CHAPTER I INTRODUCTION

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1 N.R. ISPAT & POWER PRIVATE LIMITED Chapter CHAPTER I INTRODUCTION 1.1 PREAMBLE India is on a threshold of a steel revolution. The National Steel Policy envisages production of 110 million ton per annum (MTPA) of steel in India by the year This implies that the country, which produces 40 MTPA of steel currently, will have to add around 70 MTPA of new steel making capacity in the next 13 to 14 years. This translates into addition of more than 5 MTPA of steel making capacity every year till On a national level, a multi-pronged strategy has been formulated for attaining this goal. The demand for steel will increase through rapid infrastructural development and a quantum increase in rural steel consumption. Keeping pace with the demand, domestic steel production will be enhanced through creation of additional capacity. The expansion plans of existing steel producers and entry of new players are all indicative of a very bright future for steel industry. The National Steel Policy has set a long-term goal that India should have a modern and efficient steel industry of world standards, catering to diversified steel demand. The focus of the policy is to achieve global competitiveness not only in terms of cost, quality and product-mix but also in terms of global benchmarks of efficiency and productivity. In view of the above M/s N.R. Ispat & Power Private Limited has proposed to establish an Integrated Steel Plant to produce steel and also products that aid in making steel. Pioneer Enviro 1-1 Environmental Impact Assessment Report

2 N.R. ISPAT & POWER PRIVATE LIMITED Chapter PURPOSE OF THE REPORT As per the Ministry of Environment & Forests, New Delhi notification, dated 14 th September, 2006 all Primary metallurgical processing industries are classified under Category A. In order to obtain Environmental Clearance for the proposed Integrated Steel plant Form -I, proposed draft TOR along with Pre-Feasibility Report were submitted to the Honourable Ministry. A presentation was made before the Expert Appraisal Committee of MOEF on 11 th June, 2008 for the approval of TOR for EIA study. The Draft EIA report has been prepared in accordance with the Terms of Reference (TOR) issued by the Ministry vide letter no. J-11011/225/2008-IA II (I) dated 3 rd July, This report furnishes the details of location of Site, Description of the project, prevailing baseline status w.r.t Air Environment, Water Environment, Noise Environment; land Environment, Flora & Fauna and Socio-economic environment. This report also helps in identification of environmental impacts and suggesting mitigation measures to be followed during Construction and Operation of the project as a part of Environmental Management Plan. This report also acts as guidance manual for the proponent for following the Environmental Management Plan (EMP) and for adopting post project Environmental Monitoring Program as per statutory norms. 1.3 IDENTIFICATION OF PROJECT & PROJECT PROPONENT M/s N.R. Ispat & Power Private Limited (NRIPL) has been promoted by well established entrepreneur belongs to Raigarh in Chhattisgarh state and already established in the field of manufacturing and trading of Finished/ semi finished Steels at Village: Gourmudi, Tehsil: Tamnar, District Raigarh (C.G.). Pioneer Enviro 1-2 Environmental Impact Assessment Report

3 N.R. ISPAT & POWER PRIVATE LIMITED Chapter - 1 NRIPL already purchased land admeasures about 53 acres, which is quite sufficient for the installation. M/s NRIPL propose to generate Power by installing 1 x 10 MW FBC based and also install 2 x 2 MW WHRB based power plant aggregating generation capacity to 14 MW for captive consumption only. To meet the annual coal requirement for Sponge iron manufacturing as well as Power generation will be meet through either Captive mining or Long term Coal Linkage with South Eastern Coalfields Ltd. (SECL) mines. The project cost estimate for installation of the proposed plant works out to Rs Crores. This is inclusive of equipment cost as erected including civil and structural works, taxes & duties and contingencies. It is proposed to achieve synchronization and commercial operation within 24 months, which is to be reckoned from the date of financial closure. Financial analysis has been carried out for the project considering that the fund requirement will be met on a debt equity ratio of 63:37. The following is the list of some of the important people in the organization: Name of Directors : i. Shri Sanjay Kumar Agrawal ii. Shri Rajesh Kumar Agrawal iii. Shri Vijay Kumar Agrawal Steel being a basic commodity for all industrial activities, quantum of its consumption is considered an index of industrial prosperity. Since independence, there has been a substantial growth in the steel sector in India from 1.5 Million Tons in to about 31 Million Tons at present. Additional steelmaking capacity of about 8 to 10 Million Tons /year exists in the secondary steel sector. Pioneer Enviro 1-3 Environmental Impact Assessment Report

4 N.R. ISPAT & POWER PRIVATE LIMITED Chapter - 1 Despite the above growth in the steel sector, the per capita steel consumption continues to remain at a level of about 27 kg only, compared to about 350 to 450 kg in the developed countries and 40 to 100 kg in some of the developing countries. Further, with nearly 20% of the world population, India s contribution is only of the order of 3.4% of world steel production. Hence, short-term and long-term strategies are necessary in planning the development of the steel industry in the country to improve the level of per capita steel consumption. It is expected that with the measures taken by Govt. of India for promotion consumption of iron and steel and expected growth of Indian economy the requirement of steel will significantly increase and accordingly the domestic manufacturing capacity needs to be increase. Considering the potential of iron and steel in India and the experience gained by the group in this sector, M/s N.R. Ispat & Power Private Limited (NRIPL) propose to install the following units at Village: Gourmudi, Near Gerwani, Tehsil: Tamnar District: Raigarh in the state of Chhattisgarh. 1.4 BRIEF DESCRIPTION NATURE The proposed Integrated Steel Plant involves manufacturing of following products Sponge iron : using Iron Ore, Coal and Dolomite as raw materials Ingots / Billets : Using DRI, MS scrap as raw materials in Induction Furnace TMT bars : Using Ingots as raw materials in Rolling mill for producing TMT bars Power generation : By utilizing waste hot gases from DRI in WHRB and using Dolochar (generated from DRI) as fuel in AFBC boiler Pioneer Enviro 1-4 Environmental Impact Assessment Report

