Bhushan Steels Or.

BHUSHAN STEEL AND STRIP LIMITED
EIA / EMP FOR 3.1 MTPY INTEGRATED STEEL PLANT AT AT MERAMANDALI, DIST. DENKANAL (ORISSA)
MECON LIMITED
RANCHI 834 002
BHUSHAN STEEL AND STRIP LIMITED
EIA / EMP FOR 3.1 MTPY INTEGRATED STEEL PLANT AT AT MERAMANDALI, DIST. DENKANAL (ORISSA)
MECON LIMITED
RANCHI 834 002 11.S2.Q6BK September 2007
Bhushan Steel & Strips Limited

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa)
CONTENTS
Sl. No. 1. Description INTRODUCTION Page No. 1 1 to 1 8
2.
PROJECT DESCRIPTION & ANNEXURES
2 1 to 2 31 2 sheets
3.
PRESENT ENVIRONMENTAL STATUS & ANNEXURES
3 1 to 3 22 7 sheets
4.
ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION 4 1 to 4 28 MEASURES
5.
ENVIRONMENTAL MANAGEMENT PLAN (EMP)
5 1 to 5 30
6.
EMP IMPLEMENTATION AND MONITORING.
6 1 to 6 8
7.
DISASTER MANAGEMENT PLAN (DMP)
7 1 to 7 24
8.
SOCIO-ECONOMIC IMPACT ASSESSMENT
8 1 to 8 15
9.
ORGANISATION AND MANPOWER
9 1 to 9-4
10.
ENVIRONMENTAL COST & PROJECT BENEFITS
10 1to 10 - 4
11.
CONSULTANT CREDENTIALS
11-1 to 11-4
2007 MECON Limited. All rights reserved
(i)

LIST OF FIGURES Fig. Description No. 2-1 PROCESS FLOW DIAGRAM 3-1 4-1 4-2 WIND ROSE DIAGRAM (3 SHEETS) FLOW CHART OF IRON MAKING PROCESS ISOPLETH OF SPM, SO2 & NOx Chapter No. 2 3 4 4
LIST OF DRAWINGS Sl. No. 1. 2. 3. 4. Description GENERAL LAYOUT OF PLANT WATER BALANCE DIAGRAM THE MATERIAL FLOW SHEET LOCATOR MAP Drawing No. DRG.No.MEC/11/14/Q6AT/DE/GN/50/0001 DRG.No.BSSL/0/ISP/7-1 REV.-1 DRG.No.MEC/Q671/11/18/01
SHOWING Drg. No. MEC/Q6BK/11/S2/01
MONITORING STATIONS
(ii)

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 1.0 INTRODUCTION
1.1
General The Indian steel industry has recorded remarkable performance in recent years. The industry is now capable of producing high quality materials to stringent international specification for high-end applications. 21st century is widely perceived to be the century of Asia and India is looked upon as one of the economies with most promising prospects. This possesses a formidable challenge as well as an opportunity to the Indian corporate sector. Bhushan Steel & Strips Limited (BSSL) as the leading steel maker is in position to fulfill its role in the nations quest for higher growth and development in the new millennium. BSSL is the dominant player in steel producer in the country having its plants at Shahibabad (UP) and Khapoli in Maharastra state etc. The national steel policy has set a target of 60 million tonnes (MT) of steel production by 2010 and to increase it to a level of 100 million tonnes by 2018. The major steel producers in India are planning to expand their capacities in the tune with the national steel policy formulation. BSSL is also not exception to that and therefore intends to increase the capacity of its Steel Plant at Meramandali, Dhenkanal (Orissa) from its present capacity of 1.5 MT per annum to 3.1 MT per annum of steel products.
The developments of industrial projects play a key role in the economic growth of any country. Industrial process is invariably involving the conversion of raw materials and resources into semi finished and / or finished products. During this process, residues in the form of wastes will be formed. If the residues are not recycled/ re-utilised they become waste and have to be discharged into environment as pollutants. The degree to which the pollutants affect the physical environment depends upon their quantitative and qualitative characteristics as well as the receiving media.
1-1

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Iron is perhaps the most important metal to the mankind and its principal alloy, steel, is widely used for domestic, agricultural, industrial and defense purposes. Per capita steel consumption is a major indicator of economic status of any country. The growth of the steel industry significantly contributes to economic growth as it generates employment both directly and also due to development of downstream industries.
However, any industrial development process is accompanied by some environmental problems. Proper planning at the conceptual stages can minimize many of these problems. Once an industry is commissioned it becomes difficult and expensive to retrofit pollution control equipment, as such incorporation of the same at conceptual stage is the best alternative.
Setting up of an industry has both positive and negative impacts on the environment. The negative impacts include environmental degradation and adverse socio economic changes. It is the responsibility of scientists and environmentalists to document the likely impacts so that they can be identified and attempts are made to minimise the effects due to negative impacts and maximise benefits due to the positive impacts. In this regards Environmental Impact Assessment (EIA) and Environmental Management Plan (EMP) has been considered as one of the most important documents for utilisation by all the concerned to understand the environmental implications due to the proposed development activity and take decisions in the best interest of the Environment.
1.2
Purpose of the Report
The purpose of EIA study report is to take stock of the prevailing quality of environment, to assess the impacts of proposed industrial activity on environment and to plan appropriate environmental control measures to minimise 2007 MECON Limited. All rights reserved 1-2

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) adverse impacts and to maximise beneficial impacts. The following major objectives have been considered:
Assess the existing status of environment. Assess the impacts due to the modification-cum-expansion of project. Suggest pollution control and ameliorative measures. Prepare an action plan for implementation of suggested ameliorative measures. Suggest a monitoring programme to assess the efficacy of the various adopted environmental control measures. Assess financial considerations for environmental control plans.
In pursuance of Government of India Policy, under The Environment (Protection) Act 1986 and Orissa State Pollution Control Board (OSPCB), the proposed modification-cum-expansion will require clearance from environmental angle. Bhushan Steel & Strips Limited entrusted MECON LIMITED (MECON) to prepare an Environmental Impact Assessment and Environmental Management Plan (EIA/EMP) report for their proposed modification-cum-expansion plant at Meramandali, Dhenkanal in Orissa. The present report, an EIA/EMP report is prepared based on monitored data for one season covering three months (summer season). The present report is prepared in accordance with the guideline of MOE&F & OSPCB.
For carrying out the Environmental Impact Assessment (EIA) study, the area falling within 7 km radius of project site at Meramandali area has been considered for generation of base line data with respect to present air quality, water quality, noise level, soil quality, ecology, socio-economic and meteorology etc. The site studies were carried-out during summer season in April, 2006 to June 2006. 2007 MECON Limited. All rights reserved 1-3

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) This EIA report has been prepared on the basis of environmental data generated in and around the existing plant site during the summer season in the month of April 2006 to June 2006. The data regarding meteorological conditions, air quality, water quality, noise levels, soil quality, ecology and socio-economic environment were generated in the study area falling within 7km radius with the plant site as center.
An in-depth analysis of the baseline environmental data generated by actual field monitoring and collected from various secondary sources has been carried out for identifying and predicting the probable environmental impacts due to the expansion of project. Reasonable assumptions have been made, wherever data is found lacking. Based on the findings a suitable environmental management plan has been suggested.
1.3
Project & Project Proponent
Bhushan Steel & Strips Limited (BSSL) is the project proponent. M/s Bhushan Steel & Strips Limited (BSSL) is a reputed producer in the secondary steel sector, with consumption of more than a million tonnes of HR steel coils without themselves producing any HR steel coil. Therefore, depending on the availability of funds, BSSL can plan to go for an integrated 3.1 Mt/yr HR steel coils plant as backward integration without the botheration on the marketability of the products. With the sound financial status of BSSL, the expected growth in consumption of iron and steel in the country and no problem in marketability of HR coils, as mentioned above, M/s BSSL have decided to install an integrated HR coils plant and be in the primary steel sector. Hence, BSSL is contemplating to modify and expand the existing 1.5 Mtpy integrated steel plant to 3.1 Mtpy level at Meramandali in Dhenkanal district (Orissa).
1-4

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 1.4 Nature, Size, Location of the Project
The nature of project is ferrous metallurgical industries and fall under the category of primary metallurgical industry including sponge iron manufacturing and further processing to secondary metallurgical industry for HR coil product in flat category.
The size of the project is 3.1 Mtpy of steel product through DR-BF-EAF-Rolling mill route. M/s Bhushan Steel & Strips Limited (BSSL) is intending to modify the existing 1.5 Mtpy integrated steel plant to 3.1 Mtpy level at Meramandali in Dhenkanal (Orissa). This steel plant is based on the Directly Reduced Iron (DRI) - Electric Arc Furnace (EAF), Blast Furnace Ladle Furnace & RH-OB continuous casting rolling mill route with waste heat recovery based captive power plant(CPP). The site is located between latitude 204641 to 204920 N and longitudes 851522 to 851621 E at Meramandali block of Dhenkanal district of Orissa. Land measuring about 1664 acres falling under villages Sibpur, Narendrapur, Itapo, and Asanabani in district Dhenkanal in Orissa had been selected for steel plant. The plant is situated about 5 km from Meramanadali Railway Stations (on Angul Cuttack broad gauze main railway line). The National Highway no. 42 touches northern side of plant. The plant is 18 km from Angul and 42 km from Dhenkanal. Nearest Railway station is Meramanadali on Eastcoast railway and nearest port is Paradeep, which is more than 215 km away.
1.5
Project Importance to the Country/Region
The integrated steel plant is being set up with capital outlay of 6330 crores. This will help the local economy directly as well as indirectly. The project will continue
1-5

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) to contribute to state as well as to national exchequer by way of taxes in the form of excise duty, custom duty as most of the products are going to be exported. Therefore project is having great importance to national economy.
In the state the project will generate jobs in the form of direct as well as indirect employment for local people and local economy will flourish due to income expenditure in the local market.
1.6
Scope of Study
This report shall contains various informations on the existing environmental attributes, including air, water, noise, solid waste, soil quality, ecology and socioeconomic patterns etc. The report evaluates the predicted impact of the proposed plant activities on the environment. It also cover the various remedial measures considered by plant management like air pollution control systems, complete recycling of process cooling water, green belt development plans and reuse of solid waste and other environmental management system which are useful for control of environmental degradation due to the proposed steel plant. A detailed coverage of the emission sources, emission control equipment, background air quality levels, predicted air quality levels, meteorological measurements, dispersion model and all other aspects of pollution have been provided in this report. The draft Draft EIA/EMP has been discussed for the adequacy and completeness in its the 69th Meeting of the Expert Appraisal Committee (Industry) held during 4th 6th July, 2007 for preparation of final EIA/EMP. The EAC (I) recommended the following additional TORs for inclusion in the revised EIA/EMP: 1. Point-wise compliance to the conditions stipulated for the existing 1.5 MTPA plant by the MoEF. 2007 MECON Limited. All rights reserved 1-6

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 2. Permission for the drawl of 1,29,600 m3/day water from Brahmani river and water balance data including quantity of effluent generated, recycled and reused and discharged is to be provided. Methods adopted/to be adopted for the water conservation. 3. Action plan for the development of green belt in 33 % area. 4. Action plan for the utilization of 100 % char and coal washery rejects in FBC boiler for the power generation and long term management plan for SMS slag utilization should be incorporated. 5. An action plan to control and monitor secondary fugitive emissions as per CPCB guidelines should be included 6. APCS for the control of emissions from the kiln and WHRB and utilization of kiln gases in WHRB. 7. Use of BOD effluent for quenching should be included. 8. A plan for the adoption of dry coke quenching instead of wet quenching within 5 years should be incorporated. 9. Plan for the implementation of the recommendations made for the steel plants in the CREP guidelines must be prepared.
The report includes the general structure of EIA given in Appendix III and IIIA in the EIA Notification, 2006. The reply of point 1 shall be submitted separately while other points are suitably incorporated in different chapters of EIA report. The EIA report is structured as follows:
Introduction Project Description Present Environmental Status Anticipated Environmental Impacts 1-7

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Environmental Management Plan(EMP) EMP Implementation and Monitoring. Disaster Management Plan(DMP) Social Impact Assessment Cost considerations and project benefits Consultant credentials etc
1.7
Acknowledgment
MECON wishes to place on record its deep appreciation for the trust reposed in MECON by BHUSAN STEEL & STRIPS LIMITED (BSSL) for the EIA/EMP study and also for the active interest and the help extended by the concerned officials of BSSL. The Co-operation extended by the officials of various State and Central Government agencies is also gratefully acknowledged.
1-8

2.0
PROJECT DESCRIPTION
2.1
General M/s Bhushan Steel & Strips Limited (BSSL) is proposing to modify and expand 1.5 Mtpy integrated steel plant to 3.1 Mtpy level at Meramandali in Dhenkanal (Orissa). The steel plant is based on the Directly Reduced Iron (DRI) - Electric Arc Furnace (EAF), Blast Furnace Ladle Furnace & RH-OB - continuous casting rolling mill route with waste heat recovery based captive power plant(CPP).
The land measuring 1664.56 acres had been acquired by Orissa Industrial Infrastructure Development Corporation (IDCO) and was transferred to Bhushan Steel & Strips limited to set up integrated steel plant. A detailed report was prepared earlier for selection of plant site at Meramandali and was the best site as per the availability of Water, Power, infrastructure facilities and raw materials particularly coal. Coal is one of the major raw materials for steel and power generation and is available in Talcher coalfield within 45-50 km of Meramandali site. This was one of the major factors for deciding this site for the steel plant.
2.2
Type of Project The proposed project is an expansioncum-modification of existing 1.5 Mtpy integrated steel project at Meramandali, Dist Dhenkanal (Orissa). The plant is in implementation stage and after the detailed analysis and economy of scale has given impetus for modifying some of the facilities earlier proposed during 1.5 Mtpy stage and adding few other facilities to reach the level of 3.1 Mtpy integrated steel plant.
2.3
Need for the Project The steel industry in India is poised for faster growth in the decades ahead as the industrial and economic development of the country gains pace. Indian Steel
2-1

industry is also emphasizing its presence in the global market. The domestic market growth outlook for finished steel has been estimated and is given below. Domestic Market Growth Outlook Growth Trajectory GDP @ 6.5% 2006 07 (million tonnes) 2011 12 (million tonnes) 39.5 - 40.7 57.8 - 59.9
The total steel consumption of finished steel has been estimated to touch 60 MT in the year 2010-12 from the current level over 31 MT. Even after approximately doubling the production capacity the per capita domestic consumption would continue to be substantially below the world average of 145 Kg. There is good prospect of domestic steel consumption growing at about 6 7% up to the year 2012. BSSL has drawn up a growth plan with the objective of increasing its market share, including market penetration and maintaining its leading position in Indian steel industry. One of the key objectives of BSSL is to be of a world-class company and leader in Indian steel business by leveraging its key competencies. This competency will enable BSSL to manufacture products at a lower cost and more speedily than its competitors. Keeping all these in mind, BSSL has plan to increase the production capacity of steel plant to 3.1 MT per annum steel
product and also to make technology up-gradation in different units in an environment friendly way.
Since the present steel scenario is favorable to go for expanding the integrated steel plant and Bhushan Steel & Strips Limited is in an advantageous position to go for backward integration with a hot rolled plant upto a capacity of 3.1 million tonnes per year. Presently HR coils are procured indigenously as well as
imported from foreign countries.
2-2

BSSL has initiated several steps as part of their backward integration programme and this is one such step to establish 3.1 Mtpy integrated steel plant.
2.4
Location (Maps Showing General Location, Specific Location, Project Boundary, Project Site Layout) The Plant is located between latitude 204641 to 204920 N and longitudes 851522 to 851621 E at Meramandali block of Dhenkanal district of Orissa. Land measuring about 1664 acres falling under villages Sibpur, Narendrapur, Itapo, and Asanabani in district Dhenkanal in Orissa. The locator map showing general topography and related feature is attached vide drawing no. MEC/Q6BK/11/S2/01 sheet 1 of 1. The land is situated about 5 km from Meramandali Railway Stations (on Angul Cuttack broad gauze main railway line). The National Highway no. 42 touches northern side of plant site. The plant site is 18 km from Angul and 42 km from Dhenkanal. Nearest Railway station is Meramandali on Eastcoast railway and nearest port is Paradeep, which is more than 215 km away. The project layout is given in drg. No.
MEC/11/14/Q6AT/DE/GN/50/001 sheet 1 of 1 REV.-5.
2.5
Size or Magnitude of Operation The size of the plant will be 3.1 Mtpy and plant operations shall confine to the existing plant boundary and will not change the process route of operation as given in the report.
2.6
Schedule for Approval & Implementation
Project planning The project envisages expanding existing project upto a 3.1 Mtpy Steel plant at Meramandali, Orissa by M/s. Bhushan Steel & Strips Limited. The project will involve the following main technological units:
2-3

