CHAPTER I INTRODUCTION

Transcription

1 Chapter 1 1 CHAPTER I INTRODUCTION 1.0 PREAMBLE M/s B.S. Sponge Private Limited is an existing plant operating 2 x 100 TPD Sponge Iron plant in Taraimal Village, Ghargoda Tehsil, Raigarh District, Chhattisgarh. The existing plant is having valid Consent to Operate issued by Chhattisgarh Environment Conservation Board vide order No s 4496/TS/CECB/2008 & 4498/TS/CECB/2008 dated which is valid up to Now as a part of proposed expansion it has been proposed to enhance the production of Sponge Iron and also to go forward integration to produce Billets and Structural steels. The existing and proposed production capacities are furnished below Sr. Existing production Proposed production Total Units No capacity (TPA) capacity (TPA) (TPA) 1. Sponge Iron 60,000 1,20,000 1,80, Induction Furnace --- 1,62,000 1,62,000 with Concast 3. Rolling Mill --- 1,05,000 1,05, Ferro alloys ,000 25, Power Plant WHRB FBC Total The proposed expansion will be taken up in the existing plant premises only. 1.1 PURPOSE OF THE REPORT As per the Ministry of Environment & Forests, New Delhi notification, dated 14 th September, 2006 Sponge Iron plant of 200 TPD and above capacity is classified under Category A. Hence Form I along with proposed draft TOR for REIA study & Pre - PIONEER ENVIRO 1-1 Environmental Impact Assessment Report

2 Chapter 1 Feasibility report have been submitted to the Ministry Of Environment & Forests and presentation was made before the Honourable Expert Appraisal Committee of the MoEF on 13 th May, 2008 for the approval of TOR for REIA study. This Draft REIA report has been prepared incorporating all TORs issued by the Ministry vide letter No. J /313/2008-IA II (I) dated 6 th June 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 expansion 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. 1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT M/s B.S. Sponge Private Limited is a registered company established in the year of 2000 The following are the Board of directors of the company. 1. Shri. Parmanand Agarwal, Managing Director 2. Shri. Ashish Agarwal, Director The turnover of the company is presently Rs Crores approximately. Now it has been proposed to enhance the production capacity of existing Sponge Iron, forward integration i.e. to produce Billets and structural steel, produce Ferro alloys generate 48 MW Electricity using wastes generated from DRI Kiln (WHRB based) & Char/ Dolochar/ Coal (FBC based). Expansion project will be taken up in the existing plant premises only (admeasuring about 90 acres). PIONEER ENVIRO 1-2 Environmental Impact Assessment Report

3 Chapter BRIEF DESCRIPTION NATURE OF THE PROJECT The proposed expansion project involves production of Sponge Iron, Billets, Structural steels, Ferro alloys and generation of 48 MW electricity SIZE OF THE PROJECT M/s B.S. Sponge Private Limited has proposed to go for expansion in the existing Plant premises. The existing and proposed expansion details are furnished below S.No Units Existing production Proposed production Total capacity (TPA) capacity (TPA) (TPA) 1. Sponge Iron 60,000 1,20,000 1,80, Induction Furnace --- 1,62,000 1,62,000 with Concast 3. Rolling Mill --- 1,05,000 1,05, Ferro alloys ,000 25, Power Plant WHRB FBC Total The capital investment of the expansion project is Rs Crores LOCATION OF THE PROJECT M/s B.S. Sponge Private Limited is an existing plant operating 2 x 100 TPD Sponge Iron Plant in Taraimal Village, Ghargoda Tehsil, Raigarh District. The following factors have been considered for selection of site for the existing plant. 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 PIONEER ENVIRO 1-3 Environmental Impact Assessment Report

4 Chapter 1 No National Parks, Wildlife Sanctuaries, Bird sanctuaries within 10 Km. radius of the plant. (TOR # 1) No Historical places of tourist importance within 10 Km. radius of the site. Based on the above guidelines the existing plant premises have been chosen for proposed expansion. The existing plant is having a valid Consent to operate issued by CECB. The existing plant is in accordance with MOEF norms. The proposed expansion will be taken up in the existing plant premises only. Total land available for existing and expansion project is 90 acres. Hence the area earmarked for expansion will also be in accordance with MOEF norms. The topographical map showing the location of the plant is shown in Fig PIONEER ENVIRO 1-4 Environmental Impact Assessment Report

5 Chapter 1 PROJECT SITE TOPOGRAPHICAL MAP SHOWING LOCATION OF PROJECT Fig No.1.1 PIONEER ENVIRO 1-5 Environmental Impact Assessment Report