5 N.R. ISPAT & POWER PRIVATE LIMITED Chapter SIZE OF THE PROJECT The proposed Integrated Steel Plant envisages manufacturing the following products TABLE 1.1 PRODUCTS AND CAPACITIES PROPOSED Sr. No. Details Plant Configuration Install Capacity 1. Sponge Iron Unit 2x 100 TPD Induction Furnace with 2 x 10 MT/ Heat Concast 3. Rolling Mill 1 x 200 TPD Power Plant (WHRB Based) 2 x 2 MW 4 MW 5. Power Plant (FBC) 1 x 10 MW 10 MW The capital investment of the proposed project is Rs. 95 Crores LOCATION OF THE PROJECT M/s. N.R. Ispat & Power Private Limited is proposed to establish an Integrated steel plant in Village: Gourmudi, Near Gerwani, Tehsil: Tamnar District: Raigarh, Chhattisgarh. The following factors have been considered for location of project. a. Availability of suitable and adequate facilities. b. Availability of water. c. Availability of raw materials. d. Availability of man power. e. Availability of infrastructural facilities f. Suitability of land from geological and topographical aspects. g. The following Environmental aspects (TOR # 3 & 4) h. There are no national parks / wild life sanctuaries within 10 Km radius of the proposed area. While following are the Reserved forest in the vicinity: Pioneer Enviro 1-5 Environmental Impact Assessment Report

6 N.R. ISPAT & POWER PRIVATE LIMITED Chapter - 1 Sr. No. Name of Reserved Forest Distance from Site Direction 1. Taraimal RF 3.0 KM NE 2. Rabo RF 8.0 KM NW 3. Urdana RF 5.0 KM SW i. However, we have filled an application has been filled to the State Forest Department regarding impact of the proposed unit on the Taraimal RF, which is under process. j. Nearest habitation is at a distance of about 1 km. from the site. k. No forest land is involved in the site. Based on the above guidelines the site has been chosen for the proposed Integrated Steel Plant. The proposed site is in accordance with MOEF guidelines, The topographical map showing the location of the plant is shown in Fig Pioneer Enviro 1-6 Environmental Impact Assessment Report

7 N.R. ISPAT & POWER PRIVATE LIMITED Chapter - 1 TOPOGRAPHICAL MAP SHOWING LOCATION OF PROJECT Fig No.1.1 Pioneer Enviro 1-7 Environmental Impact Assessment Report

8 N.R. ISPAT & POWER PRIVATE LIMITED Chapter IMPORTANCE OF PROJECT Steel has been regarded as the most useful product for mankind. It reaches every home, and has a wide range of applications from a small pin to the manufacture of automobiles, building of the railway systems, ships, big construction projects, housing, oil rigs, nuclear power stations an so on. Steel is also eco-friendly. Steel products are categorised into broad segments : Non-flat (popularly known as Long products) and Flat products. Finished steel Non-flat products include rounds, bars including re-enforcement bars, wire rods, structural such as angles, channels, joist / beams and railway materials in the shape of rails, wheels and axles. All these products play a key role in the growth of a country's more important sectors like construction, power, oil and gas, engineering, railway and road transportation, port, irrigation etc. INDIAN STEEL SCENARIO Indian steel industry is undergoing a period of restructuring, improving its ranking among global steel producers from the 9th place to the 7th place. In the last 5 years, the production and consumption of steel has grown at exceeding rates of 9% per annum. The pace of growth has further accelerated in the current year to over 10%. As per the latest CRISIL report a stable trend in the domestic steel industry s operating margin in as compared with that of , is predicted. The firm steel prices will keep the rise in input cost under check. The global demand-capacity ratio, which figured at around 89 percent in 2006, is expected to remain the same during 2007, which will maintain the similar price range as registered in the preceding year. Domestic prices are expected to follow the international prices trend. The CRISIL report also predicts buoyancy in the domestic steel demand. With healthy activity in pipes and tubes, automobiles and the construction segment, the demand for steel products is all set to scale. The report predicts a double-digit Pioneer Enviro 1-8 Environmental Impact Assessment Report

9 N.R. ISPAT & POWER PRIVATE LIMITED Chapter - 1 growth in demand for flat products with 11 percent to 21 Mn Tons during , where as demand for long products is expected to grow by 7.6 percent to 19 Mn Tons. The Eleventh Five Year Plan projects a 9% average annual growth in our GDP. Higher expectations to see a massive increase in investment in infrastructure is probable. Consequently, massive growth in demand for steel in the next few decades is also credible perhaps to levels never visualized before. BENEFIT TO THE REGION With the establishment of the proposed plant, there will be a lot of employment opportunities to the local people during construction and operation of the plant. During construction it creates employment to about 350 persons and during operation it creates employment to about 100 persons. Priority will be given to locals in employment. There will be upliftment of the socio-economic status of the people in the area due to the proposed project. In the light of the above scenario, M/s. N.R. Ispat & Power Private Limited has proposed to establish an Integrated steel plant in Village: Gourmudi, Near Tamnar, Tehsil: Tamnar District: Raigarh, Chhattisgarh SCOPE OF THE STUDY The scope of work includes a detailed characterization of the environment in an area of 10 km. radius of the plant for various environmental parameters like air, water, noise, land, biological and social-economic aspects and preparation of Draft EIA report incorporating all TOR issued by MOEF. Pioneer Enviro 1-9 Environmental Impact Assessment Report