Coal Washery (2.4 Mtpy) Sinter Plant ( 1 x 177 m2) DR Plants (14 x 170,000 tpy) Blast Furnace ( 1 x 1681 m) SMS I Induction Furnace (12 x 15t) Ladle Furnace (4 x 30t) Billet Caster (2 x 2 strand) SMS II (Part) Electric Arc Furnace (2 x 60t) Ladle Furnace (2 x 60t) VD / VOD Unit (1 x 60t) Conventional Slab Caster (1 x 1 stand) SMS II (Balance) Electric Arc Furnace (2 x 180t) Twin Shell CONARC Furnace 145 MVA Ladle Furnace (1 x 180t) RH OB Unit (1 x 180 t) Conventional Slab Caster (1 x 1 strand) Semi continuous Hot Strip Mill Pig Casting machine ( 2 x 2000 tpd) Slag Granulation Plant Power Plant (33 + 77 + 45MW) Lime & Dolomite Plant Oxygen Plant
In addition to the above main technological units, suitable supporting facilities have also been envisaged like raw material handling facilities, compressed air
2-4

facilities, power distribution system, shop electrics and effluent and sewage treatment plant, air conditioning & ventilation system, laboratories, etc.
The above project has been planned to be executed in 48 months from the Zero-Date, which has been reckoned as go ahead from MOE&F.
2.7
Technology and Process Description BSSL was granted NOC by MOE&F to set up 1.5 Mtpy plant at Meramandali earlier in 2004-05. The main technological and auxiliary units for 1.5 Mtpy integrated steel plant were as follows: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) 3.2 Mtpy Coal Washery 8 x 170,000 tpy DR plant 1 x 100 m2 Sinter Plant 1 x 1250 m3 Blast Furnace Pig Casting Machine 8x15t Induction Furnace(IF) 2 x 100 t+1x40 t Electric Arc Furnace 2 x 100 t+1x40 t Ladle Furnace 1 x 100 t RH-OB 1.2 Mtpy Slab Caster 1.2 Mtpy Hot Strip Mill 0.3 Mtpy Billet Caster 0.2 Mtpy Bar Mill 1x300 tpd Oxygen Plant 2x300 t Lime Plant 1 x 33 MW + 1 x 77 MW + 1 x 120 MW Power Plant (approx. 80 MW from kilns hot gases and 30MW from AFBC boiler and 120 MW from CFBC boiler)
2-5

xvii) xviii)
Required services and auxiliary facilities Matching Raw Materials Preparation Plant (RMPP)
The total plant schedule was expected to be completed by 2005 06. Proposed Modification-Cum-Expansion of Plant BSSL is now intends to augment their steel production capacity from 1.5 Mtpy to 3.1 Mtpy by suitable modification-cum-expansion in existing units proposed earlier. These are as follows: One blast furnaces of capacity 1681 m3 instead of 1250 m3 earlier proposed with cast house slag granulation facility, 2x2000tpd Pig casting machine One sinter plant of capacity 177 m2 instead of 100 m2 earlier proposed, Six additional DR kiln of 170000 tpy capacity The configuration also changed in SMS and casting facilities Three no Walking beam furnaces in the hot strip mill based on BF gas mixed with LPG/Propane or mixed gas Two limited recovery coke oven battery of 0.45 Mtpy each to meet the coke requirement of steel plant Lime and Dolo shaft to meet the flux requirement. 2.4 Mtpy coal washery instead of 3.2 Mtpy Coal Washery.
To supplement the auxiliary demands one 950 tpd Oxygen plant and augmentation of raw material handling facilities is envisaged The Plant Configuration at 3.1 Mtpy Stage The ultimate plant facilities after the modification-cum-expansion shall be as follows:
2-6

Table-2.1: The Plant Facilities at 3.1 Mtpy level

Sl. Description No. 1. Coal Washery 2. Direct Reduction Iron ( DRI ) 3. Coke Oven Plant 4. 5. 6. 7. Units in 1.5 Mtpy Stage(NOC Granted) 1x3.2 Mtpy 8 kilns x 170000tpy The Plant Configuration at 3.1 Mtpy Stage 1x2.4 Mtpy 14 kilns x 170,000 tpy 2x0.45 Mtpy limited recovery type Coke Oven Batteries 1x177 m2 1 x 1681m3 2x2000 tpd 415500 tpy
Sinter Plant 1x100 m2 Blast Furnace 1X1250M3 Pig Casting Machine Slag Granulation Plant 8. Primary Steel making 2 x 100 t+1x40 t EAF 8x15t Induction Furnace (IF) 9. Secondary refining 10. Continuous Plant 2 x 100 t LF 1x40 t LF 1 x 100 t RH-OB
1 x 180 t CONARC 2x60 t Electric Arc Furnace ( EAF) 12x 15 t Induction Furnace ( IF ) 1 x 180t LF, 2 x 60t LF and 4x 30t LF, 1x 60t VD/VOD unit, 1 x 180 t RH-OB 2 x 1 strand slab caster and 2 x 2 strand billet casters Conventional hot strip mill with 5stand finishing train (2.514 Mtpy HR coils) and provision for 6th & 7th stand in future. 1x500+1x100tpd lime plant 1x500 tpd dolo plant 1 x 33+1x77 +1x45 MW WHRB based power plant
Casting 1.2 Mtpy Slab Caster 0.3 Mtpy Billet Caster 1.2 Mtpy Hot Strip Mill 0.2 Mtpy Bar Mill 2x300 t Lime Plant 1 x 33 +1x77+1x120 MW CFBC & WHRB based power plant Matching the production facilities
11. Rolling Mill (HSM)
12. Lime & Dolo Plant 13. Power Plant
14. Oxygen Plant 15. Raw materials Preparation Plant (RMPP)
1x950 tpd Oxygen Plant Matching the production facilities
2-7

Fig-2.1: Process Flow Diagram
? ? ?
? ? G
Boiler & Power Plant
Coal
COG
BFG
Fuel Gas
Steam
Coke Oven Iron Ore COLD PIGS
Power
Blast Furnace
LF
DRI
?
Continuous Slab/Billet Casters

Slab Billets
Sinter Plant Hot Strip Mill HR COILS
EAF
Re-heating Furnace
CC BILLETS
PRODUCTION FACILITIES PLANNED IN 3.1 MTPA EXPANSION
2-8

The Material Flow Sheet corresponding to the ultimate stage of implementation of the project is given in the Drg.No.MEC/Q671/11/18/01 sheet 1 of 1 and the major facilities of the respective production units with their technical parameters have been detailed in the following table.
Table-2.2: Major plant facilities and their capacities Sl. No. 1 Coal washery 2 Direct reduction plant 3 Iron ore crushing 2.4Mt 14 x 170,000 tpy One No. double stage crushing circuit for DR plant (4,862,000 tpy) 4 Sinter Plant 5 Blast furnace 6 Pig casting machine 7 Slag granulation plant 8 Primary steel making 1 x 177m2 1 x 1681 m3 useful volume 2 x 2000 t/d 415,500 tpy 1 x 180 t CONARC, 2 x 60 t EAF and 12 x 15t IF 9 Secondary refining 1 x 180t LF, 2 x 60t LF and 4 x 30t LF, 1x 60t VD/VOD unit, 1 x 180 t RH-OB 10 Lime and dolo plant (1 x 500 + 1 x 100) t/d lime and 1 x 500t/d dole 11 Continuous casting 2 x 1 strand slab caster and strand billet casters 12 Captive power plant 13 Oxygen Plant 14 Hot Strip mill (1 x 33 + 1 x 77 + 1 x 45) MW 1 x 950 TPD Conventional hot strip mill with 5-stand finishing train (2.514 Mtpy HR coils) and 2 x 2 Plant facility Capacity
2-9

Sl. No.
Plant facility
Capacity provision for 6th & 7th stand in future.
15 Coke Oven Plant
2x0.450 Mtpy Limited recovery type coke oven Batteries
Based on the envisaged product mix, considered analyses of the required raw materials and the facilities envisaged for the proposed project, a process cum material flow has been worked out for the project.
Site and infrastructure The proposed site for integrated steel plant complex is located at Meramandali, Dhenkanal district of Orissa, which is about 18 km from Angul, 42km from Dhenkanal and about 100km north-west of Cuttack city. The selected land for site measures 1623 acres falling under villages Sibpur, Narendrapur, Itapo and Asanabani. It lies 125km from capital city, Bhubaneshwar. The South Eastern Railways line connecting Angul and Cuttack railway station and the National Highway NH-42 are passing on the north of the plant site. The nearest railway station is Meramandali, which is about 4km from the plant. The river Brahmani flows from north-west to south east on the northern side of the plant at a distance of about 6km.
Power The power requirement of the plant is about 410 MVA. It is envisaged that the power for the main plant will be supplied by CPP running in parallel with grid over a double circuit 220kv transmission line from Meramandali sub-station of GRIDCO.
2 - 10

Water Water requirement of the plant is about 5400 m3/h. This requirement for the plant will be met from the river Brahmani. River is at a distance of about 6km from the plant site by road.
Raw Materials The annual requirements of various raw materials at 3.1 Mtpy level of the steel plant and their indicative size specification, proposed sources, distance from plant and mode of transport are given in Table-2.3.
Table-2.3: Estimated annual requirement of raw materials

Sl. No. 1 2 3 4 5 6 7 8 9 10 Iron ore lump (BF grade) Iron ore fines (BF grade) Iron ore Lump(DR grade) Non-coking coal for injection (BF) Limestone (BF grade) Raw Dolomite (BF grade) Purchased BF coke Purchased Coke breeze Quartzite Non-coking coal for DR Raw Material Size (mm) 8-30 5-20 0-80 <100 0-80 0-80 25-80 25-80 10-50 0-20 489,300 14,400 5,141,200 215,200 208,900 201,800 639,200 131,200 58,700 2,382,500 Banspani/ Barbil Banspani / Barbil Banspani / Barbil Port Satna/Maihar Baradwar Port Port Local Patrapara, Coal block. F grade (Talcher Coal fields) Port Belha Qty.(tpy) Source
11 12
Limestone (SMS grade) Raw Dolomite(SMS grade)
30-60 30-60
351,300 227,300
2 - 11

Sl. No. 13
Raw Material
Size (mm)
Qty.(tpy)
Source
Purchased washed sized coal for DR
<100
1,557,800
Patrapara, Coal block. F grade (Talcher fields) Coal
14
Raw dolomite (DR grade)
1-4
74,000
Baradwar
It has been envisaged that raw material shall be received by Rail except quartzite. Quartzite shall be received by Road. Accordingly 4 nos. wagon tipplers with Side arm charges have been envisaged to handle full length of rake of 58 wagons. 4 nos. truck tipplers with hopper of 50 m3 capacity each is also
envisaged to unload the raw material which is received in truck from mines or from in-house generation. Raw material received in sick wagons shall be unloaded in track hopper. The holding capacity of track hopper shall be 3400t.
Coal Washery The proposed coal washery will form a part of the proposed material handling plant (MH). The sized raw coal will be fed to the washery by raw coal conveyor of the MH plant. Similarly clean coal and middlings will be carried away by respective conveyors of the proposed MH plant.
In the coal washery plant, total clean coal requirement has been fixed 1,032,200 tpy on dry & net basis. The clean coal product shall be sized at (-) 20mm, 4-1, 20mm & 0-4mm.
The quality parameters of the clean coal will be as follows: Ash content Moisture content : : 27.5% 10%
2 - 12

For raw coal quality, following quality parameters has been assumed. Ash Content Moisture Content : : 39% ~ 9%
Thus total raw coal requirement has been worked out as 2,411,300 tpy catering to the needs of DR kilns.
Direct reduction plant The direct reduction (DR) plant will comprise of fourteen rotary kilns of capacity 170,000 tpy each along with related accessories including waste heat power generating units and related facilities. The production program of the direct reduction plant, as envisaged is given below:
Product Sponge iron (DRI) lump (3-18 mm) Sponge iron fines (-3 mm)
Production, tpy 1,785,000 595,000
Technological parameters of each DR kiln and cooler Diameter of Kiln (ID), m Length of kiln, m Kiln speed, rpm Diameter of cooler (ID), m Length of cooler, m Production, t/d/kiln (max) Generation of DRI fines (-3mm), % Kiln off gas volume (after ABC) (Nm3/hr) Working days / year, No. 4.8 80.0 0.25 0.75 3.6 50.0 500 25 109,764 (max) 93,300 (avg) 340
2 - 13

The typical quality of DRI would be as follows. Degree of metallisation, % Fe (t), % Fe (m), % FeO, % SiO2, % Al2O3 S, % P, % C,% CaO MgO 90 + 2 92 83 9.5 1.80 1.30 0.014 0.046 0.20 (max) Trace Trace
Sinter Plant In order to match the plan of construction of one 1681M2 volume Blast furnace of Bhushan steel complex with an annual production capacity of 1,250,000 tons of pig iron and as per the specified BF burden consisting of 75% iron ore and 25% lump ore one Sinter machine with 177m2 of effective sinter area shall be set up to produce 1.88 Mt of product sinter per annum (or maximum 1.96Mt of product sinter per annum). The basic design and operating parameters as given in Table 2.4 Table2.4: Design and operating parameters S.No 1 2 3 Item Description No. of sinter machine x area Productivity (rated) Annual sinter demand Unit No. x m2 T/m2/h Mt/y Value 1 x 177 1.3 1.88 avg. 1.96 max. 4 Size of finished sinter Mm 5-50
2 - 14

S.No 5 6 7
Item Description Annual working regime No. of working hours/ day Gaseous energy / consumption for ignition/ton of BF sinter
Unit D/y H/d Mj/t 330 24 100
Value
Coke breeze consumption/ton of BF sinter
Kg/t of skip Mm
70
11
Cooler type / bed height
Circular
cooler
having 26m Dia / 1400mm 12 13 Temperature of cooled sinter Dust content in exhaust gases at stack C Mg/Nm3 Below 100 Below 50
Coke Oven Battery Complex BSSL shall set up two-recovery type coke oven battery of 0.425 Mtpy capacities each. The recovery type coke oven battery complex broadly consists of the following units:
Coal preparation Plant Coke oven battery Coke Handling plant By-Product Plant Effluent treatment Plant
The coal preparation plant has been envisaged to cater to daily requirement of coke ovens. The imported coal will be received at port by ship and further transportation of coal by rail to the plant site. The coal will be unloaded through wagon tipplers and then stored in the open storage yard.
2 - 15

Each battery consisting of two blocks of 32 ovens each (64 ovens) has been selected for this project. The major cold dimensions of the ovens will be as follows: Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Description Total Length of carbonization chamber Effective length of carbonization chamber Total height of carbonization chamber Effective height of carbonization chamber Average width Taper of carbonization chamber Central line distance of carbonization chamber Effective volume of carbonization chamber Nos. of heating flues in heating wall Central line distance of vertical flue Dimensions 14080 mm 13280 mm 4300 mm 4100 mm 500 mm 20 mm 1200 mm 26.68 m3 28 of 480 mm
combustion chamber The battery anchorage system will consist of bucks trays, tie rods, springs and bracing and modern leak-proof oven casting equipment such as flash plates, door frames, oven doors compatible to meet pollution control norms etc.
Gas off-takes: the system will comprise of ascension pipes, goosenecks, isolation valves, gas collecting mains, necessary flushing liquor spraying. The gas collecting mains will be provided on ram side only. Each oven will be provided with stamp charging of cake.
Under firing system of ovens: the heating system for ovens will be so designed that the battery can be heated with coke oven gas as well as blast furnaces gas.
2 - 16

The supply of heating gases will be provided through gas mains laid in the cellar floor on the pusher side and coke side of the battery.
The following oven machines will be provided for the two batteries: Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. Description Stamping and charging Car Pushing Car Dust guide car De-dust guide car Elec. Locomotive Quenching Car Stamping machine Hydraulic exchanger Quantity 2 sets 2 sets 2 sets 3 sets 2 sets 2 sets 2 groups 2 sets
The coke guide car machine will be two spot operations. It will remove door, clean the frame and also cleans the oven door. It will move to place the guide cage at the oven, the door of which has been opened.
The coke-quenching car will be hauled by electric loco. The incandescent coke is brought to a quenching station and sprayed with water for quenching, and after quenching coke is discharged to coke wharf.
Quenching tower shall be of RCC construction with acid resistant brick lining and arrangement for water spray system. Grit arresters along with vapour spray system will be provided in quenching tower to contain quenching emissions.
Coke handling plant: coke-handling plant of 100 t/h capacity has been envisaged to receive the run of oven coke from wharf through wharf conveyor. The coke will be screened into the 3 fraction e.g. (-)10 mm, 10 mm 25 mm and 25-80 mm.
2 - 17