6 Chapter IMPORTANCE OF PROJECT Steel Production in India India is one of the few countries where the steel industry is poised for rapid growth. India's share in world production of crude steel increased from 1.5% in 1981 to around 3.5 % in While plant closures and privatization are rare in India, the private sector is considered to be the engine of growth in the steel industry and technological changes and modernization are taking place in both the public and the private sector integrated steel plants in India. Steel production of India accounted for million tons in , which gradually increased to million tones in , as shown in Table below. The Indian steel industry got a giant importance in the recent past when the Tata Steel purchased the Corus steel. Today India plays a significant role in the production of steel in the world. The Indian steel industry is growing at 8.74 % of CAGR. Production of steel in India (In Million Tonnes) Year Main Producers Secondary Producers Grand Total Annual Compound Growth Rate = 8.74% PIONEER ENVIRO 1-6 Environmental Impact Assessment Report

7 Chapter 1 In the light of the above scenario, M/s B.S. Sponge Private Limited has proposed to enhance the existing production capacity of Sponge, produce Billets, Structural steels, Ferro alloys and to generate Electricity. The proposed expansion will be taken-up in the existing plant premises 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. This report is prepared in accordance with the TOR issued by the Ministry vide letter No. J-11011/313/2008-IA II (I) dated 6 th June PIONEER ENVIRO 1-7 Environmental Impact Assessment Report

8 Chapter 2 2 CHAPTER II PROJECT DESCRIPTION 2.1 TYPE OF PROJECT Steel consists mostly iron, with a carbon content between 0.02% and 1.7 or 2.04% by weight (C: , 8.67 Fe), depending on grade. Carbon is the most cost-effective alloying material for iron, but various other alloying elements are used such as manganese and tungsten. Carbon and other elements act as a hardening agent, preventing dislocations in the iron atom crystal lattice from sliding past one another. Varying the amount of alloying elements and form of their presence in the steel (solute elements, precipitated phase) controls qualities such as the hardness, ductility, and tensile strength of the resulting steel. Steel with increased carbon content can be made harder and stronger than iron, but is also more brittle. The maximum solubility of carbon in iron (in austenite region) is 2.14% by weight, occurring at 1149 C; higher concentrations of carbon or lower temperatures will produce cementite. Alloys with higher carbon content than this are known as cast iron because of their lower melting point. Steel is also to be distinguished from wrought iron containing only a very small amount of other elements, but containing 1-3% by weight of slag in the form of particles elongated in one direction, giving the iron a characteristic grain. PIONEER ENVIRO 2-1 Environmental Impact Assessment Report

9 Chapter NEED FOR THE PROJECT Driven by buoyant steel-intensive economic activity including construction and infrastructure building in many developing economies, global apparent consumption of steel has increased at an average pace of more than 7 percent per annum since 2002 to reach a record level of billion tonnes last year. To meet this rise in demand, steel production growth has accelerated sharply, reaching 1.24 billion tonnes in 2006, up by as much as 393 million tonnes (or 46%) compared to its level of 850 million tonnes in This growth in demand for steel is creating a favourable situation for many steelmakers. India's rapid economic growth is being built on a frame of steel. Soaring demand by sectors like infrastructure, real estate and automobiles, at home and abroad, has put India's steel industry on the world map. Growth potential: The per capita steel consumption in India is abysmally low at around 30 kgs as compared to 210 kgs of China and over 400 kgs in the developed countries. This wide gap in relative steel consumption indicates that the potential ahead for India to raise its steel consumption is high. Continued demand: Meteoric rise in steel prices since 2003 until early 2005 helped the domestic steel companies immensely as many of them managed to reduce their debt burden considerably, helping them either turn into profits or increase the same significantly. Going forward, the demand for the metal is likely to sustain on the back of continuing demand from the US and other South East Asian nations. PIONEER ENVIRO 2-2 Environmental Impact Assessment Report

10 Chapter 2 Domestic help: A robust housing and infrastructure sector, with growth potential in the auto and the consumer durables sectors is likely to be a big positive for the domestic steel sector. 2.3 LOCATION M/s B.S. Sponge Private Limited is an existing plant operating 2 x 100 TPD sponge iron plant at Taraimal Village, Gharghoda Tehsil, Raigarh District, Chhattisgarh. The existing plant is having valid Consent For Operation from CECB which is valid up to Now as a part of the proposed expansion company has proposed to Enhance the production of Sponge Iron Produce Billets, Structural Steels, Ferro alloys and Generate Electricity of 48 MW in the existing Plant premises. 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 2.5 Km. The existing land is industrial. There are no National Parks, Wild life Sanctuaries and Bird Sanctuaries within 10 Km radius. (TOR # 1); however the following are the Reserved forests exist in the vicinity: Sr. No. Name of Reserved Forest Distance from Site Direction 1. Taraimal RF 0.6 KM N 2. Rabo RF 8.5 KM W 3. Urdana RF 5.25 KM SW Topography of the land is more or less flat without many undulations. PIONEER ENVIRO 2-3 Environmental Impact Assessment Report