10 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 2 2 CHAPTER II PROJECT DESCRIPTION 2.1 TYPE OF PROJECT The proposed Integrated Steel plant involves following activities Manufacturing of Sponge iron through DRI kiln using iron ore, Coal and Dolomite as raw materials Manufacturing of Steel ingots / Billets using Sponge iron / Pig Iron and Scrap as raw materials Manufacturing of TMT bars through Rolling Mill using Ingots / Billets as raw materials. Generation of Power using waste hot gases from sponge iron kiln through WHRB boilers and using Dolochar as raw material in FBC boiler. 2.2 NEED FOR THE PROJECT Indian steel industry is undergoing a period of restructuring, improving its ranking among global steel producers from the 9th place to the 7th place. In the last 5 years, the production and consumption of steel has grown at exceeding rates of 9% per annum. The pace of growth has further accelerated in the current year to over 10%. As per the latest CRISIL report a stable trend in the domestic steel industry s operating margin in as compared with that of , is predicted. The firm steel prices will keep the rise in input cost under check. The global demand-capacity ratio, which figured at around 89 percent in 2006, is expected to remain the same during 2007, which will maintain Pioneer Enviro 2-1 Environmental Impact Assessment Report

11 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 2 the similar price range as registered in the preceding year. Domestic prices are expected to follow the international prices trend. The CRISIL report also predicts buoyancy in the domestic steel demand. With healthy activity in pipes and tubes, automobiles and the construction segment, the demand for steel products is all set to scale. The report predicts a double-digit growth in demand for flat products with 11 percent to 21 Mn Tons during , where as demand for long products is expected to grow by 7.6 percent to 19 Mn Tons. The Eleventh Five Year Plan projects a 9% average annual growth in our GDP. Higher expectations to see a massive increase in investment in infrastructure is probable. Consequently, massive growth in demand for steel in the next few decades is also credible perhaps to levels never visualized before. In view of the above M/s. N.R. Ispat Private Limited has proposed establish a mini Integrated Steel Plant in Raigarh District. 2.3 LOCATION The proposed Integrated Steel Plant will be established at Gourmudi Village, Temnar Tehsil, Raigarh District, Chhattisgarh. The proponents have taken due care while selecting the site for this industry. The site is well in accordance with the guidelines issued by MOEF. The following are the salient features of the site proposed. Nearest habitation is at a distance of about 1.2 Kms. from the site There are no National Parks, Wild life Sanctuaries and Bird Sanctuaries within 10 Km radius. (TOR # 1) The following are the Reserved forests exist in the vicinity: Sr. No. Name of Reserved Forest Distance from Site Direction 1. Taraimal RF 3.0 KM NE 2. Rabo RF 8.0 KM NW 3. Urdana RF 5.0 KM SW Pioneer Enviro 2-2 Environmental Impact Assessment Report

12 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 2 We have submitted a letter to the State Forest Department regarding impact of the proposed unit on the Taraimal RF. (TOR # 4) Topography of the land is more or less flat without many undulations. No clearance of vegetation is required thus there will not any Soil erosion No habitations with in the site. Hence rehabilitation & resettlement are not involved. No forest land is involved in the site acquired. The following industries are situated in 25 Km radius (TOR # 5) TABLE 2.1 INDUSTRIES WITHIN 25 KM RADIUS S.NO NAME OF THE INDUSTRY TYPE 1 M/s. Nalwa Sponge Iron Ltd Steel Plant 2 M/s. Ind Agro Limited Steel Plant 3 M/s. MSP Steels Pvt. Ltd Steel Plant 4. M/s. Singhal Enterprises pvt. Ltd. Steel Plant 5. M/s. Seleno Steels Ltd. Steel Plant 6. M/s. Ambica Sponge Iron ltd. Steel Plant 7. M/s. Shyam Steel Pvt Ltd. Steel Plant 8. M/s. Anjani Steels (P) Ltd. Steel Plant 9. M/s. Navadurga Fuels(P) Ltd. Steel Plant 10. M/s. Salasar Sponge Iron & Power Ltd. Steel Plant 11. M/s. Raigarh Ispat Ltd. Steel Plant 12. M/s. B.S. Sponge Pvt Ltd. Steel Plant 13. M/s. Raigarh Iron Industries Ltd. Steel Plant 14. M/s. Siddhi Vinayak Sponge Iron Pvt Ltd. Steel Plant 15. M/s. Jindal Industrial Park. Steel Plant Pioneer Enviro 2-3 Environmental Impact Assessment Report

13 N.R. ISPAT & POWER PRIVATE LIMITED Chapter Acres of land is acquired for the proposed project. The following is the land use statement. LAND USE STATEMENT Item Area in Acres Built up area Internal roads 3.20 Storage yard 6.00 Greenbelt Open area Total land The general location of the proposed site is shown in fig The topographical map showing the location of the proposed site is shown in fig Pioneer Enviro 2-4 Environmental Impact Assessment Report

14 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 2 GENERAL LOCATION OF THE PROPOSED SITE L O C A T I O N O F T H E P R O J E C T I N T H E S T A T E N.R. ISPAT (P) LTD Fig 2.1 Pioneer Enviro 2-5 Environmental Impact Assessment Report

15 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 2 Fig 2.2 TOPOGRAPHICAL MAP Pioneer Enviro 2-6 Environmental Impact Assessment Report

