is located in 8 acres and expansion will be carried out in additional 4 acres.  No additional land is required and expansion will be carried out inside the existing compound only. Total cost of the project is Rs. 1,698.04 Lakhs. PAs have informed vide e-mail dated 05.04.2010 that amount is reduced from  Rs. 100.00 Lakhs and Rs. 18 Lakhs to Rs. 25 lakhs and Rs. 6 lakhs respectively as earmarked towards total capital cost and recurring cost/annum for environmental pollution control measures. Following are the details of existing and proposed products to be manufactured:

 

Existing

2,00,000 TPA TMT Bars

Proposed

1,90,000 TPA TMT Bars

TOTAL

3,90,000 TPA TMT Bars

 

            Billets and blooms will be used in the rolling mill.  Billets procured from M/s Tata Steel Ltd. will be converted into rolled products viz. TMT Bars.

 

            Dust and fumes from rolling mills will be controlled by providing stacks of adequate height (33.5 m) to control emissions within and 50 mg/Nm3. Adequate stack height will be provided to D.G. Sets.  Water sprinkler will be provided to suppress fugitive emission.

 

PAs informed to the Commttee that existing ground water requirement is 20 m3/day. Additional, total ground water requirement from bore wells will be 20 m3/day and have applied for the ‘permission’ for the drawl of water to ADDA.  Close circuit cooling system will be adopted in rolling mills. Oil and grease will be separated using oil traps and skimming devices.  The treated effluent will also 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.  Sanitary Sewage will be treated in septic tank followed by soak pit.  No effluent will be discharged outside the premises and ‘Zero’ discharge will be adopted.

  

            Ash granules will be generated from the producer gas plant and will be used in the cement plant/filling low-lying areas. Mill scales  will be sold to steel plants for processing usage. Ingots/billets will be reheated at 12000C in reheating furnace, conveyed through rolling table (first stand) to the roughing unit and then to furnishing mill to manufacture TMT bars/rods and then cut according to requirement. Waste/used/spent oil and used batteries will be sold to authorized recyclers/ re-processors.

 

Green belt will be developed in 4.0 acres (33%). Rubber padding / noise isolators and silencer will be used to modulate noise. Acoustic enclosures will be provided to D.G. Sets  (2x125 KVA) to control noise within permissible limits. Existing power (3333 KVA) and proposed for expansion (3,000 KVA) will be sourced from Jamshedpur Utilities and sources CO. (JUSCO).  HSD will be used for fueling D.G.Sets (2x125 KVA).

 

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

2.    Details and classification of identified and acquired land should be included.

3.    Present land use should be prepared based on satellite imagery.

4.    A small Indian map of 1: 10, 00,000 scale followed by 1:50,000/1:25,000 scale on an A3 sheet with at least next 10 Kms of terrains i.e. circle of 10 kms and further 10 kms on A3 sheets with proper longitude/latitude/heights with min. 100/200 m. contours should be included.

5.    Location of national parks / wildlife sanctuary / reserve forests within 10 km. radius should specifically be mentioned.

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

7.    Permission and recommendations of the State Forest Department regarding impact of proposed expansion on the surrounding reserve forests, if any, should be included.

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

9.    Residential colony should be located in upwind direction.

10.  List of raw material required and source alongwith mode of transportation should be included.

11.  Manufacturing process details for Rolling Mill should be included.

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

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

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 ‘NOC’/environmental clearance for the existing plant.

16.  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.

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.  Ambient air quality monitoring modeling alongwith cumulative impact should be included as an annexure for the day (24 hrs) considered 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. A-F 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.

19.  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.

20.  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.

21.  Air quality modelling for steel plant for specific pollutants needs to be done.  APCS for the control of emissions from the rolling mill should also be included.

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

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

24.  An action plan to control and monitor secondary fugitive emissions from all the sources as per CPCB guidelines should be included.

25.  Permission for the drawl of 20 m3/day water 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.

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

27.  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. Incorporation of water harvesting plan for the project is necessary, if source of water is bore well.

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

29.  Ground water monitoring minimum at 8 locations and near solid waste dump zone, Geological features and Geo-hydrological status of the study area are essential as also.  Ecological status (Terrestrial and Aquatic) is vital.

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

31.  Action plan for solid/hazardous waste generation, storage, utilization and disposal from all the sources including mill scales.

32.  Risk assessment and damage control needs to be addressed.

33.  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.

34.  Display of Information about safe work practice in local language with attractive slogans & picture.

35.  Green belt development plan in 33 % area and a scheme for rainwater harvesting have to be put in place.

36.  Socio-economic development activities need to be elaborated upon.

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

38.  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.