11 Chapter 2 No clearance of vegetation is required thus there will not be any Soil erosion No habitations with in the site. Hence rehabilitation & resettlement are not involved. No forest land is involved in the existing plant. The following industries are situated with in 25 Km. radius.(tor # 4) Sr. 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. (Applicant) Steel Plant 13. M/s. Raigarh Iron Industries Ltd. Steel Plant 14. M/s. Scania Steel Pvt Ltd. Steel Plant 15. M/s. Jindal Industrial Park. Steel Plant 16. M/s Jindal Steel Plant, Raigarh Total land available for existing and expansion is 90 acres. The following is the land use statement LAND USE STATEMENT Area in acres Existing Expansion Total Built up area Internal roads Storage yard Greenbelt Open area Total land PIONEER ENVIRO 2-4 Environmental Impact Assessment Report

12 Chapter SIZE / MAGNITUDE OF OPERATION The details of the existing and proposed production capacities are furnished below S.No Units Existing production capacity (TPA) Proposed production capacity (TPA) Total (TPA) 1. Sponge Iron 60,000 1,20,000 1,80, Induction Furnace with Concast --- 1,62,000 1,62, Rolling Mill --- 1,05,000 1,05, Ferro alloys ,000 25, Power WHRB Plant FBC Total The plant will be operated for a maximum of 300 days in a year. The total capital investment of the proposed expansion project is Crores. The proposed expansion project will be implemented in 18 months from the date of issue of Environmental Clearance. 2.5 TECHNOLOGY AND PROCESS DESCRIPTION RAW MATERIALS (TOR # 5) The following will be the raw material requirement for existing and proposed expansion project are furnished below RAW CONSUMPTION ( TPA) S.NO. MATERIAL Existing Expansion Total STEEL & POWER PLANT 1 Iron Ore 96,000 1,92,000 2,88,000 SOURCE OF SUPPLY NMDC, Chhattisgarh, Barbil, Orissa METHOD OF TRANSPORT 2 Coal (DRI) 78,000 1,56,000 2,34,000 SECL -- 3 Dolomite 2,400 4,800 7,200 Local Covered trucks 4. Scrap --- 1,41,750 1,41,750 Local -- 5 Ferro Alloys Local -- 6 Coal (Power) --- 1,67,400 1,67,400 SECL Covered trucks FERRO ALLOYS PLANT 9 Manganese Ore ,500 82,500 Orissa Covered trucks 10 Coke/Coal ,500 44,500 SECL Covered trucks 11 Dolomite ,200 13,200 Local 12 Quartz ,200 13,200 Local PIONEER ENVIRO 2-5 Environmental Impact Assessment Report --

13 Chapter RAW MATERIAL STORAGE & TRANSPORT Major raw materials will be stored in covered sheds. SIZES OF SHEDS (Existing) IRON ORE - 60M X 20M X 8M COAL - 60M X 20M X 8M SIZES OF SHEDS (Proposed Expansion) IRON ORE - (60M X 20M X 8M) x 2 COAL - (60M X 20M X 8M) x 2 Transportation of raw materials All the trucks required for transportation of raw materials will be covered. Pucca road exist up to the site. The existing road is capable of absorbing this additional truck movement. Hence there will not be any adverse impact on air environment due to the transportation of raw materials MATERIAL BALANCE EXISTING PLANT The following is the material balance for the existing plant SPONGE IRON (60,000TPA) INPUTS OUTPUTS S. No. Item Quantity (TPD) Item Quantity (TPD) 1 Iron Ore Sponge Iron Coal Char/Dolochar Lime stone 2400 Gases Ash / Dust Wet Scraper sludge Accretion slag 540 Total 1,76,400 Total 1,76,400 Gases * Gases Electricity (WHRB) 2 X 2 = 4 MW PIONEER ENVIRO 2-6 Environmental Impact Assessment Report

14 Chapter 2 * In the proposed expansion these gases w ill be utilized for power generation through WHRB Boiler EXPANSION PROJECT The following is the material balance for the proposed expansion project. SPONGE IRON (1,20,000 TPA) INPUTS OUTPUTS S. No. Item Quantity (TPA) Item Quantity (TPA) 1 Iron Ore Sponge Iron Coal Char/Dolochar Lime stone 4800 Gases Ash / Dust Wet Scraper sludge Accretion slag 1080 Total Total Gases Gases Electricity (WHRB) 4 X 2 = 8 MW SMS (Billets: 1,62,000 TPA) INPUTS OUTPUTS S. No. Item Quantity (TPA) Item Quantity (TPA) 1 DRI Billets Scrap, Mill end cuttings Slag Ferro Alloys Gases including 810 dust 8910 Total Total ROLLING MILL (1,05,000 TPA) INPUTS OUTPUTS S. No. Item Quantity (TPA) Item Quantity (TPA) 1 Ingots/ Billets TMT Bars Mill scales 2625 Gases 525 Total Total PIONEER ENVIRO 2-7 Environmental Impact Assessment Report