16 N.R. ISPAT & POWER PRIVATE LIMITED Chapter SIZE / MAGNITUDE OF OPERATION The following are the proposed units and production capacities of the proposed project. Sr. No. Details Plant Configuration Production Capacity 1. Sponge Iron Unit 2x 100 TPD 60,000 TPA 2. Induction Furnace with Concast 2 x 10 MT/ Heat 60,000 TPA 3. Rolling Mill 1 x 200 TPD 60,000 TPA 4. Power plant WHRB Based 2 x 2 MW 4 MW FBC based 1 x 10 MW 10 MW Total power generation 14 MW The total capital investment of the proposed project is 95.0 Crores. 2.5 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION The project will be implemented in 12 months from the date of issue of Environmental Clearance. 2.6 TECHNOLOGY AND PROCESS DESCRIPTION RAW MATERIALS (TOR # 6) The following will be the raw material requirement for the proposed project. Item Quantity Source Method of Transportation (TPA) Iron ore 96,000 NMDC Bailadila By Rail/ Road (in covered trucks) Coal 1,17,000 SECL, Chhattisgarh By Rail/ Road (in covered trucks) Dolomite 2,400 Local areas By Road (in covered trucks) Scrap 4,950 Local areas By road (in covered trucks) Ferro alloys 300 Local areas By road (in covered trucks) Pioneer Enviro 2-7 Environmental Impact Assessment Report

17 N.R. ISPAT & POWER PRIVATE LIMITED Chapter RAW MATERIAL TRANSPORT, STORAGE & HANDLING Most of the raw materials will be transported through rail up to the nearest Railway station and from there they will be transported in covered trucks. Raw materials received will be transferred through loaders and conveyors to both open pile and enclosed storage sheds METHOD OF TRANSPORTATION Most of the raw materials will be transported by Rail to the nearest railway station. All the trucks used for transportation will be covered. Pucca road exist upto the site. The existing road is capable of absorbing this additional truck movement. Hence there will not be adverse impact due to the increased vehicular traffic due to the proposed project MATERIAL BALANCE The following is the material balance for the proposed plant 1. SPONGE IRON (60,000 TPA) INPUTS OUTPUTS S. No. Item Quantity (TPA) Item Quantity (TPA) 1 Iron Ore 96,000 Sponge Iron 60,000 2 Washed Coal 78,000 Dolochar 18,000 3 Dolomite 2,400 Gases Ash / Dust Wet Scraper sludge 2760 Accretion slag 540 Total 1,76,400 Total 1,76,400 Gases Gases E l e c t r i c i t y ( W H R B ) 2 X 2 = 4 MW 2) INDUCTION FURNACE (SMS - Billets: 60,000 TPA) INPUTS OUTPUTS S. No. Item Quantity (TPA) Item Quantity (TPA) 1 Sponge Iron (Own.Gen) 60,000 Billets 60,000 2 Scrap 8,700 Slag 6,000 3 Ferro Alloys Gases including 300 dust 3,000 Total 69,000 Total 69,000 Pioneer Enviro 2-8 Environmental Impact Assessment Report

18 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 2 3) ROLLING MILL (60,000 TPA) INPUTS OUTPUTS S. No. Item Quantity (TPA) Item Quantity (TPA) 1 Billets 63,330 (Own gen TMT bars 60,000 Ext. purchase-3330) Mill scales 3000 Gases 330 Total 63,330 Total 63,330 4 ) POWER PLANT (10 MW FBC Based Power Plant) INPUTS OUTPUTS S. N o. I t e m Quantity (TPA) Ite m Quantity (TPA) 1 Dolochar 18,000 Ash 28,350 2 Coal 39,000 Gases 28,650 Total 57,000 Total 57,000 ENERGY BALANCES ( T O R # 2 1 ) Total Captive Power Generation 1 4 M W D R I i n c l u d i n g A u x i l i a r y c o n s u m p t i o n i n W H R B SMS Rolling Mill FBC Power Plant A u x i l i a r y c o n s u m p t i o n M W 10 M W 1. 5 M W M W MANUFACTURING PROCESS (TOR # 7) PRODUCTION OF SPONGE IRON (DRI) 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 Pioneer Enviro 2-9 Environmental Impact Assessment Report

19 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 2 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 100 o C in cooler by spraying water. The 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 STEEL MELTING SHOP Induction furnaces 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, 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 2 nos. of induction furnaces in the SMS plant each of 10T capacity. Pioneer Enviro 2-10 Environmental Impact Assessment Report

20 N.R. ISPAT & POWER PRIVATE LIMITED Chapter Concast Machine Billets will be produced in concast machine ROLLING MILL (Manufacturing of TMT Bars) The company has proposed to establish a rolling mill with a capacity of 60,000 TPA. Furnace oil will be used as fuel in the reheating furnace POWER GENERATION (TOR # 20) Waste Heat Recovery Boilers will be installed behind the DRI kiln in bypass configuration. Electricity generation in the proposed power plant is characterized by the main source of heat generation being firing of coal, char and waste heat of DRI kilns. The waste gases from the DRI kilns will pass through WHRB s to generate Power. Steam is produced in a boiler, and it drives a turbine connected to an alternator. Heat energy is converted to electric energy within the so-called steam cycle. The flue gases after ABC will be taken to unifired furnace chamber and then flow over banks of super heater, convective evaporator and economizer before being discharged to atmosphere through ESP, ID fan and stack. In the Fluidized Bed Combustion boiler envisaged, combustion of fuel particles is achieved in suspension with an inert aggregate i.e. sand. Combustion air will be fed through air nozzles from underneath into the sand fuel bed. Oil burner will be provided for start up and low load flame stabilization. The fuels proposed in FBC Boiler are coal & dolochar. The flue gases will pass over various heat transfer surfaces to ESP and then finally discharged into chimney by ID fan. The condensate after condenser of STG will be pumped to a common deaerator by condensate extraction pumps. Feed water from the deaerator will be pumped to the waste heat recovery boiler as well as FBC boiler by boiler feed pumps. The steam generated from both the WHRB and FBC boilers will drive the steam turbine through a common steam header. Pioneer Enviro 2-11 Environmental Impact Assessment Report

