SINGHAL ENTERPRISES PRIVATE LIMITED

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2 SINGHAL ENTERPRISES PRIVATE LIMITED (INTEGRATED MINI STEEL & POWER PLANTS) Taraimal Village, Gharghoda Mandal, Raigarh District, Chattisgarh State. 1.0 INTRODUCTION SINGHAL ENTERPRISES PRIVATE LIMITED have proposed to increase the production capacity of Sponge iron from 1,93,500 TPA to 2,83,500 TPA, Liquid Steel (by Induction furnaces) production from 48,000 to 2,16,000 TPA, TMT bars of capacity 90,000 TPA, Ferro Alloys of capacity 10,800 TPA, Power plant of 8 MW to 74 MW capacity (through WHRB and FBC boilers) and proposed the installation of few new units viz. Blasts Furnace with installed capacity of 125 M 3, sinter plant an ancillary unit to Blast Furnace with Grate area of 50 M 2 and a new Coal Washery unit with an installed capacity of 1,50,000 TPA. The expansion project will be implemented in the existing plant premises in Taraimal Village, Gharghoda Mandal, Raigarh District, Chhattisgarh State. The existing plant is having a valid Consent to Operate from Chhattisgarh Environment Conservation Board (CECB). They have acquired 137 hectares of land for the proposed plant. Sr. Existing Proposed Total Details No. Capacity Capacity Capacity 1. DRI Kiln for Production of Sponge Iron TPA TPA TPA 2. Induction furnace for production of Steel TPA TPA Ingots/ Billets with Continuous Casting TPA Machine/ Ladle Refine Furnace 3. Rolling Mill for production of Re-rolled products TPA TPA 4. Ferro Alloy plant for production of Silicomanganese TPA TPA 5. Blast Furnace for production of Pig Iron TPA TPA 6. Sinter Plant x 50 M 2 1 x 50 M 2 7. Coal Washery for clean coal ,50,000 TPA TPA 8. Power Plant through Waste Heat Recovery 8 MW 8 MW 16 MW 9. Power Plant through FBC Boiler x 8 MW 8 MW 2 x 25 MW 50 MW 2

3 Pioneer Enviro Laboratories & Consultants Private Limited have prepared Rapid Environmental Impact Assessment (REIA) report for the proposed expansion of Steel plant in Taraimal Village, Gharghoda Mandal, Raigarh District, Chattisgarh State. The report contains detailed description of the following. a. Detailed characterization of status of environment with in an area of 10 km. radius from the proposed project site for major environmental components including air, water, noise, soil, flora, fauna and socio-economic environment. b. Assessment of air emissions, liquid waste and solid waste from the proposed project along with the noise level assessment. c. Pollution control measures proposed to be adopted and Environmental Impact Statement. The summary of the report is presented below. 2.0 PROJECT SITE DETAILS 137 hectares of land is in the possession of the management. The plant is located at about 600 m from State Highway (Gharghoda to Raigarh). Nearest villages from the proposed project site are Ujalpur, Gerwani, Amghat, Punjipathara, Harrridih, Jamdabri, Ratrot, Gaurmudi, Taraimal, Shivpuri, Kesdol, Delari, Lakha, Saraipali, Tumnar, Urdana, etc., The nearest railway facility is available at Raigarh, which is about 18 Kms. from the proposed project site. 3

4 3.0 DETAILS ABOUT THE PROJECT 3.1 Raw Materials Requirement The following will be the raw material requirement after expansion. PROPOSED EXPANSION Raw materials Quantity (Tons/Annum) Iron ore 1,44,000 Coal Dolomite 3,600 CI Scrap 17,202 Scrap 17,685 Ferro Alloys 1,680 Washery Rejects 42,000 Annual requirement of raw materials (Net & Dry) for Sinter Plant Raw Materials Quantity, (Tons/Annum) Iron ore fines 2,20,050 Limestone 27,000 Dolomite 22,500 Coke breeze Flue dust 6900 RMP Waste 3310 Mill scale 2300 The requirement (dry and net) of raw materials for the Blast Furnace is given below. Sr. Raw material Requirement No. (Tons/Annum) 1. Iron ore lump 4,18, BF coke 4,78, Quartzite 2, Sinter 9, Manganese ore 1, DESCRIPTION OF MANUFACTURING PROCESS 4