15 Chapter 2 POWER PLANT (36 MW AFBC Based Power Plant) INPUTS OUTPUTS S. No. Item Quantity (TPA) Item Quantity (TPA) 1 Dolochar Ash Coal Gases Total Total MANUFACTURING PROCESS (TOR # 6) DRI KLIN: Major plant facilities The major plant facilities for the sponge iron plant envisaged are as follows: Day bins Rotary kiln and cooler Off gas system Product processing and product storage. Day bins There shall be a day bin building to cater to raw material requirement of the kiln. The day bin building will comprise of six bins, one for iron ore, two for feed coal, one for limestone/dolomite and two bins for injection coal. These bins will generally have storage of about one day's requirement of screened iron ore feed (5-20 mm), feed coal (6-12 mm, mm), limestone/dolomite (1-4 mm) and injection coal (3-6 mm. 6-12mm). Weigh feeders will be provided to draw the required quantity of various materials in proportion from the bins and the same will be conveyed to the kiln feed end and discharge end. Rotary kiln and cooler The rotary kiln of 3.0 m dia. and 42 m length will be provided for reduction of iron ore into sponge iron using non-coking coal as reductant. The kiln will be lined with abrasion PIONEER ENVIRO 2-8 Environmental Impact Assessment Report

16 Chapter 2 resistant refractory castables throughout its length with damps at feed end and discharge end. The rotary kiln will be supported on four piers. A slope of about 2.5% shall be maintained. Then main drive of the kiln will be by two DC motors with thyristor control. The speed of the kiln can be varied depending upon the operating conditions. The speed of the kiln will be in the range of rpm. The auxiliary drive of the kiln will be by two AC motors. The other main components of the kiln will be as given below: Feed end and discharge end transition housing of welded steel construction with refractory lining including feed chute. Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating system at feed end and discharge end. On board equipment like fans, manifolds, ports, slip ring, instrumentation etc. Cooling fans at feed end and discharge end. Feed end double pendulum valve & dust valves. The kiln feed from the charging end will consist of sized iron ore (5-20mm), non-coking coal (6-25 mm) and limestone/dolomite (1-4mm). Air will be supplied to the kiln through shell mounted air fans. A part of the required coal (3-6mm, 6-12mm) shall be thrown from kiln discharge end. The slinger coal will be withdrawn from the respective bins in suitable proportion and pneumatically injected into the kiln. Necessary rotary feeder, compressor, piping and valves will be provided. In the kiln, the iron ore will be dried and heated to the reduction temperature of ºC. The iron oxide of the ore will be reduced to metallic iron by carbon monoxide PIONEER ENVIRO 2-9 Environmental Impact Assessment Report

17 Chapter 2 generated in the kiln from coal. The heat required for the reduction process will also be supplied by the combustion of coal. Thermocouples will be installed along the length of the kiln shell for measurement of thermal profile of the kiln. The temperature will be controlled by regulating the amount of combustion air admitted into the kiln through no. of ports with the help of fans mounted on the kiln shell and by controlled coal slinging. The DC main drives provided to rotate the kiln will have variable speed. Auxiliary drive is provided for slow rotation. The reduced material from the kiln will be cooled indirectly in a rotary cooler by an external water spray. The kiln will be provided with one rotary cooler. The rotary cooler will be of 2.3 m dia. And 22 m length and will be supported on two piers with a slope of about 2.5 %. The main drive and the auxiliary drive of the cooler will be by one no. separate AC motor. The speed of the drive will be about 1 rpm. The cooler will be provided with one plain riding ring and one thrust riding ring and will be provided with two sets of support rollers at two piers and one set of hydraulic thrust rollers with antifriction bearings. About 1 m end portion of the cooler acts as a screening section, which separates all the accretions larger than 50 mm from the reduced material. These lumps will be discharged separately via Lump gate. Rest of the material will be discharged on to the conveyor via double pendulum valve. The other main components of the cooler will be the following. Feed end housing (part of reactor to cooler transition) of welded steel construction with refractory lining. Cooler discharge end housing of welded steel construction. PIONEER ENVIRO 2-10 Environmental Impact Assessment Report

18 Chapter 2 Pneumatic cylinder acuted labyrinth air seal complete with auto lubricating system at feed end and discharge end. The cooler will be lined with refractory castable for about 4.0m length from the feed end. Bypass arrangement will be provided at the discharge end of the cooler for emergency discharge of materials. The cooled product will be conveyed to the product processing building by a system of belt conveyors. The cooling water will be collected in the trough below the cooler and sent to the cooling tower for cooling. The cooled water will be re-circulated. Closed circuit cooling system will be followed in the plant. The rotating parts of the kiln and cooler will be sealed suitably against the stationary parts at the connecting points to avoid leakage of dust laden gases. Off gas system The kiln shall have its separate off gas circuit. Hot waste gases leave the rotary kiln at about ºC through kiln feed end housing, dust settling chamber and come to an After Burning Chamber (ABC), where combustibles are burnt completely by supplying excess air. The gases at about ºC will then be led to a Waste heat recovery Boiler. After heat recovery the gases will pass through an Electro-static precipitators (ESPs) before letting them out into the atmosphere through ID fan and a combined stack of 60 m height( with twin fuels). Product processing and storage There shall be one product processing unit for handling the cooler discharge. The product containing sponge iron, char and spent lime, from the cooler discharge end will be discharged to a set of conveyors and sent to the product processing building. The kilncooler system shall have a separate surge bin of approx. 800 Tons. Product from surge PIONEER ENVIRO 2-11 Environmental Impact Assessment Report