21 N.R. ISPAT & POWER PRIVATE LIMITED Chapter FLUE GAS UTILIZATION (TOR # 20) From DRI Kilns: The hot gases from DRI kilns will be taken to WHRB and after heat recovery it will be used for Power Generation. A total of 4 MW will be generated through flue gases from DRI CARBON CREDIT PROJECT (TOR # 26) CDM initiatives will be considered in due course. 2.7 ENVIRONMENTAL MITIGATION MEASURES 1. AIR POLLUTION CONTROL (A) Sponge Iron (DRI) After Burning Chamber will be provided to eliminate the CO emissions. In the proposed plant the exhaust gases from the rotary kiln will pass through a Waste Heat Recovery Boiler (WHRB) and after heat recovery the gases will pass through a state-of-the-art Electro Static Precipitator to bring down the particulate matter in the exhaust gases to less than 50 mg/nm 3. Then the treated gases will be let out through a combined stack (with twin flues) of 60 m height for effective dispersion of emissions into the atmosphere. Dust extraction system with Bagfilters will be provided at material transfer points, crusher area, cooler discharge, product separation area, etc. to control dust emission. All the material handling systems will be connected with de dusting system. All the 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. Water sprinklers will be provided for dust suppression during unloading of raw materials. All conveyors will be covered with GI sheets to prevent the fugitive dust. All internal roads will be asphalted to prevent the fugitive dust due to vehicular transport. Pioneer Enviro 2-12 Environmental Impact Assessment Report

22 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 2 (E) Steel Melting Shop The Fugitive emissions from the Induction furnace will be sucked through hoods and will pass through a fume extraction system with bag filters and then let out through a combined stack of 30m height. The outlet dust emission in the exhaust gases will be (F) less than 50 mg/nm 3. The dust will be pneumatically carried to covered bins. Rolling Mill The flue gases from the Rolling Mill will be let out through a stack of 40 m height for effective dispersion of emissions into the atmosphere. The stack height is designed as (G) per CPCB norms. Power Generation The flue gases from the boiler will be treated in a state-of-the-art Electro Static Precipitator to bring down the particulate emission to less than 50 mg/nm 3 and will be let out through a stack of 50 m height for effective dispersion of emissions into the (H) atmosphere. Internal Roads All internal roads will be asphalted to prevent fugitive emissions due to vehicular movement. 2. WATER POLLUTION There will not be any process waste water (or) cooling blowdown generation from the DRI Kilns, SMS and Rolling mill plants as closed circuit cooling system will be followed. Boiler blowdown, CT Blow down & DM Plant regeneration will be the sources of effluent generation from the power plant. This effluent will be treated in Neutralisation tank and utilized for dust suppression and for greenbelt development. Zero effluent discharge will be maintained in the premises. Sanitary waste water will be treated in septic tank followed by soak pit. Pioneer Enviro 2-13 Environmental Impact Assessment Report

23 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 2 3. NOISE POLLUTION Acoustic enclosures will be provided to Turbines. All turbines & other machinery will be manufactured to comply with MOEF standards on Noise Levels. The noise levels will be confined to the working zones of the plant. Ear plugs will be provided to all employees who will enter into the noise prone areas. The ambient Noise levels will be in accordance with MoEF notification dated i.e. noise levels will be < 75 dba during daytime and < 70 dba during night time. 4. SOLID WASTE (TOR # 19) Dolochar from DRI units will be completely utilized in FBC boiler to generate power. Slag from SMS will be used as sub base material in road construction or for back filling material. Mill scales will be used in SMS. Ash will be given to Cement Plants / given to Brick Manufacturers. Hence there will not be any adverse impact on land environment due to the solid waste generation. 5. GREEN BELT 15 m wide greenbelt will be developed all round the plant. 6. INTERNAL ROADS All Internal roads will be asphalted to prevent the fugitive dust emission due to vehicular movement. Pioneer Enviro 2-14 Environmental Impact Assessment Report

24 N.R. ISPAT & POWER PRIVATE LIMITED Chapter ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR THE RISK OF TECHNOLOGICAL FAILURE Manufacturing technologies of all the units proposed in this project are well proven technologies all over the world. Hence there will not be any risk of technological failure from this plant. Pioneer Enviro 2-15 Environmental Impact Assessment Report

25 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 3 CHAPTER III DESCRIPTION OF ENVIRONMENT (BASELINE ENVIRONMENTAL STATUS) This chapter gives an idea and description of environmental status of the study area with reference to the prominent environmental attributes. The general study area covers 10 Km. radius of the steel plant. The impact identification always commences with the collection of baseline data such as ambient air quality, ground water quality, noise levels, land environment, land use pattern, flora & fauna and socio economic aspects with in the study zone of 10 Km. radius. 3.1 AIR ENVIRONMENT METEOROLOGY (TOR # 8) Meteorology of the study area plays an important role in the air pollution studies. The prevailing micro meteorological conditions at the Steel plant site will regulate the dispersion and dilution of air pollutants in the atmosphere. The predominant wind directions and the wind speed will decide the direction and distance of the most affected zone from the proposed activity. The meteorological data collected during the monitoring period is very useful in interpretation of baseline data as input for dispersion models for predicting the Ground Level Concentrations (GLC). Rainfall The average annual rainfall based in 10 years data collected from the nearest meteorological center is found to be 1143 mm. Pioneer Enviro 3-1 Environmental Impact Assessment Report