5 3.2.1 DRI Kiln: The production program of the direct reduction plant, as envisaged, is given below: Annual Capacity, Tons Description Existing Expansion Sponge iron (DRI) lump TPA TPA A refractory lined rotary kiln will be used for reduction of Iron ore in solid state. A central Burner located at the discharge end will be used for initial heating of the kiln. Sized Iron ore will be continuously fed into the kiln along with coal, which has dual role of fuel as well as reductant. Dolomite will be added to scavenge the sulphur from the coal. A number of air tubes will be provided along the length of the kiln. The desired temperature profile will be maintained by controlling the volume of the combustion air through these tubes. The Carbon Monoxide generated due to the combustion of coal, reduces the iron ore and convert it into sponge iron. The rotary kiln is primarily divided into two zones viz. the pre heating zone and the reduction zone. The preheating zone extends over 30 to 50 % of the length of the kiln and in this the moisture in the charge will be driven off and the volatile matter in the coal will be burnt with the combustion air supplied through the air tubes. Heat from the combustion rises the temperature of the lining and the bed surface. As the kiln rotates, the lining transfers the heat to the charge. Charge material, pre-heated to about 1000 o C enters the reduction zone. Temperature of the order of 1050 o C will be maintained in the reduction zone, which is the appropriate temperature for solid-state reduction of iron oxide to metallic iron. This hot material will be transferred to rotary cooler. In rotary cooler the material will cool from 1000 o C to 170 o C in cooler by spraying water. The 5

6 cooler discharge material consists of sponge iron lumps, sponge iron fines and char. Magnetic and non-magnetic material will be separated through magnetic separators and stored in separate bins INDUCTION FURNACE: Initially scrap & other metallics such as pig Iron will be charged into the induction furnace. After scrap & other metallics are fully melted, the temperature of the melt reaches above 1600 o C, and then DRI will be continuously charged into the furnace. As soon as the charge is melted, bath samples will be taken and temperature will be measured. There will be 6 nos. (2x12 T & 4x8 T capacity) of induction furnaces in the SMS plant LADLE REFINING FURNACE Lime, ferro-alloys, aluminium and fluorspar will be added as per the requirement and the final temperature and analysis will be adjusted BILLET CASTER In Billet caster, the liquid steel after ladle furnace treatment will be casted into the desired billet sizes ROLLING MILL: A pusher type furnace has been envisaged for the heating of billets. The following size of billet will be fed to furnace. Furnace will be heated with LDO. A bar and round mill will be installed in the plant with a capacity of 90,000 TPA to produce 8 mm, 10 mm & 12 mm bars of 6-12 m length. 6

7 3.2.6 Sinter Plant The proposed and sinter plant complex will consist of one sinter Machine of 50 m 2 grate area along with associated services facilities. The sinter plant is rated for a total production of Tonnes of BF Sinter at a rated productivity of 1.2 t/m 2 /hr Blast Furnace Plant The blast furnace shop will comprise of one furnace of 125 m 3 working volume. The blast furnace is envisaged to operate with sized lump iron ore, coke, fluxes and additives. The hot metal produced will be cast at pig casting machines to produce cold pigs. The liquid slag will be granulated at cast house granulation unit. The BF top gas will be cleaned in dust catcher and gas cleaning system and distributed to the stoves, burners for runner drying, boilers for process and process steam supply. The excess gas will be supplied to power plant POWER GENERATION: The exhaust waste flue gases from the rotary kiln will pass through a waste heat recovery boiler (WHRB) of 10.5 TPH capacity. The rotary kiln gases will have a temperature of 1000ºC at the exhaust of WHRB the temperature will be C. Three nos. of FBC boilers of 1x45 TPH, 2 x 120 TPH capacity will also be provided to generate steam by using coal, Dolochar, coal Washery rejects as fuel. The steam generated will pass through respective steam turbines and will be coupled to respective generators to generate electricity aggregating to 66 MW. This power generated will be utilized to meet the internal power requirements of the Mini integrated steel plant. The flue gases will pass over various heat transfer surfaces to ESP and then finally discharged into chimney by ID fan. The boiler will have its own ESP, ID fan and chimney. 7