19 Chapter 2 bin can be withdrawn through vibrating feeder and fed to the product processing building by conveyor. In the product processing building, the product will first be screened in a double deck screen having 3mm and 20mm screens. +20mm material shall be dumped as rejects. The screened product i.e., mm and -3 mm fraction shall separately be sent to the product storage separation. Sponge iron lump (3-20 mm) shall be sent to the product storage building for storing in two no. of bunkers where three days storage has been proposed. The sponge iron fines (-3 mm) will be stored in the fines bunker in the product processing building itself where one day storage capacity will be provided. The sponge iron lump & sponge iron fines will be further conveyed from the respective bunkers by truck. The char/non-magnetic shall be stored in separate bins. Char will be utilized for power generation in the FBC Boiler STEEL MELTING SHOP Steel Melt Shop (SMS) is crated to melt the Sponge Iron along with melting scrap and fluxes to make pure liquid steel and than to mould it in required size billets. The shop consists of following equipment and subassemblies: Induction Furnaces: Induction Furnace is a device to melt the charge material using electrical power. It consists of Crucible lined with water cooled induction coils, Electrical system to give controlled power to induction coil, Hydraulic tilting system, Heat exchanger to cool the circulating water, water softener for generating soft water, furnace transformer, Power Factor improvement system and surge suppressor. Ladles: Ladles are pots with refractory lining inside to withstand 1600º C temperature. It has side arms so that can be lifted with the help of crane. Ladles are used to stores the PIONEER ENVIRO 2-12 Environmental Impact Assessment Report

20 Chapter 2 liquid steel from Induction Furnace and take it for further processing. Ladles are with bottom nozzle and pneumatically operated gate for discharge of liquid. Ladle Refining Furnace (LRF): Ladle furnace is a mini electric arc furnace. It has three carbon electrodes, roof to cover the ladle, and furnace transformer of suitable capacity. The operation of electrodes, roof etc are controlled by hydraulic system. Ladle furnace is used either to keep the liquid steel for sequence casting or for further refining of the liquid steel to make better quality steel. Cranes: Electric Over-head (EOT) cranes of various capacities are used to carry the ladles/materials at different places. Cranes are used in Melting hall to charge melting scrap, remove the ladles to the LRF, further to place it over the Tundish of the Continuous Caster, to remove billets from the cooling bed and store at designated places, and also for other petty use. Accordingly the sizes, capacity and numbers of cranes are decided. Continuous Casting Machine (CCM): CCM is used to continuously cast the liquid steel in required cross section and in length. It consists of Tundish, Mould, Bow with Withdrawal mechanism, straightening mechanism and cooling bed, hydraulic system for withdrawal mechanism, water umps and cooling towers for water spray on the withdrawn section as well as on the cooling bed. Dummy bar is provided to start the casting. Tundish is a rectangular vessel, lined with refractory and having discharge nozzle with pneumatically operated gate. A stand is erected over it where the ladle is stationed for discharging the liquid in it. Mould is of copper with water cooled jacked. Its crosssection in the bottom is of the size of which billet is to be drawn. Initially the dummy for of the same size is kept inserted. When the liquid steel is poured in the mould the dummy PIONEER ENVIRO 2-13 Environmental Impact Assessment Report

21 Chapter 2 bar is drawn slowly, so that the liquid steel in partially frozen state comes out of the mould. Water spray nozzles are installed to spray water over the just drawn billet to cool it further and to harden the skin of the drawn billet ROLLING MILL: Process description Reheating furnace A pusher type furnace has been envisaged for the heating of billets. The furnace will be end charging and side discharging. It will have single row as well as double row charging facility. The furnace will be heated with FO. The furnace combustion system will comprise of air blowers, FO storage, supply and preheating system and other associated facilities. The product of combustion will leave the furnace at charging end and exhausted through under ground flue tunnel and passed through a metallic tubular recuperator before finally let off to a self supporting steel chimney of sufficient height. A set of instrument will be used for smooth operation of the furnace. Bar and round mill A cross country type mill has been envisaged for the plant. The stands have been grouped into roughing, intermediate and finishing groups. Roughing group will have 4 (four) stands, intermediate group will have 8 (eight) stands and finishing mill will have 8 (eight) stands. Roughing group of stands will be driven by one motor. 4 nos. of intermediate stands will be driven by two motors and balance 4 nos. will be driven by a separate motor. Each stand of finishing group will be driven by single motor. Necessary guides and troughs will be provided at entry and exit of mill stands. PIONEER ENVIRO 2-14 Environmental Impact Assessment Report