26 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 Meteorological data recorded at site WIND PATTERN AT SITE Summer season (March 08 May 08) The predominant winds from NW direction were observed for 20.4 % of the total time, with wind speeds (with % frequencies) in the range of 1-5 kmph (12.0 %), 6-11 kmph (3.0%), kmph (3.0 %) and >19 kmph (2.4 %). The winds from SE direction were observed from 16.0 % of the total time, with wind speeds (with % frequencies) in the range of 1-5 kmph (6.0 %), 6-11 kmph (4.0%), kmph (4.0 %) and >19 kmph (2.0 %). The winds from NE direction were observed from 14.5% of the total time, with wind speeds (with % frequencies) in the range of 1-5 kmph (6.5 %), 6-11 kmph (3.0 %), kmph (3.0 %) and >19 kmph (2.0 %). N, NEE, E, SEE, S, SSW, SW, SWW, W, NWW and NNW directions were observed for 3.0 %, 2.0 %, 1.0 %, 0 %, 2.0%, 1.0 %, 2.0 %, 1.0, 2.0, 4.0 & 2.0 % of the total time respectively. Calm conditions prevailed for 29.1 % of the total time. A Temporary Weather Monitoring Station was installed at the site and temperature, relative humidity, wind direction, wind speed, and rainfall were recorded for one season (summer). Temperature The maximum temperature recorded was C and the minimum temperature was C at the Project site. Wind direction and speed are recorded at site every hour. The wind rose diagram of the site is shown in fig COMPARISON WITH IMD DATA The wind rose plotted at site is compared with IMD wind rose. The wind rose at site is more or less consistent with regional meteorology. Pioneer Enviro 3-2 Environmental Impact Assessment Report

27 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 WINDROSE AT SITE C A L M % SCALE < 19 SCALE: 1 CM = 3 % Pioneer Enviro 3-3 Environmental Impact Assessment Report

28 N.R. ISPAT & POWER PRIVATE LIMITED Chapter AIR QUALITY (TOR # 9) The ambient air quality with respect to the study zone of 10 Km. radius around the plant site forms the baseline information. The study area represents mostly rural environment. The various sources of air pollution in the region are vehicular traffic, dust arising from unpaved village roads. The Prime objective of baseline air quality survey is to assess the existing air quality of the area. This will also be useful is assessing the conformity to standards of the ambient air quality during the plant operation SELECTION OF SAMPLING STATIONS The base line status of the ambient air quality can be assessed through scientifically designed Ambient Air Quality Monitoring Network. The selection of sampling locations in the air quality surveillance programme is based on the following. (a) Representation of project site. (b) Representation of down wind direction. (c) Representation of cross sectional distribution in the down wind direction. (d) Representation of residential areas. (e) Representation of regional background levels. Eight nos. of Ambient Air Quality Monitoring Stations were established with in the study zone of the plant in accordance with CPCB guidelines. One AAQMS was located in Taraimal RF area. The sampling locations and their distances are shown in Table and in fig 3.2 The Max., Min., Avg., and 98 th percentile values for all the sampling locations for RSPM, SPM, SO2 and NOX are shown in Table to Pioneer Enviro 3-4 Environmental Impact Assessment Report

29 N.R. ISPAT & POWER PRIVATE LIMITED Chapter PARAMETERS MONITORED (TOR # 15) At each Monitoring Station Respirable Suspended Particulate Matter (RSPM), Suspended Particulate Matter (SPM), SO2, & NOX are monitored. The sampling was carried out for 2 days in a week for three months (March-2008 to May- 2008) to assess the existing status of air pollution and pollution dispersion pattern over the whole air basin of plant. RSPM, SPM, SO2, and NOX are sampled as per MOEF guidelines SAMPLING & ANALYTICAL TECHNIQUES INSTRUMENTS USED FOR SAMPLING Envirotech RDS dust sampler is used for monitoring RSPM, SPM, SO2 and NOx. RSPM & SPM are estimated by gravimetric method West & Gaeke method (IS 5182, part III 1969) has been adopted for estimation of SO2, Jacob Hochheiser method (IS 5182, part IV, 1975) has been adopted for estimation of NOx. Suspended Particulate Matter (SPM) was analyzed for Poly-aromatic Hydro Carbons (PAH). (TOR # 10) Calibration Calibration charts have been prepared for all gaseous pollutants. The Calibration is carried out when new absorbing solutions are prepared. TABLE AMBIENT AIR QUALITY MONITORING STATIONS S.NO STATION DIRECTION DISTANCE IN KMS. 1 Project Site Gaurmudi W Dilari SE Saraipali W Punjipathara NNE Taraimal NE Gerwani SSE Jamdbari NW 3.75 Pioneer Enviro 3-5 Environmental Impact Assessment Report

30 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 Punji Patra Jamdabri Gourmudii Taraimal Saraipali Delari Gerwani P R O J E C T S I T E AMBIENT AIR QUALITY MONITORING STATIONS Monitoring Stations Pioneer Enviro 3-6 Environmental Impact Assessment Report

31 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 TABLE Sampling Location: Project Site Sampling period: Mar -May 2008 Unit : µg/m 3 P a r a m e t e r M a x i m u m M i n i m u m A v e r a g e 9 8 th percentile RSPM* SPM SO NO x * PAH in SPM was BDL TABLE Sampling Location: Gaurmudi Sampling period: Mar -May 2008 Unit : µg/m3 P a r a m e t e r M a x i m u m M i n i m u m A v e r a g e 9 8 th percentile RSPM* SPM SO NO x * PAH in SPM was BDL TABLE Sampling Location: Dilari Sampling period: Mar -May 2008 Unit : µg/m 3 P a r a m e t e r M a x i m u m M i n i m u m A v e r a g e 9 8 th percentile RSPM* SPM SO NO x * PAH in SPM was BDL Pioneer Enviro 3-7 Environmental Impact Assessment Report