8 3.2.9 PROCESS DESCRIPTION OF COAL WASHERY The coal washery will be installed inside premise near raw material yard. This section comprises of coal crushing and screening station and coal washery to produce clean coal with 25 % ash, appropriately sized and a middling fraction by treating the raised coals from the mine. The coal washery has been designed to wash the coal in heavy media circuit to reduce clean coal with 25% ash and middling. The process consists of crushing of the ROM coal in a single toothed roll crusher. The crushed coal is then washed in Zig to produce clean coal and middling with the help of water stream and air pressure MANUFACTURING PROCESS FOR FERRO ALLOYS: Standard Silico Manganese is smelted at about ºC. This is achieved by a conventional Submerged Arc Electric Furnace. The three carbon electrodes, partially submerged in the charge, are supported on hydraulic cylinders for upward and downward movements to maintain the desired electrical conditions in the furnace. The raw materials are thoroughly mixed in the proper proportion before being charged into the furnace. Manual poking rods or stoker car are used for stoking the charge on the furnace top. As the charge enters the smelting zone, the alloy formed by chemical reactions of the oxides and the reductant, being heavy gradually settles at the bottom. The slag produced by the unreduced metal oxides and the flux, being relatively lighter, floats on the alloys surface. At regular intervals the furnace is tapped. 8

9 The alloy cake from C.I. Pan is removed and broken manually with hammer to required lump size. The slag produced in the process, generally free from metal, after cooling is removed by lorry to the slag dump. 3.3 WATER REQUIREMENT The water requirement for the proposed expansion Project will be cum/day & after the expansion it will be Cum/day. Water will be required basically for cooling tower make-up, Boilers make-up, D.M. plant regeneration, Service water and for domestic requirement. The water required for proposed Project will be met partly from the Kelo River and the remaining water will be supplied by CSIDC. 9

10 WATER REQUIREMENT (CUM/DAY) SOURCE QUANTITY Existing Expansion After expansion Cooling water Make-up for DRI plant Cooling water make-up for SMS plant Cooling water make-up for Rolling mill Make-up for Coal washery Ferro alloys Sinter Plant Cooling water make-up for Blast Furnace POWER PLANT a) Cooling Tower Make-up (total) b) Boiler make-up c) D.M. plant regeneration water d) Service water Domestic Dust Suppression Greenbelt development Total Cum/day Note : Gross water requirement Recycling of treated effluent Net water requirement : cum/day : 275 cum/day : cum/day 3.4 Quantity and Quality of Effluents The total quantity of effluents generated after the expansion activity will be 1779 cum/day. The following is the break-up of the wastewater generated from the proposed project. 10

11 WASTE WATER GENERATION (CUM/ DAY) QUANTITY (cum/day) SOURCE Existing Expansion After Expansion Blast Furnace (GCP Blowdown) Power plant Cooling tower Blowdown Boilers Blowdown(WHRB & FBC Boilers) D.M. plant regeneration water Service water Domestic Total The characteristics of effluents generated from various streams are as following. CHARACTERISTICS OF EFFLUENT Parameters Sanitary waste water Cooling tower Blowdown Boiler Blowdown D.M. Plant regeneration water ph TDS (mg/l) BOD (mg/l) COD (mg/l) POLLUTION CONTROL MEASURES Air Pollution The flue gases from the waste Heat recovery Boiler, FBC Boiler will be vented in the atmosphere through Separate Electrostatic Precipitators to bring down the particulate matter in the exhaust gas to less than 100 mg/nm 3. Adequate stacks height of 50 m, 60 m & 66 m will be provided for WHRB & FBC boilers respectively for effective dispersion of the pollutants. The exhaust from both induction furnaces & ladle refining furnace will pass through a Bag House and will be let out into the 11