22 Chapter 2 One wire rod out let has been provided in the mill. The wire rod line will have 4 stand block driven by a single motor through gear box. Coil forming and handling of coil is provided. Automated tilting, drop type tilter and feeding arrangement will be provided in roughing group of stands. Repeaters have been provided in roughing / intermediate stands as necessary. Design provision has been made for introduction of slit rolling facility in future to roll 8 mm, 10 mm & 12 mm rebars in two strands. The rebars discharged from the mill will pass through a water cooling system comprising cooling pipes with high pressure water nozzles for rapid water quenching. At the cooling pipes the bar skin temperature will be reduced to about 600 o C. The core of the bar still remains hot. This entrapped heat tempers the bar. This thermo-mechanical treatment of the bars increases tensile strength without adversely effecting weldability and elongation properties. This process eliminates requirement of cold twisting of bars for production of rebars. A dividing shear, to cut the products to cooling bed length, will be located immediately after the water cooling system. This shear will divide all products to cooling bed lengths. Rake type cooling beds have been envisaged to receive the rolled product. Cooling bed will be provided with incoming and out going roller tables. One cold shear has been provided to cut the bars coming out of cooling bed into commercial length of 6 to 12 m. The bar products will be formed into bundles and will be strapped by strapping machine manually. PIONEER ENVIRO 2-15 Environmental Impact Assessment Report

23 Chapter 2 The finished products will be removed by overhead EOT crane and stored in the storage area or dispatched through road vehicles. One rolling mill of 350 TPD capacity is proposed in the expansion project FERRO ALLOYS The company is in the process of installation of a Ferro Alloys project with 1 no. of 6 MVA and 9 MVA submerged arc furnaces. The HIGH CARBON SILICO MANGANESE is an alloy of Manganese and Iron with additions of Silicon, Carbon and several other various elements. The silicon manganese can be divided into various grades depending upon the carbon content in the alloy. Manganese ore is the basic material having the major constituents of the alloy viz. iron and manganese. Different types of manganese ores are blended to achieve an appropriate manganese iron ratio used for the furnace charges. Coke is used as reductant and quartz as an addition agent. The raw materials are charged into a furnace where they are smelted by electric power supplied through three carbon electrodes. The alloy and the slag produced in the furnace are tapped at regular intervals. The specifications of silicon manganese produced will conform to Indian standards. ELECTRODE PASTE, CASING, OXYGEN LANCE AND REFRACTORIES: The soderberg electrodes are formed in situ by charging electrode paste of suitable compressive strength, electrical conductivity, porosity and apparent density, into mild steel cylindrical shell provided with inner ribs for reinforcement. There is a continuous consumption of both electrode paste and casing sheets. PIONEER ENVIRO 2-16 Environmental Impact Assessment Report

24 Chapter 2 The other consumables of the process include oxygen lancing pipes and oxygen used for opening the furnace tap-holes, and the refractory for the lining of pans / runners used for alloy collection. PROCESS DESCRIPTION: - 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 body of the furnace is cylindrical in shape, and is lined with firebricks, silicon carbide bricks and carbon tamping paste. Two tap-holes are provided at 120º. Apart form draining out both the molten alloy and the slag. During the repair works of one of the tap holes the other will function as standby. 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. The tap hole is opened by Oxygen lancing pipe and after tapping is completed, it is closed by clay plug. The liquid Silico manganese and the slag flow into the C.I. Pan. The slag being lighter overflow from the C.I. Pan and is taken into the sand mould. PIONEER ENVIRO 2-17 Environmental Impact Assessment Report

25 Chapter 2 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 POWER GENERATION: (TOR # 21) Waste Heat Recovery Boilers will be installed behind the ABC of DRI kiln in bypass configuration. 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. 12 MW electricity will be generated from WHRB. 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 Char & Coal. The flue gases will pass over various heat transfer surfaces to ESP and then finally discharged through ID fan and stack. 36 MW of Power generation proposed through FBC Boiler. 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 to generate 48 MW of Electricity. The power generated will be used for captive consumption. Process flow diagram is shown as figure 2.1. PIONEER ENVIRO 2-18 Environmental Impact Assessment Report

26 Chapter ENVIRONMENTAL MITIGATION MEASURES 1. AIR POLLUTION CONTROL (A) Sponge Iron plant After Burning Chamber will be provided to control the CO emissions. (B) 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 Bag filters 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. Major raw materials will be stored in covered sheds. Steel Melting Shop The Fugitive emissions from the Induction furnaces will be sucked through hoods and will pass through a fume extraction system comprising of bagfilters and then let out through a common stack of 30m height. The outlet dust emission will be less than 50 mg/nm 3. The dust will be pneumatically carried to covered storage bins. PIONEER ENVIRO 2-19 Environmental Impact Assessment Report