By-Product Plant: the by product plant is designed to recover only essential byproducts like ammonia, crude tar. The plant will have a capacity to process 42000 Nm3/h of coke oven gas. The quantity of by-product will be as follows: Sl. No. 1. 2. 3. 4. Description Coke oven gas Ammonium Sulphate Crude Tar Sulphur Units Nm3/h Tpy Tpy Tpy Quantity 42000 9740 40116 1626
The net calorific value of the coke oven gas is 4300 4500 Kcal/Nm3 Effluent Treatment Plant: The effluent treatment plant will be envisaged to treat the effluent generated from coke oven battery and by-products plant (capacity 24 m3/h). The treatment plant is capable to treat phenolic water generated. Phenolic water from ammonia column and other sources will be settled and freed from tar and oil and treated for other toxicants to achieve the desired limit. The treated liquor will be pumped to the quenching station where it will be used for quenching of hot coke along with fresh water.
The surplus gas utilisation: The requisite quantity of coke oven gas will be consumed by the battery itself for regular heating and balance quantity will be supply to other users within the plant.
Dry Coke Quenching: As per directives of EAC, BSSL shall adopt dry coke quenching within a period of 5 years from date of environmental clearance. Dry coke cooling shall take the advantage of waste heat and generate power and shall initiate for CDM benefits. The dry coke cooling technology is available indigenously and could be utilized to avoid wet quenching. The detailed
2 - 18

technological features and plan shall be indicated to SPCB at the time of detailed engineering.
Blast furnace Complex The blast furnace (BF) complex will comprised of one (1) BF of 1681 m3 useful volume along with its auxiliaries. The BF is envisaged to operate with sized iron ore, sinter, coke, coal dust, fluxes and additives. The BF will produce around 1.2944 Mtpy gross hot metal. The hot metal produced will be generally sent to the steel Making Shop. Surplus hot metal will be poured in two double strand pig casting machines. The liquid slag will be granulated at cast house slag granulation unit. The BF top gas will be cleaned in dust catcher and gas cleaning system and distributed for further consumption to the stoves, runner drying, pig casting machines, sinter plant, etc.
Production Programme S. No 1 2 3 Product Gross Hot Metal Net hot metal Granulated slag (dry) Annual quantity (tpy) 1,294,400 1,268,500 415,500
The major technological parameters of the Blast Furnace are given below: Useful volume, m3 Working volume, m3 Productivity, t/d/m3 On useful volume On working volume Production, t/d Coke rate (dry), kg/thm 2.2 2.55 3700 (max) 385 1681 1450
2 - 19

Coal dust injection, kg/thm Oxygen enrichment, % Slag rate, kg/thm Slag basicity, CaO / SiO2 Top pressure, kg/cm2 (g) Hot blast temperature, Deg. C Blast humidity, g/Nm3 Blast volume, Nm3 / thm Gas generation, Nm3 / thm
150 4 321 0.95 1.5 1200 60 959 1560
Steel making and continuous casting shop Two steel melting and casting shops have been envisaged namely SMS-I and SMS-2. Under SMS-I, steel melting and casting shop has been designed to produce about 1,313,100 tpy of liquid steel and cast the same into 600,000 tpy of continuously cast billets and 670,600 tpy slabs.
Under SMS-2, steel melting and casting shop will produce 1,967,200 tpy of liquid steel. The entire quantity of liquid steel will be cast to 1,908,200 tpy slabs.
SMS1 SMS-I will consist of twelve (12) induction furnaces (IF) each of capacity 15t, four (4) number of ladle furnace along with two (2) double strand billet caster. This shop will have two (2) 60 t electric are furnace, two (2) 60 t ladle furnace, one (1) 60 t VD/VOD unit and one (1) single strand slab caster.
SMS-2 The SMS-2 will consist of one (1) twin shell CONARC of 180 t capacity, one 180 t ladle furnace, one (1) RH-OB unit and one (1) single strand slab caster will be installed to meet the annual production requirements.
2 - 20

Hot Strip Mill The mill will primarily comprise a slab charging table fed by slab charging cranes located in the slab yard. Two 300 tph walking beam type slab reheating furnace with slab charging and discharging equipment designed for cold as well as hot charging of slabs, one 4-hi reversing roughing stand with attached edger, one coil box, one hot crop shear, five 4-hi finishing stands, runout roller table equipped with laminar cooling, two down coilers, coil handling facilities, coil storage yards, necessary auxiliary facilities and roll shop equipment.
The mill will have an in-built capacity to produce about 2.5Mt of HR coils per annum. Future provision for third reheating furnace, second roughing stand with attached edger, 6th & 7th finishing stands and third down coiler has been envisaged.
The broad technological parameters of the hot strip mill are given in Table2.5.
Table-2.5: Technological parameters of hot strip mill S. No 1 2 A B C D E 3 a b Parameters Capacity HR coils Input material Type Thickness Width Length Weight Finished products Type Strip thickness mm HR Coils 1.6 20 --mm mm mm t Continuously cast slabs 230 800 1680 10,300 max. ~31 Unit tpy Value/feature 2,514,300
2 - 21

S. No c d e f
Parameters Width Coil ID Coil OD Coil weight
Unit mm Mm Mm t
Value/feature 800 1680 760 2,100 max. 30max.
Power Plant Production of sponge iron in DR kilns generates huge quantities of the flue gases carrying considerable sensible heat. The surplus gas of the 1681 m3 blast furnace has considerable heating value. These fuels if not used properly would be simply wasted leading to inefficient use of energy as well as causing disposal problems and to some extent pollution hazard in the plant premises. Surplus blast furnace gas which is having a good calorific value can also be utilized for power generation. Thus a captive power plant would be an ideally suited proposition of effectively make use of these waste fuels. The quantities and heat content of the waste fuels are enough to produce about 155 MW power which is more than the requirement of the entire complex. Besides, the facility will also cater to the requirement of steam driven turbo blowers and process. Thus the CPP would not make the plant independent of external source of electric power but would also result in energy conservation and environment improvement. A composite power plant cum blowing station comprising the following has been envisaged.
1x33+1x77+1x45 MW steam turbo-generator and auxiliaries. 14x48.5 tph waste heat recovery boilers (WHRBs) and auxiliaries, 1x80 t/h blast furnace gas fired boiler (BFG) and auxiliaries. Steam turbine driven blowers 2x60%, Deaerators 4 nos.
2 - 22

Lime and dolo plant The line and dolomite plant will comprise of 1No. vertical lime shaft kiln and 1 No. dolomite shaft kiln of capacity 500 tpd each and 1 No. 100 tpd lime shaft kiln which is being installed for SMS-1. The lime plant will have the following production capacity as given below.
Sl. No. 1. 2.
Item Lime of size 15-55 for SMS Calcined dolomite of size 15-55 for SMS
Qty. tpy. 162,200 105,600
Technological parameters: Lime and Dolomite calcination unit i) ii) Nos. of Kiln Kiln Capacity 3 2 Nos. 500 tpd each and 1 No. 100 tpd. iii) iv) v) Kiln feed size, mm Calcination temp. C Specific consumption of fuel kcal/kg of burnt lime and dolomite. 25-55 950-1150 850
Oxygen Plant Oxygen will be required mainly for blowing into the EAF & CONARC for steel melting and for enrichment of blast in the B. F. complex. Oxygen will also be required for further removal of carbon in RH-OB, tap hole opening in blast furnace, and also to meet cutting and general repair needs in the SMS / CCM, Sinter Plant, Rolling mills and other units of the steel plant.
2 - 23

Argon will be required in the CCM for rinsing the steel in the ladle to homogenize the bath temperature & chemical consumption and also for shrouding of tundish during casting.
Nitrogen will be required in the blast furnace complex to meet cooling and purging needs for the bell less top equipment, above burden probe, etc. and also in the coal dust preparation and injection system. Nitrogen will also be required to meet the testing & purging needs of LPG facilities and other units of the steel plant.
To meet the above requirements of oxygen, nitrogen and argon, an oxygen plant of capacity 950 t/ d will be provided with facilities for generation and compression of gaseous products, storage of gaseous and liquid products, and distribution system for products. Oxygen, nitrogen and argon will be produced by air
separation process based on low pressure cryogenic cycle and double column rectification system.
Electrics The estimated power requirement of the proposed steel plant is as follows. Maximum demand Annual energy consumption : : 410 MVA -2000 M kWh
The power supply for the proposed plant will be made available by Orissa Power Grid Co. Ltd., at 220 kV from Meramandali grid sub-station located near the plant site. The power will be received through three circuits of 220 kV transmission lines. Both the transmission towers will however be designed for double circuit lines as a future provision.
2 - 24

It is proposed to install 77 MW and 33 MW captive power plants for in-plant generation. The captive power plants will generate power at 11 kV. The 77 MW CPP will by synchronized with the grid power supply at 220 kV at MRS through 100 MVA, 11/220 kV step up generator transformers. The 33 MW and 45 MW CPP will be synchronized with the Grid power supply at 33 kV switchboard located at Power Plant through 42 MVA and 60 MVA, generator transformers respectively. 11/33 kV step up
The 33 kV switchboards at PP will be
connected to the 33 kV switchboards at MRS through two Nos. tie line feeders.
Fuel oil and gas facilities Blast furnace (BF) gas will be used mainly as fuel in stoves, sinter plant and power plant. In addition to the above consumers, BF gas will also be used for cast house runner drying; LRS, PCK, and PCI, semi-clean BF gas will be used for BF top pressure equalization etc. BF gas will be distributed to the consumers through a system of piping network, operating at a pressure of 600-800mm WC Mixed gas has been proposed to be utilized as fuel for the reheating furnace. Light diesel oil (LDO) is proposed to be utilized as fuel for the initial firing and flame stabilization in the boilers. In addition to boilers, LDO will also be required for DR plant and SMS. The daily requirement of LDO is estimated at 120 kl. Hence 2 Nos. of 450 kl capacity each LDO storage tanks will be required to be provided for storage of 7 days requirement.
LPG/ propane storage facilities have been envisaged for about 6 days requirement of the gas for different consumers of SMS (CONARC and EAF/IF) and BF. The hourly average requirement of LPG/propane is 2.2 tph. Two Nos. cylindrical storage vessels, each having a capacity to store 150 t of LPG/propane have been planned.
2 - 25

The Fuel Balance of the Plant

Sr. No. Name of Shop / Unit Annual hours of operation A. 1 GENERATION Blast Furnace Total Generation B. 1. 2. 3. 4. 5. CONSUMPTION BF stoves Pre-heater PCI Minor Consumers Top Pressure Equalization 6. 7 Sinter Plant Reheating Furnace for HSM 8. Lime Stone & Dolomite Calcining Plant Total Consumption 378.48 156.48 222.0 8400 7920 8400 2000 9800 kcal/kg 9800 kcal/kg 46.0 46.0 11.18 176.0 11.18 176.0 8400 8400 8400 8400 8400 932 932 932 932 932 102.59 15.0 9.32 1.63 16.76 102.59 15.0 9.32 1.63 16.76 8400 932 220 220 220 220 CV of gas kcal/Nm
3
Hourly Fuel Consumption (G cal) Total BF Gas LDO/LPG
To meet the requirement for pulverized coal injection (PCI) system of the blast furnace complex following shall be provided in the building. Two Nos of centrifugal compressors each of 70 Nm/min capacity discharging air at 14.5 kg/cm2 (g) pressure are envisaged. Out of these two compressors one will be working and one will be kept as a stand by. One No of service air receiver of 60m for PCI is envisaged. compressed air station. This air receiver shall be provided outside the
2 - 26

Water supply facilities The main source of raw water for the proposed steel plant will be river Brahmani, which is about 6 km away from the plant site. It is proposed to construct an intake structure on the river bank with necessary pumping and transportation facilities up to the plant site. Water will be pumped from the intake pump house to the raw water reservoir inside the plant through pipeline of approximate length 6 km. The raw water reservoir shall have a storage capacity of 7 days requirement of the plant.
The total requirement of fresh water from surface water source to meet process make-up and drinking needs is estimated as 5400m/h. Raw water, received at the plant water reservoir, shall be treated through Clarifier/ Demineralisation (DM) Plant / Softening plant before addition to the system as make up. Water will be further treated in a demineralised water plant and water softening plant to meet the DM and Soft water demand of the plant.
The raw water and treated water shall be mainly used for the purpose of cooling, steam generation and waste water for dust suppression in different production units of the plant. Apart from this, small quantity of water shall also be used for fire fighting, drinking and sanitary uses. Water balance for the plant is indicated in the drawing DRG.NO. BSSL/0/ISP/7-1 Rev 0.
Manpower Planning In order to operate and maintain the plant facilities, including its technical general administration needs, the estimated manpower requirement at the full development stage of the integrated complex has been estimated to be 2827. Category wise breakup of manpower
2 - 27

Sl. No. 1 2 3 4 5 6
Category Managerial Executive Skilled Semi-skilled Unskilled Clerical Total :
Requirement 29 310 938 735 775 40 2827
2.8
Mitigation Measures to Meet Environmental Standards
Environmental management The steel plants are considered pollution causing units and to mitigate environmental problems and meet the environmental norms prescribe by the regulatory bodies process pollution control equipment are envisaged in the design stage to comply the norms. The facilities planned for controlling the air and water pollution are summarised in Table-2.6.
Table-2.6: Proposed facilities for control of air and water pollution

Sl. No. 1 2 3 4 Shop/Unit Coke oven and by product plant Sinter plant Blast furnace plant Steel melting shop Proposed Facilities Scrubbers, tall chimney, BOD plant etc. Electrostatic precipitators, etc. GCP, SGP, Electrolyte precipitator etc. Fume Extraction System, gas coolers, chimney etc. 5 6 7 8. Material handling system Refractory materials plant Power plant DRI units Bag filters, dust suppression systems, etc. Bag filters etc Electrostatic precipitators, chimney etc. Electrostatic precipitators, chimney etc.
2 - 28

Apart from above there shall be effluent treatment facilities to treat the waste water and recycle for lower quality of water at appropriate point.
2.9
Township BSSL proposes to develop a housing colony for 250 families, for the staff members working in the plant. For this purpose, it is envisaged that four different types of quarters would be constructed.
The land for the proposed housing colony is yet to be acquired by BSSL. The nearest town, Angul is about 18 km by road from the plant site. Angul has educational facilities, hospitals, markets and other social amenities. However, some supporting facilities like first aid station, convenience shops and a primary/nursery school have been envisaged in the proposed housing complex.
Sewage from the township shall be treated in a sewage treatment plant and the treated water shall be used for greenbelt development.
2.10
Environmental Cost Considerations The total project cost has been estimated to be Rs. 63300.0 Million (Rupees Sixty three thousands three hundred million). The capital cost of environmental control measures is Rs. 3481.5 Million.
2 - 29

BHUSHAN STEEL & STRIPS LTD., MERAMANDALI HOURLY FUEL GAS BALANCE
Sl No Name of Shop/ Unit Product Annual Output/ Input (x 1000T) Annual Hours of Operation Sp. Yeild/ consumpti on (Gcal/t) Calorific Value of GAS kcal/Nm3 Hourly Fuel Supply/ Consumption ( Gcal / hr) (Million kcal / hr) BF C.O. BOF Annual Fuel GAS GAS GAS OIL / LPG 212.80 0.00 212.80 0.00 175.82 175.82 0.00 0.00 0.00
Total
1 2
GENERATION Blast Furnace Coke Oven & By-product Total Generation CONSUMPTION Blast Furnace Plant a) Stoves b) Preheaters c) PCI d) Blast top pr. equalisation e) Minor consumers Coke Oven Batteries Batteries on coke oven gas * Sintering Plant a) S P Steel Melting Shop a) SMS-I
Hot Metal Dry Coal
1250 1146
8400 8760
1.430 1.344
900 4200
212.80 175.82 388.62
Hot Metal Hot Metal Hot Metal Hot Metal Hot Metal Dry Coal
1250 1250 1250 1250 1250 1146
8400 8400 8400 8400 8400 8760
0.576 0.182 0.121 0.109 0.021 0.666
900 900 900 900 900 4200
85.71 27.08 18.01 16.22 3.14 87.13
85.71 27.08 18.01 16.22 3.14 0.00
0.00 0.00 0.00 0.00 0.00 87.13
0.00 0.00 0.00 0.00 0.00 0.00
3 4
Sinter Liq. Steel
1880 920
7920 7680
0.050
900 9800 25000 9800 25000 25000 25000
11.87 0.00 0.00 0.00 0.00 0.00 0.00
11.87 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 13,984 t LDO 28,000 Nm3 LPG 44,080 t LDO 134400 Nm3 LPG 408320 Nm3 LPG 1658500 Nm3 LPG
b) SMS-II
Liq. Steel
4000
7680
c) CCM (SMS-I) d) CCM (SMS-II) 5 RMP
Billet Slab
970 3940
7680 7680
2 - 30