32 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 TABLE Sampling Location: Saraipali Sampling period: Mar -May 2008 Unit : µg/m 3 P a r a m e t e r M a x i m u m M i n i m u m A v e r a g e 9 8 th percentile RSPM* SPM SO NO x * PAH in SPM was BDL TABLE Sampling Location: Punjipathara Sampling period: Mar -May 2008 Unit : µg/m 3 P a r a m e t e r M a x i m u m M i n i m u m A v e r a g e 9 8 th percentile RPM SPM SO NO x * PAH in SPM was BDL TABLE Sampling Location: Taraimal Sampling period: Mar -May 2008 Unit : µg/m3 P a r a m e t e r M a x i m u m M i n i m u m A v e r a g e 9 8 th percentile RSPM* SPM SO NO x * PAH in SPM was BDL Pioneer Enviro 3-8 Environmental Impact Assessment Report

33 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 TABLE Sampling Location: Gerwani Sampling period: Mar -May 2008 Unit : µg/m3 P a r a m e t e r M a x i m u m M i n i m u m A v e r a g e 9 8 th percentile RSPM* SPM SO NO x * PAH in SPM was BDL TABLE Sampling Location: Jamdbari Sampling period: Mar -May 2008 Unit : µg/m 3 P a r a m e t e r M a x i m u m M i n i m u m A v e r a g e 9 8 th percentile RSPM* SPM SO NO x * PAH in SPM was BDL The avg. SPM concentration at the Project site is µg/m 3. The avg. RPM concentration at the Project site is 44.9 µg/m 3. The avg. SO2 & NOx concentrations recorded at the Project site are 10.4 & 13.3 µg/m 3 respectively. The maximum average RPM concentration was recorded at near Project site with a value of 44.9 µg/m 3. The maximum average SPM concentration was recorded at Patrapali with a value of µg/m 3. The maximum average SO2 concentration was recorded at Patrapali with a value of 10.4 µg/m 3. The maximum average NOx concentration was recorded at Kotarlia with a value of 13.3 µg/m 3. PAH at all the monitoring stations is Below Detectable Level (BDL). (TOR # 10) Pioneer Enviro 3-9 Environmental Impact Assessment Report

34 N.R. ISPAT & POWER PRIVATE LIMITED Chapter NOISE ENVIRONMENT The physical description of sound concerns its loudness as a function of frequency. Noise in general is sound, which is composed of many frequency components of various loudness distributed over the audible frequency range. Various noise scales have been introduced to describe, in a single number, the response of an average human being to a complex sound made up various frequencies at different loudness levels. The most common and heavily favored of those scales is the weighted decibel (dba). This is more suitable for audible range of 20 to 20,000 Hertz. The scale has been designed to weigh various components of noise according to the response of a human ear. The impact of noise sources on surrounding community depends on Characteristics of noise sources (instantaneous, intermittent or continuous in nature). It is well known that steady noise is not as annoying as one that is continuously varying in loudness. The time, at which noise occurs, for example loud noise levels at night in residential areas are not acceptable because of sleep disturbance. The location of the noise source, with respect to noise sensitive area, which determines the loudness and period of noise exposure. The environmental impact of noise can have several effects varying from Noise Induced Hearing Loss (NIHL) to annoyance depending on loudness of Noise levels. The environmental impact assessment of noise from the plant can be carried out by taking into consideration of various factors: potential damage to hearing, potential physiological responses, annoyance and general community responses. The main objective of noise level monitoring is to assess the background noise levels in different zones viz., industrial, commercial, residential and silence zones within the study area. Pioneer Enviro 3-10 Environmental Impact Assessment Report

35 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 The basic studies conducted were a. Assessment of background noise levels. b. Identification and monitoring the major noise generating sources in the study area. c. Impact of noise on general population in the study zone of 10 Km. radius RECONNAISSANCE Noise levels were measured at different locations within 10 Km. radius of the plant such as villages, bus stands etc BACKGROUND NOISE Baseline noise data has been measured at different locations using A-weighted sound pressure level meter. The equivalent day-night noise levels in the study zone are ranging from dba to dba SOURCES OF NOISE Typical considerations in environmental noise assessment can be divided into two categories, one is related to noise sources and the other related to potential receiver. Two quantities are needed to describe completely the strength of the source. They are sound power level and directivity. Sound power levels measures the total sound power radiated by the source in all directions where as directivity is a measure of difference in radiation with direction. This concept of sound power level and directivity index makes it possible to calculate the sound pressure level created by the source COMMUNITY NOISE The ambient noise level is characterized by significant variations above a base or a residual noise level. The residual noise level is that level below which the ambient noise does not seem to drop during a given time interval and is generally caused by the unidentified distant sources. It differs in rural and urban areas. At night, its level is low due to lesser elements of noise. The Pioneer Enviro 3-11 Environmental Impact Assessment Report

36 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 annoyance that people experience depends upon the number of noise elements that produce noise concurrently at a given time that occur during a time interval. The noise rating developed by EPA for specification of community noise from all sources is the day night sound level, Ldn. It is similar to a 24 hour equivalent sound level except that during the night period, which extends from p.m. to 7.00 a.m. A 10 dba weighing penalty is added to the account for the fact that noise at night when people are trying to sleep is judged more annoying than the same noise during the day time. The Ldn for a given location in a community is calculated from an hourly equivalent sound level given be the following equation. Ldn =10 log (1/24 [15 (10 (Ld/10) + 9 (10 (Ln+10)/10 )] ) Where Ld is the equivalent noise level during day time (7A.M. to 10 P.M.) Ln is the equivalent noise level during night time (10 P.M. to 7 A.M.) OCCUPATIONAL EXPOSURE To assess the magnitude of impact due to noise sources, it is essential to know the following. a. The duration of sound. b. Distribution through the working day. c. Overall noise levels. d. It s composition including frequency and intensity at various intervals of time. Other factors regarding receiver include a. The age of the individual. b. The sensitivity of the individual. c. The efficiency of the protective devices used. After characterizing the noise sources noise at receiver s location, the impact must be assessed. The environmental impact of noise can lead to the following effects. Pioneer Enviro 3-12 Environmental Impact Assessment Report