12 atmosphere through a single stack of 30 m height. Dust extraction system followed by bag filters will be installed to control the dust emission at all the material transfer points and other dust prone areas. The hot waste flue gases from the Sinter plant will be treated in a Electro Static Precipitator and let out into the atmosphere through a stack of 50 m height for effective dispersion of emissions into the atmosphere. The waste flue gases from the Blast Furnace will be treated in a Electro Static Precipitator and let out into the atmosphere through a stack of 50 m height for effective dispersion of emissions into the atmosphere. In Reheating Furnace of the Rolling Mill the fuel proposed to be use is FO. A stack height of 35m will be provided for effective dispersion of SO 2 into the atmosphere. All conveyors will be covered through G.I. sheets to control dust. All bins will be totally packed and covered so that there will not be any chance for dust leakage. All the material handling systems will be connected with de-dusting system. All discharge points and feed points, wherever the possibility of dust generation is there a de-dusting suction point will be provided to collect the dust. The collected dust will be taken to a dust storage bin through a pneumatic conveying system. This dust will be used in the Boiler Water Pollution The total wastewater generated after expansion will be 1779 cum/day. EFFLUENT TREATMENT PLANT The effluent generated from the expansion project will be treated in the following manner. 12

13 Initially the acidic and alkaline effluent streams coming from cation and anion units of DM plant will be neutralised in a neutralisation tank of size 5m x 3m x 2.5m. Service water will then pass through an Oil Separator to remove the oil content in the effluent. The ph of Boiler blowdown will be between 9.5 and Hence this effluent stream shall be neutralized in a neutralization tank of size 3m x 4.5m x 1.7m before mixing with other effluent streams. All these effluent streams will be mixed in a Holding tank along with cooling tower blowdown. Part of the treated effluent will be recycled into the DRI plant & Rolling mill make-up water for cooling and the remaining treated effluent will be used for ash conditioning, dust suppression and for greenbelt development. The sanitary wastewater will be treated in septic tank followed by soak pit. Total effluent generation : 1764 m 3 /day (Excluding sanitary waste) Effluent qty. to be used for ash conditioning : 96 m 3 /day Effluent to be used for dust suppression : 90 m 3 /day Effluent to be recycled in DRI & cont. casting : 275 m 3 /day Total effluent qty. to be used for on land for irrigation : 1303 m 3 /day Hence a greenbelt of 50 hectares will be developed within the plant premises by using the treated effluent. A dedicated pipe distribution network will be provided for using the treated effluent for on land for irrigation. The characteristics of the treated effluent are well with in the CECB Standards for on land irrigation. Hence there will not be any impact on ground water / surface water due to the proposed expansion project. 13

14 3.5.3 Solid Waste Management The following will be the solid waste generation from the proposed project. Sr. Type of Solid Quantity (in TPA) After No waste Existing Expansion Expansion Disposal Proposed 1. Ash Cement plants/ use in own Fly ash bricks manufacturing plant. 2. Accretion Slag Land fill in designated from DRI area/used in road construction 3. Wet scraper sludge 4. Dust from bag filters Given to brick manufacturers inject in the DRI Kilns attached with WHRBs. 5. Dolochar Consumed as fuel in FBC Boiler 6. Slag from IF s Land fill in designated area/used in road construction 7. Slag from Ferro Alloys Nil Middling from Coal washery Nil Granulated slag from Nil 23,500 23,500 Blast Furnace Land fill in designated area/used in road construction Consumed as fuel in FBC boiler. Granulated slag ESP ash will be given to cement plant The ash generated will be used for Own brick manufacturing unit/ given to cement plants. The slag generated will be used in Land fill in designated area/used in road construction. Middling and Dolochar will be consumed as fuel in FBC Boilers. 4.0 Baseline data Baseline data has been collected on ambient air quality, water quality, noise levels, flora & fauna and socio-economic details of the people within 10 km. radius of the proposed project site. 14