Sl No Name of Shop/ Unit Product Annual Output/ Input (x 1000T) Annual Hours of Operation Sp. Yeild/ consumpti on (Gcal/t) 0.890 0.890 0.950 0.400 0.250 Calorific Value of GAS kcal/Nm3 9500 9800 9800 2000 2000 Hourly Fuel Supply/ Consumption ( Gcal / hr) (Million kcal / hr) BF C.O. BOF Annual Fuel GAS GAS GAS OIL / LPG 0.00 0.00 0.00 11800 t LDO 0.00 0.00 21.48 13.43 0.00 0.00 50.13 31.33 0.00 0.00 0.00 0.00 10t LDO 10t LDO 10t HSD 0.030 0.010 900 4200 6.38 1.76 373.67 14.95 6.38 0.00 203.33 9.47 0.00 1.76 170.34 5.48 0.00 0.00 0.00 0.00 24200 t LDO 3200 t LDO
Total 0.00 0.00 0.00 71.61 44.76
Lime Plant Lime Plant
Burnt Lime & dolo Burnt Lime & dolo Burnt Lime Slab(cold charge) Slab(hot charge) DRI
124 272 33 1289 1289
7920 7920 7920 7200 7200
Hot Strip Mill Reheating Furnace
7 8 9 10
DR Kiln Captive Power Plant DG Set Losses a) BF Gas - 3% b) C.O.Gas - 1% TOTAL CONSUMPTION SURPLUS (AVAILABLE)
BF gas generation : 2,36,400 Nm3/h @ 900 Kcal/Nm3 CO Gas generation : 46,450 Nm3/h @ 4200 Kcal/Nm3 Sinter Plant Consumption: 50,000 Kcal/t Sinter Production: 1880,000 t/y (avg) DC has guaranteed BF gas CV: 900 - 1000 Kcal/Nm3 50% slabs are hot charged at 600 C * Battery under firing has been considered by coke oven gas Annual production SMS is for both phase A & phase
2 - 31

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 3.0 PRESENT ENVIRONMENTAL STATUS Information on the existing environmental status is essential for assessing the likely environmental impacts of the proposed
modification-cum-expansion of existing project.
In order to get an idea about the existing state of the environment, various environmental attributes such as meteorology, air quality, water quality, soil quality, noise level, ecology and socio-economic environment have been studied/ monitored.
Study Period It has been planned to carry out baseline environmental data generation for air, water, noise and soil quality monitoring around the proposed plant site for one full season covering three months of Summer (April-June2006).
Study Area The present report covers baseline environmental data generated in the study area (10 km radius all around the plant site).
3.1
Baseline Monitoring of Environmental Component In order to get an idea about the existing state of the environment, various environmental attributes such as meteorology, air quality, water quality, soil quality, noise level, ecology and socio-economic environment are being studied/monitored. The present report covers baseline environmental data generated during April to June2006 for meteorology, air quality, water quality, noise levels and soil characteristics. Meteorological, air, water, noise and soil monitoring stations are marked in Drg.No. MEC/Q6BK/11/S2/01 sheet 1 of 1. Sampling and analysis has been carried out by Environmental Engineering Laboratory of MECON, Ranchi which is having accreditation from regulatory authority Central Pollution Control Board (CPCB) New Delhi.
3-1

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 3.2 Meteorology A meteorological station was set up at the roof top of MRS building within the proposed plant premises. Meteorological data was generated during the summer season monitoring period.
The following parameters were recorded at hourly intervals continuously during monitoring period:
Wind speed Wind Direction Air Temperature Relative Humidity Cloud Cover
Rainfall was recorded on daily basis.
Table-3.1 gives wind frequency pattern of day-night (24 hours), day and night respectively as monitored during the monitoring period.
Table-3.1: Summarized Meteorological Data for the Monitoring Period (Summer, 2006)
Month Wind speed m/s Max. Min. Mean Temperature (C) Mean Max. Min. Relative humidity Rainfall (mm) (%) Highest Lowest Total 24hrs. highest Cloud cover No. of (Oktas mean) rainy days
April 2006 May 2006 June 2006
7.03 <0.44 8.64 <0.44 9.31 <0.44
1.29 1.59 0.85
28.4 34.7 32.8
48 46 45
19 20 18
73 92 96
17 20 23
2 2 2
3-2

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Table-3.1: Wind Frequency Distribution at Meramandali during Summer Season2006
A. 24 hours Overall Velocity Ranges (m/s) Direction 0.44<V<=2 N NNE NE ENE E ESE SE SSE S SSW SW WSW W WNW NW NNW SUM % 0.74 3.44 2.16 7.90 8.29 10.46 3.51 3.30 2.97 2.69 2.69 5.67 4.92 2.97 1.08 1.89 64.68 2<V<=3 0.27 0.88 0.47 1.62 1.89 1.75 0.61 0.81 0.47 0.47 0.40 1.15 1.42 0.94 0.14 0.34 13.63 3<V<=5 0.06 0.06 0.27 0.67 1.15 0.47 0.14 0.20 0.14 0.20 0.14 0.74 0.81 0.27 0.06 0.14 5.52 5<V<=6 0.00 0.00 0.00 0.06 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.06 0.00 0.06 0.18 V>6 0.00 0.06 0.00 0.06 0.06 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.18 Sum % 1.07 4.44 2.90 10.31 11.39 12.68 4.26 4.31 3.58 3.36 3.23 7.56 7.15 4.24 1.28 2.43 84.19 15.81
CALM %(V< 0.44 m/s ) =
Figs-3.1: a the wind-rose diagrams at Meramandali for day-night (combined)

B. Day Time (0600 1800 Hrs)
3-3

Velocity Ranges (m/s) Direction 0.44<V<=2 N NNE NE ENE E ESE SE SSE S SSW SW WSW W WNW NW NNW SUM % 0.81 3.77 2.29 7.80 5.90 8.89 2.80 3.20 3.36 2.29 3.77 7.68 7.00 3.23 1.62 2.69 67.10 2<V<=3 0.14 0.54 0.27 1.10 1.48 1.48 0.67 0.67 0.40 0.27 0.40 1.88 2.29 1.10 0.14 0.40 13.23 3<V<=5 0.14 0.14 0.14 0.54 0.94 0.40 0.14 0.00 0.14 0.40 0.27 1.10 1.10 0.40 0.14 0.14 6.13 5<V<=6 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 V>6 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Sum % 1.09 4.45 2.70 9.44 8.32 10.77 3.61 3.87 3.90 2.96 4.44 10.66 10.39 4.73 1.90 3.23 86.46 13.54
CALM %(V< 0.44 m/s ) =
Figs-3.1: b the wind-rose diagrams at Meramandali for day
3-4

C. Night time (1800 0600 Hrs.) Velocity Ranges (m/s) Direction 0.44<V<=2 N NNE NE ENE E ESE SE SSE S SSW SW WSW W WNW NW NNW SUM % 0.68 3.11 2.02 7.97 10.60 12.02 4.18 3.38 2.57 3.11 1.62 3.65 2.84 2.70 0.54 1.10 62.09 2<V<=3 0.41 1.22 0.68 2.16 2.29 2.02 0.54 0.95 0.54 0.68 0.41 0.41 0.54 0.81 0.14 0.27 14.07 3<V<=5 0.00 0.00 0.41 0.81 1.35 0.54 0.14 0.41 0.14 0.00 0.00 0.41 0.54 0.14 0.00 0.14 5.03 5<V<=6 0.00 0.00 0.00 0.14 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.14 0.28 V>6 0.00 0.14 0.00 0.14 0.14 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.42 Sum % 1.09 4.47 3.11 11.22 14.38 14.58 4.86 4.74 3.25 3.79 2.03 4.47 3.92 3.65 0.68 1.65 81.89 18.11
CALM %(V< 0.44 m/s ) =
. Figs-3.1: c the wind-rose diagrams at Meramandali for Night
3-5

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) From the above table predominant wind direction is found to be from Northeastern to south eastern sector. During day time, East of South-East (ESE) is the predominant wind direction (prevailing for about 10.77 % of the time), followed by WSW (10.66 %) and W (10.39 %). Calm conditions prevailed for 13.54 % of the time. During night also the predominant wind direction is ESE (14.58%), followed by E (14.38 %) and ENE (11.22%). Calm condition
prevailed for 18.11 % of the time. Overall (24 hours), the predominant wind direction is also ESE (12.68 %), followed by E (11.39 %) and ENE (10.31 %). Calm conditions prevailed for 15.81 % of the time.
Figs-3.1: a, b and c give the wind-rose diagrams at Meramandali separately for day-night (combined), day and night time respectively, based on the monitored data.
3-6

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 3.3 Air Environment To quantify the impact of the proposed power plant on the ambient air quality, it is necessary at first to evaluate the existing ambient air quality of the area. The existing ambient air quality, in terms of Suspended Particulate Matter (SPM), Respirable Particulate Matter (RPM), Sulphur-dioxide (SO2), Oxides of Nitrogen (NOx), Carbon Monoxide (CO), Lead (Pb) and Dust Fall has been measured through a planned field monitoring. To assess the ambient air quality level, 5 (five) monitoring stations were set up. Of these five stations, one was within the plant premises (Core Zone), while rest were outside the lease up to a maximum distance of 10.0 km from core zone limit (Buffer Zone). Table-3.3 gives location of the ambient air quality monitoring stations. Table-3.3: Ambient Air Quality (AAQ) Monitoring Stations Sl. No. 1. 2. 3. 4. 5. Location Motanga Galpoda Nalatangra Nuahata MRS building Stn. Code A1 A2 A3 A4 A5 Distance & Direction from center of lease 4.75 km E 4.5 km SE 4.5 km W 4.75 km NW Core Zone
Monitoring Schedule Samples of 24 hourly duration were taken for monitoring SPM, RPM, SO2 and NOx whereas for CO three one hourly sample was taken on each monitoring day. Lead was also monitored in limited samples. Dust fall was recorded as 30 days average at each AAQ monitoring station.
3-7

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Methods of Sampling and Analysis The methods of sample collection, equipment used and analysis procedure as followed are given in Table-3.4.
Table-3.4: Methodology of Sampling & Analysis and Equipment used
Sl. No. Suspended 1. Particulate Matter (SPM) Respirable 2. Particulate Matter (RPM) Nitrogen (NOx) Oxides Parameters Instrument Apparatus used Respirable Sampler Dust (RDS/ Gravimetry CPCB Notification 11.4.94 Dust (RDS), Gravimetry CPCB notification of 11-4-94 and of / Method followed Reference
HVS), Balance Respirable Sampler Balance RDS/HVAS Impinger with tubes, Jacobs
3.
Hochheiser modified (Na-arsenite) Method Improved West &
CPCB notification of 11-4-94
spectrophotometer RDS/HVAS Impinger with tubes,
4.
Sulphur di-Oxide (SO2)
spectrophotometer RDS/HVAS, Atomic
Gaecke method
5.
Lead in SPM
Absorption Spectrophotometer (AAS)
Gravimetric followed by AAS
6.
Carbon Monoxide
CO Analyser
NDIR Method
CPCB notification of 11-4-94.
Results and Discussions The results of AAQ are given in Annexure-3.1. The results when compared with National Ambient Air Quality Standards (NAAQS) of Central Pollution Control Board (CPCB) for Residential and Rural Areas show that the average values of ambient air quality parameters are well within the stipulated limit.
3-8

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Dust Fall Dust fall rates were recorded as 30 days average during monitoring periods at five (5) AAQ monitoring stations. The results are given in Table-3.5.
Table-3.5: Measurement of Dust Fall Rate Station Location Station No. Results (g/m2/day)
Motanga Galpoda Nalatangra Nuahata MRS building
A1 A2 A3 A4 A5
0.39 0.33 0.34 0.41 0.45
In absence of Indian Norms, the results have been compared with the German norm published in TA Luft, 1986 which is as follows: 0.65 g/m2/d
98 percentile value
The above results indicate that the dust fall rates at all the stations are well within the compared German standards.
3.4
Water Environment Water quality monitoring of the study area was carried out in order to collect baseline data on existing water quality, which can be used to predict the impacts due to the project on water regime. Grab samples were collected from ten (10) locations comprising 7.0 ground water and 3.0 surface water samples which are listed in Table-3.6.
3-9

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Table-3.6: List of Water sampling Stations Sl. No. 1 2 3 4 5 6 7 8 9 10 11 Location Ground Water from Sibapur Ground Water from Sibapur Ground Water from Khaliberana Ground Water from Motanga Ground Water from Kochilimara Ground Water from Galpoda Ground Water from Ganthigriha Ground Water from Narendrapur Lingra Nadi Stn. Code GW1 GW2 GW3 GW4 GW5 GW6 GW7 Gw8 SW1 Surface / Ground Water Ground water Ground water Ground water Ground water Ground water Ground water Ground water Ground water Surface Water Surface Water Surface Water
Kisinda Jhor before joining river SW2 Brahmani SW3 River Brahmani, D/s of Lingra nadi
Samples were analysed following standard methods of analysis.
The results of analysis of ground water are given in Annexure-3.2. The results have been compared with the drinking Water Quality standards specified in IS:10500. From the results it is obvious that except Iron in GW3 all the ground water quality parameters meet the prescribed norms.
The results of analysis of surface water are also given in Annexure-3.3. The results have been compared with the Water Quality Criteria as per Central Pollution Control Board. It can be seen that water from these sources can be compared with class C and used for drinking after conventional treatment and disinfection.
3 - 10

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Water Quality Criteria as per Central Pollution Control Board
Parameters Class A Class B Class C Class D pH 6.58.5 6.58.5 6.0-9.0 6.58.5 Dissolved oxygen (as O2), mg/l, min 6 5 4 4 2 3 3 BOD, 3 days at 27 C, max Total coliform organism, MPN/100 ml, max 50 500 5000 Free ammonia (as N), mg/l, max 1.2 Electrical conductivity, mhos/cm, max Sodium absorption ratio, max. Boron (as B), mg/l, max. Class A: Drinking water source without conventional treatment but after disinfection Class B: Outdoor bathing (organized) Class C: Drinking water source after conventional treatment and after disinfection Class D: Propagation of Wild life and Fisheries Class E: Irrigation, Industrial Cooling, and Controlled Waste Disposal Below E: Not meeting A, B, C, D & E Criteria Class E 6.58.5 2250 26 2
3.5
Noise Levels In order to have an idea about the existing noise levels in the study area, noise monitoring has been carried out at eight (8) locations, out of these 8 locations one location is in core zone and rest 7 are in buffer zone. All these monitoring stations are listed in Table-3.7. Table-3.7: Noise Monitoring Stations Stn. No. N1 N2 N3 N4 N5 N6 N7 N8 Location Narendrapur Shibapur outside lease area Motanga Kochilimara Near MRS building Khaliberana Ganthigriha Nalatangara Core Zone /Buffer Zone Buffer zone Buffer zone Buffer zone Buffer zone Core zone Buffer zone Buffer zone Buffer zone
Distance & Direction (from Centre of proposed project)
2.2 km N 1 km ENE 4.75 km E 2.25 km SE 3.5 km NW 2.0 km W 4.5 km W
3 - 11

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Noise Monitoring Frequency At each ambient noise monitoring station, Leq. noise level has been recorded at hourly intervals for 24 hours. Readings were taken by keeping the noiserecording instrument ON for fifteen (15) minutes for each reading.
Results and Discussions The summarised monitoring results of noise level in ambient air given in Table-3.8. The results have been compared with the standard specified in Schedule III, Rule 3 of Environmental Protection Rules given in Table-3.9.
Table-3.8: Summarized Results of Noise Monitoring
Stn. No. Results Location Day (0600-2200 hr.) Max. Min. Mean.* Night (2200-0600 hr.) Max. Min. Mean.*
N1
Narendrapur Highway)
(Near
74.7
64.7
70.9
67.1
57.7
63.1
N2 N3 N4 N5 N6 N7 N8
Shibapur outside lease area Motanga Kochilimara Near MRS building Khaliberana Ganthigriha Nalatangara
* Logarithmic Averages.
54.3 48.3 56.8 68.8 47.6 48.4 53.3
44.3 44.2 45.8 58.3 42.7 41.2 46.3
50.8 46.8 54.3 66.1 46.2 46.2 50.3
44.4 45.8 48.5 62.8 43.5 44.6 45.4
39.2 40.0 40.7 58.1 39.7 38.7 41.3
41.5 42.5 43.8 59.8 41.3 41.0 43.3
All Values in dB (A).
Table-3.9: Ambient Air Quality norms in respect of Noise (As Per Schedule III, Rule 3 of Environment Protection Rules)
Type of Area Industrial Area Commercial Area Residential Area Silence Zone Day (0600 - 2200 hrs). 75 65 55 50 Night (2200 0600 hrs.) 70 55 45 40 All Values in dB (A)
3 - 12