27 Chapter 2 (C) (D) (E) AFBC Based Power Plant 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 72 m height for effective dispersion of emissions into the atmosphere. Rolling Mill The flue gases from the Rolling Mill will be let out through a stack of 45 m height for effective dispersion of emissions into the atmosphere. Ferro Alloys The emissions from each of the Submerged Electric Arc Furnaces will be controlled by providing a fume extraction system with bag filters for each unit and then let out into the atmosphere through two nos stacks each of 30 m height. The out let dust emission will be less than 50 mg/nm 3. Whenever Air pollution control systems fail, production in that unit will be stopped till that air pollution control system is rectified. 2. WATER POLLUTION Closed circuit cooling system will be provided in the process & cooling of SMS, Rolling mill and Ferro alloys plants. Hence there will not be any waste water generation from process and cooling. Boiler blowdown & DM plant regeneration waste water will be treated in Neutralization tanks and will be mixed with CT blowdown and will be stored in a Central Monitoring Basin (CMB). The treated effluent from CMB will be partly used for dust suppression, partly for ash conditioning and the remaining will be utilized for on land for irrigation. Sanitary waste will be treated in septic tank by soak pit. 3. NOISE POLLUTION The turbine will be of internationally reputed make and will be manufactured as per MOEF/OSHA standards on Noise. Acoustic enclosures will be provided to STG. The major 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. PIONEER ENVIRO 2-20 Environmental Impact Assessment Report

28 Chapter 2 4. SOLID WASTE Dolochar generated will be utilized in FBC boiler for Power generation Slag from SMS will be used in road construction. Mill scales from Rolling mill will be used in Induction furnace. Ash & dust from bag filters will be given to cement plants/ brick manufacturers/self brick making. Slag from Ferro alloys unit will be used in road construction. Hence there will not be any adverse impact on land environment due to the solid waste generation. 15 M wide greenbelt around the plant will be developed around the plant. All Internal roads will be asphalted to prevent the fugitive dust emission due to vehicular movement. 2.8 ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR THE RISK OF TECHNOLOGICAL FAILURE Sponge Iron, Billet & TMT bar & Ferro alloys manufacturing technologies are well proven all over the world. Hence there will not be any risk of technological failure from this plant. PIONEER ENVIRO 2-21 Environmental Impact Assessment Report

29 Chapter 3 3 CHAPTER III 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 10km. radius of the plant. Monitoring was conducted from December, 2007 to February, The impact identification always commences with the collection of baseline data such as ambient air quality, ground water quality, surface 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 (TOR # 3) Meteorology Meteorology of the study area plays an important role in the air pollution studies. The prevailing micro meteorological conditions at the proposed Project 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 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

30 Chapter Meteorological data recorded at site (Winter season (Dec 07 Feb 08)) The predominant winds from NE direction were observed for 22.5 % of the total time, with wind speeds (with % frequencies) in the range of 1-5 kmph (20.7 %), 6-11 kmph (1.8 %), kmph (0 %) and >19 kmph (0 %). The winds from NW direction were observed from 18.9 % of the total time, with wind speeds (with % frequencies) in the range of 1-5 kmph (17.7 %), 6-11 kmph (1.2 %), kmph (0 %) and >19 kmph (0 %). The winds from SW direction were observed from 12.3 % of the total time, with wind speeds (with % frequencies) in the range of 1-5 kmph (10.8 %), 6-11 kmph (1.5 %), kmph (0 %) and >19 kmph (0 %). Winds from N, NEE, E, SEE, SE, S, SW, SWW, W, NWW and NNW directions were observed for 2.7 %, 1.8 %, 2.1 %, 1.0 %, 8.1 %, 1.5%, 12.3 %, 2.2 %, 1.2 %, 2.1, and 1.5 % of the total time respectively. Calm conditions prevailed for 22.1 % 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 (winter season). Temperature The mean maximum temperature recorded was 29.9ºC and the mean minimum temperature was 8.9º C at the Project site. Wind direction and speed are recorded at site every hour. The wind rose diagram of winter season is shown in fig 3.1 The wind rose shows that winds are predominantly blowing from NE and NW direction. PIONEER ENVIRO 3-2 Environmental Impact Assessment Report

31 Chapter 3 WINDROSE AT SITE PIONEER ENVIRO 3-3 Environmental Impact Assessment Report

32 Chapter Air Quality (TOR # 7) The ambient air quality with respect to the study zone of 10 km. radius around the plant 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 & domestic fuel burning. 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 cross sectional distribution in the down wind direction. (c) Representation of residential areas. (d) Representation of regional background levels. Eight nos. of Ambient Air Quality Monitoring Stations were established with in the study zone of the plant. PIONEER ENVIRO 3-4 Environmental Impact Assessment Report