37 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 a. Damages the hearing capacity. b. Interference in communication. c. Interference with work. d. Interference with sleep. e. Causes annoyance NOISE LEVEL OBSERVATIONS IN THE STUDY AREA Baseline noise levels have been monitored at different locations within the study zone of the plant. Eight nos. of stations have been selected for measurement of noise levels and their distances with respect to site are shown in table TABLE NOISE LEVEL MONITORING STATIONS S.NO STATION DIRECTION DISTANCE IN KMS. 1 Project Site Gaurmudi W Dilari SE Saraipali W Punjipathara NNE Taraimal NE Gerwani SSE Jamdbari NW 3.75 TABLE EQUIVALENT DAY NIGHT NOISE LEVEL S.No. LOCATION EQUIVALENT NOISE LEVELS (dba) DAY NIGHT DAY-NIGHT 1 Project Site Gaurmudi Dilari Saraipali Punjipathara Taraimal Gerwani Jamdbari Pioneer Enviro 3-13 Environmental Impact Assessment Report

38 N.R. ISPAT & POWER PRIVATE LIMITED Chapter WATER QUALITY IMPACTS Surface water Quality (TOR # 16) The water required for the plant will draw from Delari Jharna Nallah which is situated at a distance of 1.5 kms. from the proposed site by laying a dedicated pipe line. The water analysis of the Sapnai river is given in Table no TABLE NO SURFACE WATER QUALITY ANALYSIS Station : Delari Jharma Nallah (60m upstream) S. NO. PARAMETER U N I T RESULTS P H Y S I C A L C H A R A C T E R I S T I C S 1. Colour ph Turbidity NTU 2 4. Electrical Conductivity ms/cm Total Dissolved Solids mg/l 113 C H E M I C A L C H A R A C T E R I S T I C S 6. Total Hardness mg/l Calcium Hardness mg/l Magnesium Hardness mg/l Alkalinity mg/l Sulphates mg/l Chlorides mg/l Nitrates as NO 3 mg/l Fluoride as F mg/l Sodium as Na mg/l COD mg/l Residual chlorine mg/l < Cyanides as CN - mg/l < Phenols as C 6 H 5 OH mg/l Absent 19. Hexavalent chromium as Cr mg/l < Iron as Fe mg/l Copper as Cu mg/l < Arsenic as As mg/l < Selenium mg/l < Cadmium as cd mg/l < Boron as B mg/l < Mercury as Mg mg/l < Lead as Pb mg/l < Silica as SiO 2 mg/l Mineral oil mg/l < Total coliforms (MPN/100 ml) 12 Pioneer Enviro 3-14 Environmental Impact Assessment Report

39 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 TABLE NO SURFACE WATER QUALITY ANALYSIS Station : Delari Jharma Nallah (60m down stream) S. NO. PARAMETER UNIT RESULTS PHYSICAL CHARACTERISTICS 1. Colour ph Turbidity NTU 1 4. Electrical Conductivity ms/cm Total Dissolved Solids mg/l 110 CHEMICAL CHARACTERISTICS 6. Total Hardness mg/l Calcium Hardness mg/l Magnesium Hardness mg/l Alkalinity mg/l Sulphates mg/l Chlorides mg/l Nitrates as NO 3 mg/l Fluoride as F mg/l Sodium as Na mg/l COD mg/l Residual chlorine mg/l < Cyanides as CN - mg/l < Phenols as C 6 H 5 OH mg/l Absent 19. Hexavalent chromium as Cr mg/l < Iron as Fe mg/l Copper as Cu mg/l < Arsenic as As mg/l < Selenium mg/l < Cadmium as cd mg/l < Boron as B mg/l < Mercury as Mg mg/l < Lead as Pb mg/l < Silica as SiO 2 mg/l Mineral oil mg/l < Total coliforms (MPN/100 ml) 16 Pioneer Enviro 3-15 Environmental Impact Assessment Report

40 N.R. ISPAT & POWER PRIVATE LIMITED Chapter 3 SURFACE WATER QUALITY ANALYSIS Station : at other surface drains S. NO. PARAMETER UNIT SAMPLE I SAMPLE II SAMPLE III SAMPLE IV PHYSICAL CHARACTERISTICS 1. Colour ph Turbidity NTU Electrical Conductivity ms/cm Total Dissolved Solids mg/l CHEMICAL CHARACTERISTICS 6. Total Hardness mg/l Calcium Hardness mg/l Magnesium Hardness mg/l Alkalinity mg/l Sulphates mg/l Chlorides mg/l Nitrates as NO3 mg/l Fluoride as F mg/l Sodium as Na mg/l COD mg/l Residual chlorine mg/l <0.01 <0.01 <0.01 < Cyanides as CN - mg/l <0.01 <0.01 <0.01 < Phenols as C6H5OH mg/l Absent Absent Absent Absent 19. Hexavalent chromium as Cr mg/l <0.01 <0.01 <0.01 < Iron as Fe mg/l Copper as Cu mg/l <0.01 <0.01 <0.01 < Arsenic as As mg/l <0.01 <0.01 <0.01 <0.01 Pioneer Enviro 3-16 Environmental Impact Assessment Report

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