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) At all the noise monitoring stations values of Leq. are well within their respective norms.
3.6
Soil Characteristics To assess the quality of soil in and around the lease area, soil samples were collected from five locations during summer season for physicochemical analysis. Soil sampling locations are mentioned in Table3.10.
Table-3.10: List of Soil Sampling Locations
Sample No. S1 S2 S3 S4 S5
Location Motanga Galpoda Nuahata Nalatangara Shibpur
Type of Land Agricultural Agricultural Agricultural Agricultural Barren
The results of analysis are given in Tables 3.11, 3.12, 3.13, 3.14 & 3.15. Table-3.11: Physical Properties of Soil
Sample No. S1 S2 S3 S4 S5 Colour Brown Light Brown Light Brown Dark Brown Dark Brown Texture Loam Loam sand Loamy sand Loam Loam Water Holding Capacity (%) 56 41 46 49 53
Table-3.12: Chemical Properties of Soil Parameters

pH Electrical Conductivity ( mhos/cm)
S1 6.5 150
S2 6.8 99
S3 6.3 326
S4 6.6 125
S5 7.3 67
3 - 13

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Soil pH plays an important role in the availability of nutrients. Soil microbial activity is also dependent on pH. In the study area the soil pH is acidic to neutral (6.3 <pH< 7.3).
Electrical conductivity (EC) is a measure of the soluble salts and ionic activity in the soil. In the collected soil samples the conductivity ranged from 67 to 326 mhos/cm.
Table-3.13: Chemical Properties of Soil

Parameters Available Nitrogen (kg/ha) and Rating Available (Kg/ha) and Rating Available (Kg/ha) and Rating Phosphorus S1 216 L 54 H Potassium 756 H 0.89 H 1.53 S2 285 M 38 H 220 M 0.44 L 0.75 S3 386 M 26 H 847 H 0.90 H 1.56 S4 229 L 5 L 419 H 1.11 H 1.92 S5 197 L 7 L 554 H 0.78 H 1.35
Organic carbon (%) and Ratings Organic matter % Rating based on : Available Nitrogen Available Phosphorus Available Potassium Organic carbon
<280 Low; 280-560- Medium; <10 - Low; 10 - 25 - Medium; <120 - Low; 120 280-Medium; <0.50- Low; 0.5 - 0.75 -Medium;
>560 High >25 - High >280 - High. > 0.75 High
Phosphorus and Nitrogen are limiting nutrients. In the tested soil samples, availability of Nitrogen varies from low to medium while Phosphorus is either low or high. Potasium and Organic carbon content are in general high.
3 - 14

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Table-3.14: Exchangeable Cations
Parameters Calcium (meq/100gm) % contribution to the Saturation Magnesium (meq/100gm) % contribution Saturation to the Base
S1 S2 S3 S4 S5
17 62.51 7.6 Base 27.96 1.45 Base 5.34 1.14 Base 4.19
5 59.24 2.0 23.70 0.97 11.49 0.47 5.57
46.9 75.34 12.9 20.56 1.33 2.14 1.22 1.96
8.9 67.04 3.4 25.28 0.48 3.58 0.55 4.10
31.2 73.74 9.8 23.16 0.60 1.42 0.71 1.68
Sodium (meq/100gm) % contribution to the Saturation Potassium (meq/100gm) % contribution to the Saturation
The above results show that the tested soil samples have moderate quantities of calcium and magnesium whereas levels of exchangeable sodium and potassium were relatively low.
Table-3.15: Available Micronutrients in Soil
Parameters Copper Zinc Iron Manganese S1 1.35 3.2 13.5 22.5 S2 1.28 2.45 12.4 18.5 S3 1.36 2.26 12.7 19.6 S4 1.21 2.54 12.9 25.0 S5 1.26 2.18 12.8 24.3 Remarks 1.44 2.82 12.4 21.5
( Values in mg/ kg).
Soil micro-nutrients also play an important role in plant growth and can act as limiting nutrients. Soil micro-nutrient analysis can be employed as a diagnostic tool for predicting the possibility of deficiency of a nutrient and the profitability of its application. For this, the critical limits of micro nutrients are fixed. The critical limits of copper, zinc and iron are 0.20-0.66 mg/kg, 0.50-0.65 mg/g and 4.56.0 mg/kg respectively. From the above Table it can be seen that concentration of copper in all the soil samples are beyond the limit. Zinc and iron is also high in all the soil samples.
3 - 15

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 3.7 Biological Environment
The study area is sparsely populated. The biotic environment can be described under following heads.
3.7.1 Project Site
The plant site is about 1664.50 acre of land. The project area is about 2 km wide and 4 km in length at max. The project site bounded by village Narendrapur on North, Taldanga on west, Nuagaon on South, Kochilimara on SE and Sibpur on East. The project area had already in the possession of BSSL.
a.
Land environment The soil in the field is heavy, which swells on wetting and cracks on drying. Irrigation facility is not upto the mark and thus only paddy is grown during rainy season. Other crops, which are grown, are Khesari and Moong.
b.
Natural Vegetation The project site mostly contains shrubs with tree spread scattered over the area.
3.7.2 Study Area
The study area covers 7 km radius around the project site. The plant species commonly found in the area is given in Table-3.16. The study area can roughly be divided in two, the one with narrow valley and alluvial plains and the other consisting of undulating tracts broken hills and mountains. The former is best utilized for paddy and other agricultural crops. The study area can be described as :
3 - 16

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Table-3.16: Plants found in study area Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. Pheonix dactylifera Acacia arabica Zyziphus mauritiana Mangifera indica Borassus flabellifer Ficus bengalensis Diaspyros melanoxylon Azadirachta indica Bambusa arundinacea Butea frondosa Albizzia lebbeck Cassia florida Artocarpus heterophylla Madhuca indica Annona squamosa Ficus religiosa Holarrhena antydysentrica Anogeissus latifolia Cassia fistula Vitex negundo Bombax ceiba Polyalthia longifolia Nerium odorum Prunus amygdalus Acacia auriculiflormis Aegla marmelos Saraca indica Khajoor Babool Ber Mango Tad Bargad Kendu Neem Bans Palasa Siris Chakunda Kathal Mahua Sharifa Peepal Korai Dhav Sonnari Sindwar Semal Ashok Kaner Badam Auriculiformis Bel Ashoka Botanical name Common name
3 - 17

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Sl. No. 28. 29. 30. 31. 32. 33. 34. 35. Shorea robusta Terminalia tomentosa Phyllanthus emblica Terminalia belirica Terminalia arjuna Terminalia chebula Syzigium jambolana Dalbergia sissoo Sal Asan Aonla Bahera Arjun Harida Jamu Sisso Botanical name Common name
a.
Forest Area There is only one patch of forest, Jharbandh reserved forest, which is in SE direction at 5.5 km from the project site. The forest is on hillocks and is of mixed dry deciduous type, in highly degraded state. The tree height varies from 2 to 5 m and trees are mostly like shrubs. The common species are D. strictus, Cephalostachyum pergracile, H. antidysentrica, A. indica, D. melanoxylon, F. bengalenisis, A. arabica, A. latifolia, A. marmelos, A. squamosa, etc.
b.
Agricultural land
The Irrigation facility is not proper in the study area, rainwater is the main source of irrigation and thus paddy is the main crop grown in the area. Other crops, which are grown, are Khesari, Groundnut, Moong, Cajanus, Til, etc. where watering facility is available seasonal vegetables are also grown.
3 - 18

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) c. Waste land
Wasteland in the study area is commonly seen in the area, is mostly covered with species like Calotropis spp, Ipomea sp, Cassia tora, Croton sp., Parthenium sp., Zizyphus sp., etc.
d.
Grassland
Grassland in the study area is secondary in origin. The common species found in the area are Dicanthium sp. Desmodium sp., Evolvulus sp, Cynodon dactylon, Cyperus sp., Imperata sp., etc.
e.
Vegetation in and around human settlement
Near villages the vegetation pattern changes from rest of the area. The common species grown near villages are Mangifera indica, Madhuca indica, Sizygium sp., Artocarpus sp., Bambusa sp., Ficus spp., Azadirachta indica, Cassia siamea, Albezzia sp., Acacia auriculiflormis, Nerium sp., Annona squmosa, Pheonix sp., Polyalthia sp., etc.
f.
Avenue trees and Plantation
The roadside along NH 42 and other roads in the study area are planted with trees in single to double rows. The common trees are Acaccia auriculiformis, Azadirachta indica, Peltophorum, Syzigium sp., Mangifera indica, Bombax ceiba, Delonix regia, Cassia siamea, etc.
There are stretches of plantation done by CPP, NALCO, and other industrial premises and residential areas, the common plants are, cassia siamea, Leucaena leucocephala, Dalbergia sisso, Sarca indica,
3 - 19

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Delonix regia, Azadirachta indica, Acacia auriculiformis, Mangifera indica, Prunus amygdolus, Callistemon lanceolatus, etc.
g.
Wild life and avifauna
There is only a small patch of Jharbandh forest falling into the study area. Which is also in highly degraded state and do not support good wild life? The common wild life found in the study area is given Table3.17. and Table-3.18 Table-3.17: List of Wild life species in the study area Sl. No. Common Name Scientific Name Status Schedule of Wildlife Protection Act in Which Listed 1. 2. 3. 4. 5. 6. 7. 8. Mongoose Spotted deer Wild boar Monkey Hare Porcupine Jackal Squirrel Herpestes edwardsi Axis axis Sus scrofa Macaca mulatta Lepus nigricollis Hystrix indica Canis aureus Funambulus palmarum IV III III II IV IV V IV
Table-4.18: List of common birds found in the region Common Name Botanical Name Status Schedule of Wildlife Protection Act in Which Listed Greying goose Comb duck Blue rock pigeon Anser anser Serkidiornis sp. Columba livia Francolinus IV IV IV IV
3 - 20

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Common Name Botanical Name Status Schedule of Wildlife Protection Act in Which Listed Black patridge Red jungle fowl Mynas Parkeet Bagula h. Aquatic life francolinus F. pondicerianus Gallus gallus Acridothere tristis Psitiacula eupatria IV IV IV IV
There are a number of ponds in the villages in the study area. On visual observation these ponds seems to be oligo-trophic to mesotrophic in nutrients status. The common rooted plants and hydrophytes on the edges of these pons are Nelumbo sp., Potamogeton sp., Aponogeton sp.,Ipomea sp., Dichanthium sp., etc. The water in these ponds are colourless to slight greenish in color.
There are three major rivers in the study area, Brahmni, Krishnajhor and Nandirajhor. Out of these Nandirajhor River is the most polluted due to the industrial effluent in the area. River Brahmni receives the water of Nandirajhor.
The common fishes found in the area are Labio rohita, Catla catla, Cirrhina mrigala, Calabasu sp., Cyprnus carpio, Grass carp, Silver carp, Wallago attu, etc.
The Phytoplanktons in the rivers are basically dominated by filamantous forms. The dominant ones are, Chaetophora sp., Cladophora sp., Pithephora sp., Oscillatoria so., Spirogyra sp., Cymbella sp., etc.
3 - 21

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) The Zooplanktons are basically dominated by Crustaceans and Rotifers. The dominant ones are Crustaceans : Crustacean eggs, Moinodaphina, Chydorus, Cyclops. Rptifers : Brachionus, Rotiferan, etc. Others : Nematodes, Dipteran larvae, etc.
i.
Animal husbandry
From the records of Veterinary hospitals it is found that there are symptoms of fluorosis and high fluoride content in urine and blood samples of few cattles in the study area. The fluorosis prone villages in the study area and their distance direction are given in Table-3.19. The reason for fluorosis in these villages may be attributed to high fluoride content in ground water in few pockets. The reason for high fluoride content in water is yet to be ascertained. Table-3.19: Name of villages and their distance / direction from project site in which Cattle are affected with fluorosis Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Name of village Gotamara Banarapal Chaurhia Jhanjiribahal Garhasantil Amana Taltali Sanjapahara Bodibahal Garhasantri Nalatangara Bhagabatpur Narendrapur Nauhata Budapank Sanjaparha Ganthigarhia Santri Distance (km) / direction from project site 6.3;NW 5.6; NW 6.3; WNW 5.6; NW 6.3; W 5.6; W 6.8; W 4.1; W 2.8; W 3.1; W 4.0; W 3.4; W 3.1; W 4.4 NW 4.4; NNW 4.4; W 1.33; W 5.9; W
3 - 22
Chapter-3 Annexure-3.1
Summerised Ambient Air Quality results of Meramandli for Summer Season'2006

Results in g/m3 Permissible AAQ standard Industrial Residential Monitoring Location Motanga Galpoda Nalatangra Nuahata MRS building SPM 500 200 Min. 81 70 81 76 84 Max. 198 133 208 162 260 Arth. Mean 110 93 119 103 137 Min. 40 37 41 40 47 RPM 150 100 Arth. Max. Min. Mean 82 66 97 87 116 54 47 59 53 63 <10 <10 <10 <10 <10 SO2 120 80 Max 17 <10 11 16 16 NOx 120 80 Arth. Arth. Min. Max. Mean Mean 15 14 13 13 15 39 43 36 48 38 29 24 26 26 22 CO 10000 4000 Min. 875 823 634 1796 1369 Max. 1456 1296 1168 3488 3859 Arth. Mean 1111 976 924 2485 2415
Chapter-3 Annexure-3.2 Results of Ground Water Analysis