33 Chapter 3 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, SO 2 and NO X are shown in Table to Parameters Monitored At each Monitoring Station Respirable Suspended Particulate Matter (RSPM), Suspended Particulate Matter (SPM), SO 2 and NO X are monitored. SPM was analysed for PAH. The sampling was carried out for 2 days in a week for winter monsoon season (December, 2007 February, 2008) to assess the existing status of air pollution and pollution dispersion pattern over the whole air basin of project site. RSPM, SPM, SO 2 and NO X were sampled as per MOEF guidelines. TABLE AMBIENT AIR QUALITY MONITORING STATIONS (TOR # 7) S. No STATION DIRECTION DISTANCE (in kms.) 1. Existing Plant Gerwani S Taraimal SE Punjipathra N Ratrot NE Gaurmuri SW Ujalpur SE Jamadbari W 3.0 PIONEER ENVIRO 3-5 Environmental Impact Assessment Report

34 Chapter 3 Fig. 3.2: AMBIENT AIR QUALITY MONITORING STATIONS Punjipathara Ratrot Jamadbari PROJECT SITE Taraimal Gourmuri Ujalpur Gerwani PROJECT SITE Monitoring Stations PIONEER ENVIRO 3-6 Environmental Impact Assessment Report

35 Chapter 3 TABLE Sampling Location: Existing plant Sampling period: December, 2007-February 2008 Unit : mg/m 3 Parameter Maximum Minimum Average 98 th pe rcentile RSPM SPM* SO NO x * PAH in SPM is BDL TABLE Sampling Location: Gerwani Sampling period: December, 2007-February 2008 Unit : mg/m 3 Parame ter Maximum Minimum Average 98 th percentile RSPM SPM* SO NO x * PAH in RSPM is BDL TABLE Sampling Location: Taraimal Sampling period: December, 2007-February 2008 Unit : mg/m 3 Parameter Maximum Minimum Average 98 th percentile RSPM SPM* SO NO x * PAH in SPM is BDL TABLE Sampling Location: Punjipathra Sampling period: December, 2007-February 2008 Unit : mg/m 3 Parameter Maximum Minimum Average 98 th percentile RSPM SPM* SO NO x * PAH in SPM is BDL PIONEER ENVIRO 3-7 Environmental Impact Assessment Report

36 Chapter 3 TABLE Sampling Location: Gaurmuri Sampling period: December, 2007-February 2008 Unit : mg/m 3 Parameter Maximum Minimum Average 98 th percentile RSPM SPM* SO NO x * PAH in SPM is BDL TABLE Sampling Location: Ratrot Sampling period: December, 2007-February 2008 Unit : mg/m 3 Parameter Maximum Minimum Average 98 th percentile RSPM SPM* SO NO x * PAH in SPM is BDL TABLE Sampling Location: Ujalpur Sampling period: December, 2007-February 2008 Unit : mg/m 3 Maximum Minimum Average 98 th percentile Parameter RSPM SPM* SO NO x * PAH in SPM is BDL TABLE Sampling Location: Jamadbari Sampling period: December, 2007-February 2008 Unit : mg/m 3 Parameter Maximum Minimum Average 98 th percentile RSPM SPM* SO NO x * PAH in SPM is BDL PIONEER ENVIRO 3-8 Environmental Impact Assessment Report

37 Chapter 3 The avg. SPM concentration at the Project site is µg/m 3. The avg. RPM concentration at the Project site is 39.6 µg/m 3. The avg. SO 2 & NO X concentrations recorded at the Project site are 9.5 & 11.5 µg/m 3 respectively. The maximum average RPM concentration was recorded at Gaurmuri with a value of 39.8 µg/m 3. The maximum average SPM concentration was recorded at Gaurmuri with a value of µg/m 3. The maximum average SO 2 concentration was recorded at Taraimal with a value of 9.6 µg/m 3. The maximum average NOx concentration was recorded at Punjipathra & Gaurmuri with a value of 11.4 µg/m 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 favoured of those scales is the A 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. PIONEER ENVIRO 3-9 Environmental Impact Assessment Report

38 Chapter 3 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 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. 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 kms. radius Reconnaissance Noise levels were measured at different locations within 10 Km. radius of the proposed Project such as villages, bus stands etc. PIONEER ENVIRO 3-10 Environmental Impact Assessment Report

39 Chapter 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 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 6.00 a.m. A 10 PIONEER ENVIRO 3-11 Environmental Impact Assessment Report

40 Chapter 3 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 by 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 (6A.M. to 9 P.M.) Ln is the equivalent noise level during night time (9 P.M. to 6 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. a. Damages the hearing capacity. b. Interference in communication. c. Interference with work. d. Interference with sleep. e. Causes annoyance. PIONEER ENVIRO 3-12 Environmental Impact Assessment Report

41 Chapter Noise level observations in the study area Baseline noise levels have been monitored at different locations within the study zone of the plant 8 no's of stations have been selected for measurement of noise levels and their distance with respect to site are shown in table and Fig. 3.3 Punjipathara Ratrot Jamadbari PROJECT Taraimal Gourmuri Ujalpur Gerwani Fig. 3.3: Noise Monitoring Stations PROJECT SITE Monitoring Stations PIONEER ENVIRO 3-13 Environmental Impact Assessment Report