15 4.1 Ambient Air Quality Ambient air quality was monitored for RPM, SPM, SO 2 & NO x at 8 stations for one season as per MOEF guidelines. The following are the concentrations of various parameters at all the monitoring stations. RPM to 38.6 µg/m 3 SPM to µg/m 3 SO to 11.8 µg/m 3 NO X to 15.2 µg/m Water Quality Ground water samples were collected at 8 locations and analyzed for various physico - chemical parameters. The water samples shows that they are suitable for potable purpose. 4.3 Noise levels Noise levels were measured at 8 stations during day time & night time. The noise levels at the monitoring stations are ranging from dba to dba. 5.0 PREDICTION OF IMPACTS 5.1 Prediction of Impact on Air Quality Stacks height of 50 m, 60 m & 66m, will be provided for one WHRB & three nos. of FBC boilers respectively for effective dispersion of pollutants into the atmosphere. Electro static precipitator will be provided separately for both WHRB & FBC boilers to bring down the particulate matter in the exhaust gas to less than 100 mg/nm 3. Dust extraction system followed by bag filters will be provided to control the dust at all the material transfer points and at other areas where dust emission is likely to occur. 15

16 The emissions from the proposed project are SPM, SO 2 & NO x. The predictions of Ground Level Concentrations have been carried out using ATDM Model. Meteorological data such as wind direction, wind speed, max. and min. temperature collected at the site have been used as input data to run the model. It is observed from the computation results that the maximum predicted incremental rise in 24 hourly ground level concentrations of SPM, SO 2 & NO x are 1.9 µg/m 3, 6.5 µg/m 3 & 6.4 µg/m 3 respectively at a distance of 1015 m from the origin stack in the down wind direction. The predicted results show that the net resultant concentrations (Max. Baseline conc. + Max. incremental rise in conc.) of SPM SO 2 & NO x will be well within the National Ambient Air Quality Standards after commissioning of the proposed Project. Hence there will not be any adverse impact on air environment due to the proposed Project. 5.2 Prediction of Impact on Noise Quality The major sources of noise generation in the proposed expansion Project will be steam turbine, WHRB, FBC Boiler and Compressors. The ambient noise levels will be with in the standards prescribed by MOE&F vide notification dated under the noise pollution (Regulation & Control), rules 2000 i.e. the noise levels will be less than 75 dba Leq during day time and 70 dba Leq during night time. The extensive greenbelt proposed to be developed in the Plant premises will further attenuate the noise levels. Hence there will not be any adverse impact due to noise on population in surrounding areas due to the proposed Project. 16

17 5.3 Prediction of impacts on water The effluent generated will be treated in the effluent treatment plant to meet CECB standards for onland irrigation. The treated effluent will be used for ash conditioning, dust suppression and for greenbelt development with in the premises. Hence there will not be any adverse impact in water environment in the study area due to the proposed expansion project. Rainwater Harvesting pits will be constructed to recharge the ground water. 5.4 Prediction of impacts on land environment The effluent generated from the steel & power plants will be treated to achieve CECB standards for onland for irrigation. All the required air pollution control systems such as ESP's, bag filters, dust suppression systems will be provided in the proposed expansion project. Hence there will not be any adverse impact on land environment due to the proposed project. With the establishment the proposed expansion the land rates in the area will increase, which contributes to the upliftment of economic status of people in the area. 5.5 Prediction of impacts on flora & fauna As all the required Air pollution control systems such as ESP, bag filters, etc., are proposed along with Effluent treatment Plant to meet CECB norms there will not any adverse impact on flora & fauna due to the proposed project. The net resultant GLC s at reserved forests are with in the National Ambient Air quality standards for sensitive area. 5.6 Prediction of impacts on Socio-economic pattern 17