Sl. No. Parameters Requirement (desirable limits) Norms* Permissible limits in the absence of alternate source Sibapur Village (within lease area) GW1 Sibapur Village (outside lease area)GW2 Khaliberana GW3
Date of sampling
26.04.2006
26.04.2006
26.04.2006
Essential Characteristics 1 2 3 4 5 6 7 8 9 Colour, Hazen Units. Odour Taste Turbidity, NTU, Max. pH value Total Hardness (as CaCO3), mg/l, max Iron (as Fe), mg/l, max. Chloride (as Cl),mg/l, max. Fluoride (as F), mg/l, max. Total Dissolved Solids, mg/l, max. Calcium (as Ca), mg/l, max. Magnesium (as Mg), mg/l, max. Copper (as Cu), mg/l, max. Manganese (as Mn), mg/l, max. Sulphate (as SO4), mg/l, max. Nitrate (as NO3), mg/l, max. Phenolic compounds (as C6H5OH), mg/l, max. Mercury, (as Hg), mg/l, max. Cadmium (as Cd), mg/l, max. Selenium (as Se ), mg/l, max. 5 Unobjection able Agreeable 5 6.5 to 8.5 300 0.3 250 1 25 10 No Relaxation 600 1 1000 1.5 <5 Unobjectionable Agreeable <5 7.1 264 0.26 28 1.23 <5 Unobjectionable Agreeable <5 7.2 276 0.15 24 1.34 <5 Unobjectionable Agreeable <5 7.6 300 0.02 30 0.68
Desirable characteristics 10 11 12 13 14 15 16 17 18 19 20 500 75 30 0.05 0.1 200 45 0.001 0.001 0.01 0.01 2000 200 100 1.5 0.3 400 100 0.002 No relaxation No relaxation No relaxation 44 0.73 <0.001 <0.0005 <0.005 <0.005 43 0.76 <0.001 <0.0005 <0.005 <0.005 34 26 <0.001 <0.0005 <0.005 <0.005 471 48 35 <0.01 496 48 38 <0.01 502 77 26 <0.01
Sl. No.
Parameters Requirement (desirable limits)
Norms* Permissible limits in the absence of alternate source Sibapur Village (within lease area) GW1 Sibapur Village (outside lease area)GW2 Khaliberana GW3
Date of sampling
26.04.2006
26.04.2006
26.04.2006
21 22 23 24 25 26 27 28 29 30
Arsenic ( as As), mg/l, max. Cyanide (as CN), mg/l, max. Lead (as Pb), mg/l, max. Zinc (as Zn ), mg/l, max. Anionic Detergents (as MBAS), mg/l, max. 6+ Chromium (as Cr ), mg/l, Max. Mineral oil mg/l, Max. Alkalinity ( as CaCO3), mg/l Aluminium (as Al ), mg/l Boron (as B), mg/l, max.
0.05 0.05 0.05 5 0.2 0.05 0.01 200 0.03 1
No relaxation No relaxation No relaxation 15 1 No relaxation 0.03 600 0.2 5
<0.03 <0.01 <0.05 ND <0.1 <0.01 <0.1 242 <0.01 <0.01
<0.03 <0.01 <0.05 ND <0.1 0.05 <0.1 268 <0.01 <0.01
<0.03 <0.01 <0.05 ND <0.1 <0.01 <0.1 260 <0.01 <0.01
* Drinking Water Specification, IS : 10500 (1991) & Amendment no.1, January1993
Sl. No.
Parameters
Norms* Requirement (desirable limits) Permissible limits in the absence of alternate source Date of sampling 25 10 No Relaxation 600 1 1000 1.5
Motanga GW4
Kochilimara GW5
Galpoda GW6
26.04.2006 <5 Unobjectionabl e Agreeable <5 6.8 416 0.46 97 1.32
26.04.2006 <5 Unobjectionabl e Agreeable <5 7.5 404 1.1 66 1.04
26.04.2006 <5 Unobjectiona ble Agreeable <5 6.6 284 0.54 54 0.78
Essential Characteristics 1 Colour, Hazen Units. 2 3 4 5 6 7 8 9 Odour Taste Turbidity, NTU, Max. pH value Total Hardness (as CaCO3), mg/l, max Iron (as Fe), mg/l, max. Chloride (as Cl),mg/l, max. Fluoride (as F), mg/l, max.
5 Unobjectiona ble Agreeable 5 6.5 to 8.5 300 0.3 250 1
Desirable characteristics
Sl. No.
Parameters
Norms* Requirement (desirable limits) Permissible limits in the absence of alternate source Date of sampling 2000 200 100 1.5 0.3 400 100 0.002 No relaxation No relaxation No relaxation No relaxation No relaxation No relaxation 15 1 No relaxation 0.03 600 0.2 5
Motanga GW4
Kochilimara GW5
Galpoda GW6
26.04.2006 762 67 60 <0.01
26.04.2006 625 35 77 <0.01
26.04.2006 556 82 19 <0.01
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Total Dissolved Solids, mg/l, max. Calcium (as Ca), mg/l, max. Magnesium (as Mg), mg/l, max. Copper (as Cu), mg/l, max. Manganese (as Mn), mg/l, max. Sulphate (as SO4), mg/l, max. Nitrate (as NO3), mg/l, max. Phenolic compounds (as C6H5OH), mg/l, max. Mercury, (as Hg), mg/l, max. Cadmium (as Cd), mg/l, max. Selenium (as Se ), mg/l, max. Arsenic ( as As), mg/l, max. Cyanide (as CN), mg/l, max. Lead (as Pb), mg/l, max. Zinc (as Zn ), mg/l, max. Anionic Detergents (as MBAS), mg/l, max.
6+ Chromium (as Cr ), mg/l, Max.
500 75 30 0.05 0.1 200 45 0.001 0.001 0.01 0.01 0.05 0.05 0.05 5 0.2 0.05 0.01 200 0.03 1
56 0.59 <0.001 <0.0005 <0.005 <0.005 <0.03 <0.01 <0.05
24 6 <0.001 <0.0005 <0.005 <0.005 <0.03 <0.01 <0.05
36 4 <0.001 <0.0005 <0.005 <0.005 <0.03 <0.01 <0.05
<0.1 <0.01 <0.1 380 <0.01 <0.01
<0.1 <0.01 <0.1 350 <0.01 <0.01
<0.1 <0.01 <0.1 272 <0.01 <0.01
Mineral oil mg/l, Max. Alkalinity ( as CaCO3), mg/l Aluminium (as Al ), mg/l Boron (as B), mg/l, max.
Sl. No.
Parameters Requirement (desirable limits)
Norms* Permissible limits in the absence of alternate source
Ganthigriha GW7
Narendrapur GW8
Date of sampling Essential Characteristics 1 2 3 4 5 6 7 8 9 Colour, Hazen Units. Odour Taste Turbidity, NTU, Max. pH value Total Hardness (as CaCO3), mg/l, max Iron (as Fe), mg/l, max. Chloride (as Cl),mg/l, max. Fluoride (as F), mg/l, max. Total Dissolved Solids, mg/l, max. Calcium (as Ca), mg/l, max. Magnesium (as Mg), mg/l, max. Copper (as Cu), mg/l, max. Manganese (as Mn), mg/l, max. Sulphate (as SO4), mg/l, max. Nitrate (as NO3), mg/l, max. Phenolic compounds (as C6H5OH), mg/l, max. Mercury, (as Hg), mg/l, max. Cadmium (as Cd), mg/l, max. Selenium (as Se ), mg/l, max. Arsenic ( as As), mg/l, max. Cyanide (as CN), mg/l, max. Lead (as Pb), mg/l, max. Zinc (as Zn ), mg/l, max. 5 Unobjectionable Agreeable 5 6.5 to 8.5 300 0.3 250 1 25 10 No Relaxation 600 1 1000 1.5
26.04.2006 <5 Unobjectionable Agreeable <5 7.4 576 0.06 103 1.2
26.04.2006 <5 Unobjectionable Agreeable <5 7.3 328 0.28 34 1.29
Desirable characteristics 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 500 75 30 0.05 0.1 200 45 0.001 0.001 0.01 0.01 0.05 0.05 0.05 5 2000 200 100 1.5 0.3 400 100 0.002 No relaxation No relaxation No relaxation No relaxation No relaxation No relaxation 15 80 6 <0.001 <0.0005 <0.005 <0.005 <0.03 <0.01 <0.05 47 9 <0.001 <0.0005 <0.005 <0.005 <0.03 <0.01 <0.05 992 61 103 <0.01 589 79 32 <0.01
Sl. No.
Parameters Requirement (desirable limits) Anionic Detergents (as MBAS), mg/l, max.
6+ Chromium (as Cr ), mg/l, Max.
Norms* Permissible limits in the absence of alternate source
Ganthigriha GW7
Narendrapur GW8
Date of sampling 25 26 27 28 29 30 0.2 0.05 0.01 200 0.03 1 1 No relaxation 0.03 600 0.2 5
26.04.2006 <0.1 0.09 <0.1 526 <0.01 <0.01
26.04.2006 <0.1 <0.01 <0.1 316 <0.01 <0.01
Mineral oil mg/l, Max. Alkalinity ( as CaCO3), mg/l Aluminium (as Al ), mg/l Boron (as B), mg/l, max.
Chapter-3 Annexure-3.3 Results of Surface Water Analysis

Sl. No. Parameters River Lingra SW1 26.04.2006 <5 <5 8.1 5.8 2 80 0.25 22 1.12 178 18 9 <0.01 7 0.57 <0.001 <0.0005 <0.005 <0.005 Kisinda Jhor before joining Rver Brahmani SW2 26.04.2006 <5 <5 7.9 5.6 1 100 0.59 44 2.21 304 32 5 <0.01 48 1.22 <0.001 <0.0005 <0.005 <0.005 River Brahmani d/s of Lingra river SW3 26.04.2006 <5 <5 7.7 6.1 2 124 0.28 24 1.0 254 24 16 <0.01 14 1.15 <0.001 <0.0005 <0.005 <0.005
Date of Sampling 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Colour, Hazen units, Max. Turbidity, NTU, Max. pH Value Dissolved Oxygen (as O2), mg/l BOD, 3 days at 27 C, mg/l Total Hardness (as CaCO3), mg/l, Max. Iron (as Fe), mg/l, Max. Chloride (as Cl), mg/l, Max. Fluoride (as F) mg/L, Max. Dissolved Solids mg/l, Max. Calcium (as Ca), mg/l, Max. Magnesium (as Mg), mg/L, Max. Copper (Cu), mg/l, Max. Sulphate (as SO4), mg/l, Max. Nitrate (as NO3), mg/l, Max. Phenolic Compounds (as C6 H5OH), mg/l Max. Mercury (as Hg), mg/l, Max. Cadmium (as Cd), mg/l, Max. Selenium (as Se), mg/l, Max.
Sl. No.
Parameters
River Lingra SW1 26.04.2006 <0.03 <0.01 <0.05 <0.1 <0.01 <0.1 72 0.01 600 0.78
Kisinda Jhor before joining Rver Brahmani SW2 26.04.2006 <0.03 <0.01 <0.05 <0.1 <0.01 <0.1 88 0.01 400 2.03
River Brahmani d/s of Lingra river SW3 26.04.2006 <0.03 <0.01 <0.05 <0.1 <0.01 <0.1 118 0.02 900 0.84
Date of Sampling 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Arsenic (as As), mg/l, Max. Cyanide (as CN), mg/l, Max. Lead (as Pb), mg/l, Max. Anionic detergent (as MBAS) mg/l, Max. Chromium (as Cr ), mg/l, Max. Mineral oil mg/l, Max. Alkalinity (as CaCO3) mg/l, Max. Aluminium (as A1) mg/l, Max. Coliform organisms, MPN/100ml Sodium Absorption Ratio
6+

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 4.0 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES
4.1
General The first step in environmental impact assessment is to list all the potentially significant environmental impacts. These are then examined critically and the major impacts (both negative and positive) are analyzed in detail for the EIA. The existing plant had been planned out considering low specific consumption of raw materials and energy and minimum impact on the environment. In order to ensure comprehensiveness, the various aspects considered in listing of impact during modification-cum-expansion of the plant are: Investigation of project components. Investigation of project phases. Investigation of Impact generating activities. Investigation of types of impacts.
There are various techniques available for listing of impact. These include checklists, matrices, networks and cause effect diagrams etc. The objective of undertaking EIA of the project under consideration at the selected site is to identify the probable impacts on the pre-project, or the present environmental setting of the project site surroundings. This gives a first-hand assessment of the degree of impacts caused by the project activities from construction stage to operational stage. From the assessment, it can be judged to what extent the potential impacts are likely to occur and if so to what level it can be minimized by implementing suggested environmental management plan (EMP) from the design stage itself.
4-1

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 4.2 Listing Matrix The possible environmental attributes that may be affected by industrial activities are: Air Water Noise Soil / land Ecology Infrastructure Socio-economics.
The various activities which could have significant impact during modificationcum-expansion of existing plant have been classified under following groups. 4.3 Existing Operations. Future Activities
Evaluation of the Steel Making Process The basic chemistry of steel making is to reduce oxides of iron ore with a carbonaceous reductant such as coke and coal to produce hot metal. This hot metal contains about 4 to 6 per cent of carbon, which needs to be oxidized by reacting with oxygen to produce crude liquid steel. The entire process chemistry works at an elevated temperature. There are two process routes that dominate the global steel production, although variations and combinations of two exist. These are the integrated one based on BF-BOF/LD route and electric arc furnace (EAF) route. The BOF route to steel making is based on the production of iron in BF and later conversion to steel in the BOF converters. In case of EAF, the source of iron is predominantly scrap/DRI with
4-2

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) the electrical energy being used in the conversion process. Although, the EAF route to large volume steel production is uneconomical in Indian conditions due to high costs of electrical power, still BSSL has chosen this route due to substantial power generation from waste heat available from hot waste gases from process. Existing plant site is generally plain with minor undulation. The existing plant is well connected to state high way and nearby railway station Meramandali. Hence only connecting line from plant to Meramandali station is required as infrastructure. Therefore, construction for infrastructure does not require and hence does not affect the environment in any way.
Construction The major construction will involve excavation and fabrication work for facilities, which are addition to existing BSSL plant. This will involve excavation, construction, erection of equipment, engagement of labour force, laying and routing of pipelines, commissioning and testing activities etc. Air, water, noise and soil / land are likely to be affected by the above activities. . It will have marginal impacts on air, water, and noise quality. Socio-economic pattern may be marginally improved due to generation of temporary employment. However, these impacts will be for a short duration only. Marginal impact is anticipated on Aesthetics, Land use and Socio Economic pattern. Operation The existing plant is partially operational and producing 650000 tpy sponge iron products. When the plant is fully operational the generation of fugitive and process dust, heat and noise may have negative impact on health and safety but due to proper management its impact shall be marginalized. While the employment generated by the project for the operation is having positive socio-economic impact. 2007 MECON Limited. All rights reserved 4-3

The proposed additional major production facilities of the modernization-cumexpansion program as described in Chapter 2 are (i) augmenting Sintering, (ii) coke making additional (iii) augmenting BFs, and (iv) Steel making in EAFs v) additional DRI kilns etc . The supporting production units and facilities are Secondary Refining Facilities, Pig-Casting, Slag Granulation, Continuous Casting, Billet Caster, Hot Strip Mill, Oxygen Plant, Lime Plant, Coal Dust Injection System in BF, etc. Each of the main such production process has got different pollution potential as may be seen from the Table 4.1.The predominant environmental pollution would be the air pollution due emissions of dusts and gases and water pollution due to Hot Strip mill effluents containing toxic substance like oil.
In addition to air and water pollution, there would be generation of solid wastes such as DRI fines, char, dust from GCP, BF slag, EAF slag, mill scales and washery rejects and middling etc, major part of which are recycled to the process or used by others and part may require dumping/storage on the ground for future use. The environmental impacts of the above additional activities are given in the following Table 4.1. Table 4.1: Sources and types of environmental impacts
Section Feed & Fuels /Units I. Construction Stage Construction materials Operation Pollutants Recipient Form of pollution Air pollution Water pollution Land pollution Air pollution
Dusts Noise Slurry water Construction debris Dusts
Air Open drain Land Air
II. Operational Stage Raw All types of solid raw Material materials Handling Coking Coal, by-product fuel gas as fuel
Mechanical handling, sizing and conveying Coal carbonization
Heat, Dust SO2, NOX VOCs
Air
Air pollution
4-4

Section /Units Feed & Fuels Operation Pollutants Phenolic Effluent Heat, Dusts, SO2 , NOX Noise Heat, Dusts, SO2, NOX Noise Particulate dusts laden water Dust, SO2 Noise Blow down water Heat , Dusts Particulate dusts laden water Heat, SO2, NOx Noise Oil and particulates laden mill effluent Heat, SO2, NOx Heat, SO2, NOx Noise Waste-water of DM Plant containing acids/ alkalis Recipient Plant Drain Air Air Air Work-zone air Plant Drain Air Work-zone air water Air Plant Drain Air Work-zone air Plant Drain Air Air Work-zone air Plant Drain Form of pollution Water pollution Air pollution Work-zone pollution Air pollution Work-zone pollution Water pollution Air pollution Air pollution Water pollution Air pollution Water pollution Air pollution Noise pollution Water pollution Air pollution Air pollution Noise pollution Water pollution
Sinter Plant
Blast Furnace
Iron ore fines, Limestone fines, LD slag etc as feed and coke and flue gas as fuel Coke, Lump Iron Ore, Sinter, Fluxes and by-product fuel gas
Sintering at an elevated temperature
Hot metal making
DRI Steel melt shop (SMS) Hot Strip Mill (HSM)
Coal, Lump iron ore, Fluxes Hot Metal, Fluxes, Ferro alloys Steel Slabs and byproducts fuel gas as fuel
Sponge iron making Steel making, refining and continuous casting of slabs Hot rolling of Slabs
Lime/Dolo calcining Captive Power Plant and Blower House
Limestone and byproduct fuel gas By-product fuel gas as fuel
Calcinations Steam raising and power generation
4.4
Identification of Impacts An attempt has been made to identify and list all possible aspects, which could generate significant impact due to various phases of the modification-cumexpansion on different environmental attributes. Some of these impacts are insignificant and don't warrant further analysis. Thus objective is to identify and list only the significant impacts, which shall require detailed analysis to the extent of decision-making purposes. The major construction activities will be of short duration and will have very few lasting impacts. The operation will have the potential of major impacts, which has been analyzed in detail. Based on the impacts identified, most affected environmental attributes have been considered for detailed evaluation.
4-5

4-6

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 4.5 Prediction of Impacts: In the screening of impact the environmental attributes that may be affected due to the proposed modification-cum-expansion of existing steel plant have been identified. Impact prediction is a way of foretelling the environmental consequences of the significant aspects of the proposed modification-cumexpansion of plant. Impacts on various environmental attributes during construction as well as operation have been discussed. The impact assessment will focus on the proposed modification-cum-expansion and will broadly cover the following:
Estimation of physical effects for all phases including construction and operation. Estimation by type and quantity of expected contaminants i.e. residues, and emissions (air, water, noise, solid wastes) resulting from the operation of the proposed expansion and modification of existing unit. Assessment of the positive and negative impacts on land use, future development, cultural / historic resources, peoples, demographics,
infrastructure, employment, income, education etc. Indirect impacts which may arise from proposed modification-cum-expansion of plant.
However, the anticipated environmental impacts of the proposed modification-cumexpansion are discussed below under the category (a) Impacts during construction and (b) Impacts during operation.
4-7

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 4.6 Prediction of Impacts During Construction
4.6.1 Land use BSSL will not acquire any new land for proposed modification-cum-expansion. Most of the units of the proposed expansion will be either higher capacity unit or modification of the existing unit cleared during 1.5 Mtpy stage. Accordingly the construction activity will be limited within the existing BSSL plant premises and in the already built up area. Thus no large-scale excavation, soil erosion, loss of topsoil is expected. The BSSL plant site is already a fairly well developed area with all sorts of infrastructure already available. It is therefore most unexpected that influx of construction labour is going to change present land use pattern. Further this land use change during construction is only temporary and will persist during construction phase only.
4.6.2 Impacts on Ambient Air Quality The existing plant is already partially in operation and its
modification/expansion will have limited construction work i.e. limited to specific modification in existing units as well as additional units to be put into the place. During the limited construction phase, civil work is being carried out to put the units in its place. The construction work leads to a generation of fugitive dust. However the fugitive dust is not expected to spread too far. In addition, water spraying is being undertaken to suppress dust being spread.
Due to limited construction activities, the impacts on ambient air quality will not be permanent and will cease once the modification construction is completed after that generation of fugitive dust will reduce drastically.
4-8

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 4.6.3 Impacts on Noise Levels The present noise level is due to construction and operation of existing plant. The production units are being chosen by criteria of environmental friendly technology and shall generate less noise level. Noise levels during this limited construction are likely to increase initially due to increased movement of trucks and other diesel powered material handling equipment. This is unavoidable and limited during day time only. Therefore, movement of trucks and machinery will be regulated to reduce the impacts of increased noise.
The construction phase will be limited to short period and temporary, the impacts on ambient noise levels will be insignificant and ceases once the construction is completed.
4.6.4 Impacts on Water Environment The water required for construction purpose will be met by extending the existing water network of the existing plant. However, during construction, a large volume of debris, mud etc will be generated, which during the rainy season, can contaminate the storm water run-offs with large amounts of suspended solids. Efforts will be made to reduce the suspended solids content of storm water run-offs by routing the storm water drains through catch pits. Moreover storm water run-offs will occur only during the monsoon season which lasts for about 2-3 months in the study area. Moreover these impacts will be temporary lasting only for the duration of the modificationcum-expansion construction period.
It has already been indicated that the proposed expansion will be limited within an existing plant. The plant is already having all infrastructure facilities including water supply. The water requirement during the construction phase will be low and can be met through the already existing water supply facilities. Thus no ground water is 2007 MECON Limited. All rights reserved 4-9

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) expected to be extracted. Therefore, it is most unlikely that construction phase will bring any significant modification in the ground water regime of the area. Therefore, the construction phase of the proposed expansion will have insignificant impact on the ground water.
4.6.5 Impacts on Ecology The modification cum expansion of existing BSSL plant will remain within the existing boundary of Steel plant and no new area will be acquired for expansion. The area involved in modification-cum-expansion shall be very small and hence the impacts on the study area as a whole will be insignificant. Impact on ecology will be insignificant.
4.6.6 Socio-Economic Impacts During the modification-cum-expansion limited construction work shall be carried out in civil as well as machinery handling. The construction phase of the project involves large deployment of manpower, both direct and indirect. This involves employment of temporary labour, which is being engaged to perform these tasks. This will have positive employment effect, both direct and indirect. This will affect the economy of the study area in positive direction as the employment shall generate income which gets routed in local economy.
4.7
Prediction of Impacts During Operation Generally operation of any production plant emits pollutants. Iron and Steel industries are also no exception to that. Once the modification-cum-expansion of existing steel plant to 3.1 Mtpy completed and total plant get operational, there expected slight increase or marginal impacts on ambient air quality, noise levels, water quantity and quality, ecology and positive socio-economic environment. Environmental releases may be in the form of:
4 - 10

a) b) c) d)
Emission to air Waste water discharges Solid waste disposal Noise level etc.
These emissions, discharges and disposal may release different pollutants, which may affect air, water, land and ecological environment directly. However, all these are mainly primary impact. In addition to these primary impacts any industrial project or expansion of a project has some overall impact on its surrounding socioeconomic environment through the existence of social and economic linkages between the project and society, which are actually secondary impact. Under this clause, all these primary and secondary impacts due to this proposed expansion are being discussed and wherever required, impacts have also been quantified. Accordingly under subsequent clauses impacts on air environment, water environment, soil, noise, land use, and socio-economic environment due to the proposed expansion are being elaborated.
4.7.1 Impacts on Ambient Air Quality The principal impacts on ambient air quality due to operation of the fully operational 3.1 Mtpy plant will be due to emissions from the stacks of the various units and emissions of fugitive dust from the iron ore and coal handling areas.
The prediction of Ground level concentrations (GLC) of pollutants emitted from the stacks has been carried out using ISCST-3 Air Quality simulation model released by USEPA. This model is basically a Gaussian dispersion model, which considers multiple sources. The model accepts hourly meteorological data records, to define the conditions of plume rise for each source and receptor combination for each hour of input meteorological data sequentially and calculates short 2007 MECON Limited. All rights reserved 4 - 11

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) term averages upto 24 hours. The impact has been predicted over a 10 km X 10 km area with centre of the sinter plant stack as the centre. To obtain greater resolution, the receptors are defined with respect to 16 radial wind directions (N to NNW) and radial distance from centre. GLC have been calculated at every 500 m grid point to have better results.
The emissions have been computed based on the following:
a) Particulate matter (SPM) has been calculated considering emission rate of 50 mg/Nm3 b) Sulphur content of the coal has been assumed to be 0.5% as per CPCB guidelines c) NOx emissions from Plant have been estimated based on the assumption 75 mg/Nm3 in flue gas and SO2 emission is based on 40 % in gas phase and 60 % in solid waste as per guideline of technology supplier Lurgi.
Details of the proposed stacks and estimated emissions are given in Table- 4.2. Table-4.2: Stack Emission Data of 3.1 Mt Steel Plant
Sl. no. Description of Stack Stack Coordinate (Plant Centre at 10,10) x-coord. Sinter Plant Complex (1x177 m2) 1. 2. SINTER PLANT (MAIN STACK) SINTER PLANT Cooler ESP stack 3. SINTER PLANT -de-dusting 10172 10022 35 2.5 223460 13.28 40 3.1 ESP 10000 10128 10000 9850 100 60 5.0 3.5 1020000 412950 20.48 12.52 150 40 14.2 5.7 4.25 5.67 ESP ESP y-coord. SPM SO2 NOx Stack Height (m) Stack Dia (m) Flow Rate Exit velocity Temp C Emission Rate (g/sec) Pollution Control equipme nt envisage d
(Nm3/hr) (m/sec)
Coke Oven Complex (2x65 Oven 4.3 ht)25:75 ratio CO gas to BF gas Stamp Charge
4 - 12

Sl. no. Description of Stack Stack Coordinate (Plant Centre at 10,10) x-coord. 4. 5. Coke Oven Plant-1 Coke Oven Plant-1 11289 11322 y-coord. 10172 10183 120 120 4.5 4.5 105600 105600 3.05 3.05 220 220 0.7 0.7 4.40 4.40 5.87 5.87 SPM SO2 NOx Stack Height (m) Stack Dia (m) Flow Rate Exit velocity Temp C Emission Rate (g/sec) Pollution Control equipme nt envisage d
(Nm3/hr) (m/sec)
Blast Furnace Complex (1x1681 m3) bag filter design norm 50 mg/Nm3 6. 7. 8. BF STOVE STACK(3 stove) BF Cast House-de-dusting BF Stock House-de-dusting 10589 10672 10539 9978 9783 10089 70 45 45 3.386 4.2 3.1 160250 816000 440000 7.02 17.18 17.01 150 1.1 2.23 3.4 2.67 Bag Filter Bag Filter
40 11.3 40 6.1
DRI Process Stacks after Waste heat Recovery Boilers(14x170000 tpy) ESP design norm 50 mg/nm3 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. DRI PROCESS STACK-1 DRI PROCESS STACK-2 DRI PROCESS STACK-3 DRI PROCESS STACK-4 DRI PROCESS STACK-5 DRI PROCESS STACK-6 DRI PROCESS STACK-7 DRI PROCESS STACK-8 DRI PROCESS STACK-9 DRI PROCESS STACK-10 DRI PROCESS STACK-11 DRI PROCESS STACK-12 DRI PROCESS STACK-13 DRI PROCESS STACK-14 8733 8811 8844 8911 8955 9022 9061 9127 9166 9233 9333 9400 9439 9506 9439 9456 9464 9483 9492 9503 9517 9536 9544 9561 9583 9600 9606 9622 76 76 76 76 76 76 76 76 76 76 76 76 76 76 2.17 2.17 2.17 2.17 2.17 2.17 2.17 2.17 2.17 2.17 2.17 2.17 2.17 2.17 120000 120000 120000 120000 120000 120000 120000 120000 120000 120000 120000 120000 120000 120000 12.79 12.79 12.79 12.79 12.79 12.79 12.79 12.79 12.79 12.79 12.79 12.79 12.79 12.79 150 150 150 150 150 150 150 150 150 150 150 150 150 150 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 2.7 20.2 20.2 20.2 20.2 20.2 20.2 20.2 20.2 20.2 20.2 20.2 20.2 20.2 20.2 ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP
DRI Kilns - De-dusting stacks (ESP design norm 50 mg/Nm3) 23. DRI KILN-1 & 2-in plant dedusting -ESP 8736 9750 45 2.7 300000 15.77 50 4.2 ESP
4 - 13

Sl. no. Description of Stack Stack Coordinate (Plant Centre at 10,10) x-coord. 24. DRI KILN-3 & 4-in plant dedusting -ESP 25. DRI KILN-5& 6-in plant dedusting -ESP 26. DRI KILN-7& 8-in plant dedusting -ESP 27. DRI KILN-9 & 10-in plant dedusting -ESP 28. DRI KILN-11& 12-in plant dedusting ESP 29. DRI KILN-13& 14-in plant dedusting -ESP SMS Complex 30. SMS-1 EAF+LF FUME EXTRACTION-I 31. SMS-1 EAF+LF FUME EXTRACTION -II 32. 33. 34. IF+LF FUME EXTRACTION -I IF+LF FUME EXTRACTION -II SMS-II EAF+LF FUME EXTRACTION-I 35. SMS-II EAF+LF FUME EXTRACTION -II HOT STRIP Mill 36. 37. 38. RE-HEATING STACK-1 RE-HEATING STACK-2 RE-HEATING STACK-3 10933 10961 10978 9372 9378 9383 70 70 70 4.5 4.5 4.5 132700 132700 132700 6.24 6.24 6.24 530 530 530 0.9 0.9 0.9 1.8 7.37 1.8 7.37 1.8 7.37 10439 9478 65.0 5.82 1600000 21.47 110 13.3 Bag Filter 9578 9783 10417 9289 9339 9522 29.5 29.5 65.0 1.75 1.75 5.82 150000 150000 1600000 22.26 22.26 21.47 110 110 110 2.1 2.1 13.3 Bag Filter Bag Filter Bag Filter 9766 9528 36.5 3.0 300000 15.15 110 4.2 Bag Filter 9444 9456 36.5 3.0 300000 15.15 110 4.2 Bag Filter 9400 9883 45 2.7 300000 15.77 50 4.2 ESP 9294 9856 45 2.7 300000 15.77 50 4.2 ESP 9161 9867 45 2.7 300000 15.77 50 4.2 ESP 9005 9805 45 2.7 300000 15.77 50 4.2 ESP 8911 9778 45 2.7 300000 15.77 50 4.2 ESP 8850 y-coord. 9778 45 2.7 300000 15.77 50 4.2 SPM SO2 NOx Stack Height (m) Stack Dia (m) Flow Rate Exit velocity Temp C Emission Rate (g/sec) Pollution Control equipme nt envisage d ESP
(Nm3/hr) (m/sec)
Raw Material Preparation Plant (Bag Design 50 mg/Nm3) 39. 40. 41. LIME PLANT 1(100tpd Shaft) LIME PLANT 2(500tpd shaft) DOLO PLANT-1(500 tpd shaft) 9567 10389 10350 9839 9744 9972 40 40 40 0.75 1.5 1.5 17000 65000 65000 13.38 12.79 12.79 100 100 100 0.2 0.9 0.9 - Bag Filter - Bag Filter - Bag Filter
Captive Power Plant(fuel Clean BF gas 5mg/Nm3) 42. BFG gas fired Boiler of CPP 10639 10056 55 2.0 140000 17.98 160 1.0 -
* Out of 14 DRI kiln maximum 10 kiln will operate at a time 2007 MECON Limited. All rights reserved 4 - 14

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) The meteorological data of the day on which the maximum GLC occurred is shown as Table-4.3. Stability has been computed by Turners method and mixing height has been obtained from literature and nearby IMD station. The predicted GLC values have been provided at Table-4.4.
Table 4.3: Meteorological inputs (Summer 2006) Time (hours) Wind Direction
Wind speed (m/s)
Temp. (K)
Stability
Mixing height (m)
01.00 315.0 1.39 302 6 02.00 315.0 1.67 301 6 03.00 202.5 1.1 301 6 04.00 292.5 0.83 302 6 05.00 315.0 0.83 302 5 06.00 247.5 0.83 302 4 07.00 292.5 1.67 302 3 08.00 315.0 0.56 303 2 09.00 292.5 0.83 305 2 10.00 315.0 0.56 307 2 11.00 315.0 0.56 308 2 12.00 315.0 0.83 310 2 13.00 315.0 0.83 311 1 14.00 315.0 0.83 313 1 15.00 292.5 0.83 313 1 16.00 337.5 1.67 312 2 17.00 315.0 1.1 311 3 18.00 315.0 1.67 310 4 19.00 315.0 1.1 308 6 20.00 315.5 1.1 302 6 21.00 292.5 1.1 302 6 22.00 292.5 0.83 302 6 23.00 315.0 0.83 302 6 24.00 202.5 1.1 302 6 NOTES: STABILITY CLASS 1=A, 2=B, 3=C, 4=D, 5=E AND 6=F. 2007 MECON Limited. All rights reserved
50 50 50 50 50 100 200 200 500 600 750 950 1100 1200 1400 1200 1000 800 700 500 250 200 150 100
4 - 15

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Table-4.4: Predicted value of GLCs Rank 1 2 3 4 5 6 7 8 9 10 Max. 24 h. Avg. (g/m3) of Pollutants SPM 30.5 (7500;11000) 29.6 (7500;11000) 29.2 (8000;11000) 29.0 (8000;10500) 28.8 (7500;11000) 28.7 (8000;10500) 28.6 (7500; 11000) 28.6 (7000; 11500) 28.2 (8000; 11000) 27.9 (8000; 10500) SO2 49.8 (8000;10500) 49.0 (7000; 11500) 47.3 (6500; 12000) 46.6 (7000; 11500) 46.5 (7500; 11000) 44.8 (6000; 12500) 44.6 (6500; 12000) 43.9 (7500; 11000) 42.5 (5500; 13000) 42.3 (7500; 11000) NOx 3.1 (9000; 11000) 3.1 (8500; 11500) 3.1 (9500; 11000) 3.0 (9000; 11500) 2.9 (9000; 12500) 2.9 (8500; 12500) 2.9 (8500; 13000) 2.9 (8000; 13000) 2.8 (9000; 11500) 2.8 (9000; 12000)
The predicted maximum contribution of GLC for all stacks is indicated in above table at different co-ordinate, which is 30.5 ug/m3 for SPM, 49.8 ug/m3 for SO2 and 3.1 ug/m3 for NOx respectively. The nearest AAQ monitoring station where maximum GLC values have occurred is Nuahata village in Northwest direction. The monitored background mean value for AAQ of Nuahata is 103 ug/m3 for SPM, <10.0 ug/m3 for SO2 and 26.0 ug/m3 NOxx for summer season respectively. The AAQ station Nuahata village is on Northwest side of the plant at a distance of 4.75 km. The predicted contributions of different pollutants from the proposed steel plant when added with the monitored existing background levels of Nuahata village indicate that the maximum concentrations will be 133.5 ug/m3, 59.8 ug/m3 and 29.9 ug/m3 for SPM, SO2 and NOx respectively. The isopleths of SPM, SO2 and NOx are enclosed as Fig 4.2, a,b,c respectively. The concentration is well within the norms of rural & residential area norms. However, the area after establishment of 3.1 MT steel plant will be a industrial area and applicable industrial area norms are 500 ug/m3 for SPM, 120ug/m3 for SO2, and 120 ug/m3 for NOx. The computed GLC values are based on assumption that only ten DR kiln will be operating at a time out of 14 DRI kiln proposed as per technologist. Since, the values are much less then the norms for rural and residential areas, therefore no significant impacts are expected from the 2007 MECON Limited. All rights reserved 4 - 16

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) steel plant provided steel plant authority incorporates pollution control measures indicated in the report and implemented holistically. From the results it is observed that impact in operation of its rated capacity of 3.1 Mtpy will be well within the norms of ambient air quality.
In order to improve the work zone air quality inside the plant premises, the following measures will be taken to prevent escape of dusty air and harmful gases from plant. All the fugitive emissions where de-dusting suction hoods cannot be provided due to physical constraints shall be provided with dry fog dust suppression system/water sprinklers.
Habitation centers such as Angul and Denkanal are about 17 and 21 km away from plant respectively and the levels of air pollutants expected are much less. Hence no significant impact can be expected.
4 - 17

ISOPLETHS OF SPM
18000
16000
14000
12000
DISTANCE (m)
10000
8000
6000
4000
2000
MAX. GLC - 30.5 ug/m3( (7500,11000)
PLANT CENTRE - (10000, 10000) 0 0 2000 4000 6000 8000 10000 12000 14000 16000 18000
DISTANCE (m)
Fig-4.2a: ISOPLETH OF SPM
4 - 18