18 With the establishment of the proposed expansion employment potential will increase along with medical facilities. The economic status of the people will improve with this project. Land prices in the area will increase hence. 6.0 ENVIRONMENTAL MANAGEMENT PLAN 6.1 During Construction Phase 1. After construction, all the excavated materials will be suitably disposed with proper back filling and leveling of excavated areas. 2. Dust suppressant spraying will be under taken to minimize the fugitive dust emission. Slopes shall be well stabilized before the on set of monsoon. 3. The workers at site during construction will be provided with proper drinking water and sanitation facilities. 4. All labors to be engaged in the construction activity will be examined by medical personnel before employment. Medical facilities will be provided to the labors during construction period. 6.2 During Operation Phase Land Environment Effluent will be treated to meet CECB standards for on land for irrigation. Extensive greenbelt will be developed in the proposed plant premises. Desirable beautification and landscaping practices will be followed Water Environment Waste water generated from the Expansion project will be treated in Effluent Treatment Plant to meet the CECB standards. The treated waste water will be used for Greenbelt development with in the plant premises / reused. 18

19 The following will be treated combined effluent characteristics. ph TSS - < 100 mg/l Oil & Grease - < 10 mg/l Free available chlorine - < 1.0 mg/l Copper - <1.0 mg/l Iron - < 1.0 mg/l Zinc - < 1.0 mg/l Chromium - < 0.2 mg/l Phosphates - < 5 mg/ l The characteristics of the treated effluent are well below the Chhattisgarh Environment Conservation Board standards for on land irrigation. Hence there will not be any impact on ground water / surface water due to the proposed expansion project. As part of post Project environmental monitoring the effluent shall be analysed weekly for ph, TDS, SS, chlorides, sulphates and oil & grease Air Environment 4 nos. ESP's will be provided for bringing down SPM in the exhaust gases of WHRB & three nos. of FBC Boilers to less than 100 mg/nm 3 as per CREP recommendations. The exhaust gases from ESP's will be let out through stacks of adequate heights for effective dispersion of pollutants. All material transfer points, dust-generating areas in the plant will be provided with dust extraction system consisting of Bag filters and dust suppression system with Nozzles will be provided. A common stack of 30 m height will be provided for induction furnaces & for Ladle furnace after treating in a Bag House. 19

20 Air pollution control measures will be strictly implemented so that the ambient air quality will be well below the National Ambient Air Quality standards after commissioning of the expansion project. Extensive greenbelt proposed to be developed in the plant premises will help in further mitigating the air emissions Noise Environment The major sources of noise in the proposed project will be steam turbine, Boilers, and Compressors. The turbine, WHRB & FBC Boiler will be of reputed make which are designed to meet the latest National / International Standards on noise levels. The employees working near the noise generating sources will be provided with earplugs. Ash Bricks will be used in the construction of the Buildings. Noise absorbing materials will be used in the construction of roofs, walls and floors. The extensive greenbelt development proposed within the plant premises will help in attenuating the noise levels further. Noise barriers in the form of trees are recommended to be grown around power house, administrative block and other utility units Green Belt development Thick greenbelt will be developed with in the plant premises of the proposed expansion project to further enhance environmental quality through limitation of air emissions, attenuation of noise levels, balancing eco environment, prevention of soil erosion and creation of aesthetic environment. 20

21 Green Belt development Extensive greenbelt will be developed in addition to the thick greenbelt existing in the premises. The greenbelt shall be developed simultaneously with the plant construction. This will further mitigate the pollution impacts. 50 hectares of greenbelt will be developed with in the plant premise (which is inclusive of existing greenbelt). A detailed greenbelt plan will be developed in consultation with local DFO. Rainwater harvesting Rainwater harvesting structures will be constructed to harvest the run off water from roof top and from the plant area & by laying a separate storm water drainage system for recharging of ground water 21

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