ISOPLETHS OF SO2
18000
16000
14000
12000
DISTANCE (m)
10000
8000
6000
4000
2000
MAX. GLC - 49.8 ug/m3( (8000,10500)
PLANT CENTRE - (10000, 10000) 0 0 2000 4000 6000 8000 10000 12000 14000 16000 18000
DISTANCE (m)
Fig-4.2b: ISOPLETH OF SO2
4 - 19

ISOPLETHS OF NOx
18000
16000
14000
12000
DISTANCE (m)
10000
8000
6000
4000
2000
MAX. GLC - 3.16 ug/m3( (9000,11000)
PLANT CENTRE - (10000, 10000) 0
2000
4000
6000
8000
10000
12000
14000
16000
18000
DISTANCE (m)
Fig-4.2c: ISOPLETH OF NOx
4 - 20

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 4.7.2 Impacts on Water Environment Impacts on Water Resources The source of water for the proposed steel plant will be the Brahmani River. The BSSL plant authority has permission for the drawal of 100 cusecs of water, from Brahmani River for use in steel plant (permission letter enclosed as Annexure at the end of this chapter). The actual requirements of integrated steel plant will be 5400 m3/h (1.5 m3/s). Drawl of 129600m3/day water from Brahmani river will not affect the availability of water for others, as the lean season flow rate in the Brahmani River is 1450 cusecs (1,48,105 m3/h).
The steel plant does not extract any ground water nor will do so in future. Thus operation of the steel plant will not affect ground water availability in the study area. Impacts on Water Quality As the plant water system is designed based on maximum re circulation system and effective discharge from plant to outside will be insignificant. The effluents likely to be generated from the proposed plant are:
Underflow from Raw Water Clariflocculator Backwash Waste from Filtration Plant DM Plant Regeneration Waste Run-off water from Raw Material Storage Yards Waste Water from Slab Caster & Billet Caster Waste Water from Hot Strip Mill Cooling tower blow-down of various shop Plant Sewage & Canteen Effluents
2007 MECON Limited. All rights reserved 4 - 21

BOD plant effluent in coke oven complex

Sludge from Raw Water Clariflocculator and Backwash from Filtration Plant will be led to a sludge pond for removing suspended solids. The overflow from the sludge pond will be used for dust suppression and irrigation of green cover. The sludge from the sludge pond will be dried and dumped in low lying area.
In the coke oven complex, phenolic effluent shall be generated. The quantity of effluent shall be estimated to be 40 m3/h. The effluent will be treated in BOD plant ETP. The treated liquor shall be recycled to the quenching station, to be used for quenching of hot coke.
Water from the BF GCP will be sent to a clarifier / thickener. The overflow from the thickener will be reused in the Pig Casting Machine.
Run-off water from the raw material storage yard will be routed through garland drains to catch pits to settle out suspended solids. The clear water will be discharged into natural drainage channels.
Acidic/ Alkaline effluents will be generated at the DM Water Plant. These effluents will be properly neutralized in neutralization pit before recycling back for dust suppression.
Effluents from the slab caster and HSM complex are likely to contain suspended solids and oil & grease. These effluents will be routed to settling pits fitted with oil & grease trap. The clarified water will be reused in the plant.
Cooling Tower Blow-down and Boiler Blow-down will be utilized for slag 2007 MECON Limited. All rights reserved 4 - 22

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) granulation in BF complex and dust suppression in the raw material handling area. Blow down from the Oxygen Plant will be used in the Pig Casting Machine. Blow-down from the Fume Extraction Units will be utilized in the Slab Caster.
Sewage from the plant canteen will be treated in septic tanks and soak pits. All storm water drains from the raw materials and solid waste handling areas will be routed through catch pits of sufficient volume to settle out suspended solids present in the storm water run-offs.
The lists of water pollution control systems envisaged are summarized in Table-4.5. Table-4.5: List of Water Pollution Control Systems Source Raw material handling yard Raw Water Treatment Plant BF Gas Cleaning Plant Phenolic effluent DM Water Plant Slab Caster and Hot Strip Mills Cooling Tower and Boiler Blow-down Canteens, Toilets Pollutants Suspended Solids Suspended Solids Suspended Solids Phenols, Ammonia, etc pH Suspended Solids, Oil & Grease Temperature, Dissolved Solids BOD, Suspended Solids Control System Catch Pits Clarifier, Thickener, Sludge Pond Clarifier, Thickener, Sludge Pond BOD Plant Neutralizing Pit Settling Tanks fitted with Oil & Grease Trap Reused in the plant for dust suppression and slag granulation Septic Tanks, Soak Pits
Thus integrated steel plant will recycle water to the maximum extent possible. However, in abnormal condition occasionally small quantities of waste water 2007 MECON Limited. All rights reserved 4 - 23

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) have to be discharged to prevent build up of excess dissolved solids in circulating water. During the monsoon requirement of water for dust suppression and green belt irrigation will be drastically reduced. Hence excess water from the sludge pond will have to be discharged. This waste water will mostly contain salts of Calcium and Magnesium and suspended solids already present in the raw water. Moreover, the waste water quality will be well within the stipulated norms. 4.7.3 Generation of Solid Waste The major solid wastes expected to be generated from the various facilities of integrated steel plant are as follows: Table-4.3: Quantity of Solid Waste Generated in the 3.1Mtpy Steel Plant
Sr. No. DRI SECTION: 1. DRI fines Iron fines:33% coal fines in the form of solids as fixed C: 9% Ash:58% 2. Char Ash:60% C:35% H2O : 3.5% VM:1.5% 3. Transfer point dust Solid dust from ESP 4. Kiln Accretion and miscellaneous waste COKE OVEN COMPLEX Coke Breeze 127000 Will be reused in sinter making 324655 100% will be utilized within plant in sinter making 42273 Dumped in low lying area and may be used in clay making for various purpose in steel plant 749700 100% will be sold to BEL who is setting up CFBC based Power Plant within plant boundary. 714000 100% will be utilize within plant in sinter making and steel making Solid Waste Nature of Solid Waste Quantity (tpy) Probable Re-use
4 - 24

Sr. No. Solid Waste Nature of Solid Waste Quantity (tpy) within steel plant SINTER PLANT Sinter dust BLAST FURNACE 5. Dust from GCP Fe:50% CaO:20% SiO2:2% Al2O3:3% 6. Granulated Slag MgO:8% Al2O3:22% 7. Usable in-plant scrap SMS SECTION: 6. Slag CaO:40-60% SiO2:12-18% MgO:4-7% Fe2O3:5-7% 7. Dust FeO:70% MgO:9% CaO:6% 8. 9. Scales Usable Scrap HSM (Mill) 9. Return Scrap Fe:>90% 38700 100% Reused in steel making 24600 100% reused in sinter making Fe:>90% 15894 100% reused in sinter making 82000 100% Reused in steel making 445032 will be used in the land fill, Boulder soling of plant roads and may be partly used in sinter making . 22888 To be reused in the sinter plant 401000 Granulated and 100% sold to cement plant 47619 Will be recycled in SMS. 50430 Will be reused in sinter making solid 11607 Will be reused in plant Probable Re-use
10. Scales ORE CRUSHING 13. Iron Ore fines COAL WASHERY:
1458600 100% reused in sinter plant
14. Middling from coal Ash : 45% washery Carbon : 24% O2:2.9%
1118000 100% sold to Bhushan Energy Limited who is setting CFBC based power plant within steel plant
4 - 25

Sr. No. H2:1.6% S:0.5% Solid Waste Nature of Solid Waste Quantity (tpy) boundary Probable Re-use
Solid waste shall be in the form of following:
Fines collected from de-dusting system, Scales & scraps Slag from BF & EAF
Scales and skulls shall be generated as solid waste from integrated steel plant of BSSL. These Scales and skulls are of ferrous nature and shall be recyclable. There will be generation of scrap, which will be recycled in the plant itself in the Induction furnace.
Slag from Blast furnace will be granulated and sold to the cement plants for slag cement. Scrap from SMS and other areas will be recycled in the proposed steel plant to the extent possible. Scale and debris from HSM will be recycled to the maximum extent possible in the plant itself.
Management of SMS slag The estimated slag generation from SMS operation shall be 445,032 tpy. The 50% SMS slag will be used in land fill at low-lying areas and will be given for road making purpose along with internal reuse. The remaining 50% shall be used in BF & inter Mix as flux.
Management of Char & Washery Reject The char is generated from DR kiln operation. The quantity and its disposal is indicated in the table 5.2. The 100% char shall be sold to Bhushan Energy Limited 2007 MECON Limited. All rights reserved 4 - 26

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) (BEL) for utilization in CFBC boilers. The coal washery shall generate 1,118,000 tpy rejects and middling. These rejects shall be sold 100% to BEL for its use in CFBC boilers to generate 300 MW power. 4.7.4 Impacts on Noise Levels During normal operations of the plant ambient noise levels will increase significantly only close to the turbines/compressor but this will be confined only within plant boundary. However noise levels will increase greatly during bleeding-off of excess steam. But such incidents are rare and will last only for few minutes at a time only. The noise level within the plant boundary is occupational noise levels and confined within shops. The level will be further minimized when the noise reaches the plant boundary and the nearest residential areas beyond the plant boundary, as elaborate green belt development is envisaged for all along the boundary for attenuation of noise and fugitive emission.
All the equipment in the steel plant will be designed/operated in such away that the noise level shall not exceed 85 dB (A) as per the requirement of OSHA Standard (Occupational Safety and Health Association). However, if during operation, the noise level exceeds the OSHA norms then the protective measures given in Environmental Management Plan will be followed.
In addition to it, green belt development around the shops is to be done to minimise propagation of noise to nearby areas.
4.7.5 Impacts on Ecology The thresh-hold limit for continuous exposure of SO2 on plants is about 50 ug/m3 and that for NOx is 100 ug/m3 (Env. Engg., Chapter 7 by H. S. Pavy, D. R. Rowe, G.T. Chobanoglous. Mc.Graw-Hill Book Co.1986). The level of air pollutants due to 2007 MECON Limited. All rights reserved 4 - 27

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) operation of the present project will be much below the above said level for most of the time, thus it is expected that the natural vegetation in the area will not be affected. Although SO2 level will exceed the threshold norms in case all ten DRI kilns are operating it is most unlikely that the excess level of SO2 will persist for a sufficiently long duration for the plants to suffer any significant damage. So far as agriculture crops are concerned, as they will remain in the field for three to six months only, the impact on the same is also not anticipated.
As green belt will be provided all around the plant and effects on ambient air quality and noise levels will be negligible beyond 4-5 km from the project site hence no impact on flora and fauna are anticipated of the project.
4 - 28

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 5.0 ENVIRONMENTAL MANAGEMENT PLAN
5.1
Introduction It has been observed in the chapter 4.0 that due to modification-cum-expansion of integrated steel plant, there will be minor impact during construction and operation of plant. The adverse impacts can be minimized, if suggested pollution control measures are undertaken and implemented. To mitigate the
environmental problem, a comprehensive Environmental Management Plan (EMP) has been formulated in this context. The EMP has been worked out based on present environmental conditions and anticipated environmental impact appraisal. The EMP has been made for formulation, implementation and monitoring of environmental protection measures during and after commissioning of the project taking into consideration the following:
Mitigation of Adverse impacts Occupational safety and Health Training facilities
5.2
Mitigation of Adverse Impacts
5.2.1 Air Pollution Management In the integrated steel plant the sources of air pollution will be:
Burning of fuel (coal) in DRI, Sinter plant, Blast Furnace and coke ovens Air pollution in the form of fumes due to melting of iron scrap and sponge iron in Electric Arc furnaces etc Fugitive dust due to handling of coal and iron ore and other raw materials etc
5-1

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) The major emission due to coal/coke burning in DRI, Sinter plant, Blast furnace, coke ovens will be Particulate Matter (PM). The hot gases from DRI and BF are taken to waste heat recovery boiler to utilize the waste heat content of gases after which these gases are discharge to atmosphere after cleaning in ESP to reduce the emissions of SPM from the stacks. The ESPs will have an efficiency of 99.8%. ESP will be designed with 50-mg/Nm3 dust emission. This will limit the emission of SPM from each flue to maximum 50 mg/Nm3. as per design norms.
The lime/dolomite in the raw material feed mix in DRI/ fluidized combustion boiler reduce the concentration of sulphur in the waste gases, which will lead to less emissions of SO2 in the air. Moreover the stack will be of 76 to 120 m tall to ensure sufficient dispersion (i.e. dilution) of the pollutants. In the proposed steel plant the sources of air pollution and their mitigation measures are described below:
Raw material handling area: The material handling section would be provided with dust suppression (DS) by water sprinkling at the stockyard and multiple dust extraction (DE) systems for the dust generation points at the screen, conveyor transfer points and gas sealing devices to arrest the dust emissions to the atmosphere. The DE system will consist of bag filter units complete with ducts, extraction fans and stack of appropriate height.
DR Kiln
The exhaust gas from the rotary kilns would be cleaned by dry gas cleaning system. The waste gas would be passed through a series of pollution control equipment, which are as follows:
i) Dust settling chamber to settle coarse dust particulate. 2007 MECON Limited. All rights reserved 5-2

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) ii) Post combustion chamber to burn out the CO in the flue gas. iii) Waste heat recovery boiler to utilize waste heat for generation of steam. iv) Electrostatic precipitator to reduce the dust particulate load to 50 mg/m3 and the clean gas would be let to the atmosphere through a tall stack.
The fugitive dust emission and transfer point dust in DRI section shall be sucked and cleaned in the ESP to the level of 50 mg/Nm3 and then discharge to atmosphere.
Sinter Plant
The main pollutants in the sinter plant are dust emissions and the flue gas emissions. It is proposed to use electrostatic precipitators to arrest the dust before discharging it to atmosphere through tall chimney. ESP will be provided for all de-dusting stack.
Coke Oven
The coke oven shall be provided with modern leak-proof oven doors and door frame compatible to meet the pollution norm for PLD & PLO. The gas off take system shall have ascension pipe gooseneck, isolation valves, gas collection main and spray system to prevent any leakage from system.
Quenching emission is controlled by water spraying system in quenching station.
Coke oven gas is cleaned and limited by-product is recovered and clean gas is supplied to various users including coke oven batteries for heating.
5-3

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Blast Furnace
Dust laden air will be sucked from different dust generating points by means of suction hood, ducts and exhausted in the atmosphere after cleaning/collecting dust in the dust collection equipment using bag filters.
For the blast furnace gas, it is proposed to use dry cyclone and wet scrubbing of gas. Settling of particulate matter will be accomplished in water clarifiers and dust settling chambers.
Lime calcining plant
The dust coming out from the lime kiln would be collected through bag filters and the cleaned gas would be led into atmosphere through a tall stack. The dust from the non point source would also be collected by DE hoods and the dust laden gas would be cleaned by bag filters.
Electric arc furnace
The emissions from melting and refining would account to about 90 percent of total EAF emissions. The remaining 10 per cent of emissions are generated during charging and tapping. The primary emissions from the EAF would be taken through a duct on the furnace roof to bag-filters.
The secondary emissions during charging and taping would be collected by a canopy hood over the EAF and taken in the same manner to the bag-filter. Both the emissions will be discharged into the atmosphere through a stack of suitable height.
5-4

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Induction Furnace
The primary emissions from the IF would be collected by canopy hood over the furnace roof and taken in to bag-filters. The emissions will be discharged into the atmosphere after bringing down the SPM level below 50 mg/Nm3.
Ladle Furnace
The dust laden hot fumes coming out from the ladle furnace would be collected with fume extraction devices and cooled in a similar manner and let into the same bag-filter after passing through a mixing chamber. Exhaust gas coming out of the bag-filter is a clean one, which is let into the atmosphere through the stack.
Slab Casting & Hot Rolling
The water required for cooling of slabs would give rise to hot fumes containing mostly water vapour. This would be collected by suitable fume extraction system and taken through a condenser to separate out the steam condensate and the spent gas let out through a roof top stack into the atmosphere. The waste water coming out from the slab caster unit and hot rolling mill would be treated in a scale pit where the coarse sized iron scales and the oil would get separated followed by clarifier separation of fine particulates. The treated water would be recycled after cooling. The hot gases from the soaking pit would be let out through tall chimneys.
To reduce fugitive dust emission due to handling of iron ore, coal, dust extraction and dust suppression systems will be installed at appropriate locations. The Crusher House will be provided dry type dust extraction system with bag filters. The dust extraction systems will consist of suction hoods, fans and bag filter units 2007 MECON Limited. All rights reserved 5-5

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) with all accessories Plain water type dust suppression system will be provided at the all around the coal/ raw material stockpiles and coal washery. The dust suppression systems will consist of water sprinkling systems.
In order to prevent the spread of fugitive dust, green belt of adequate width will be developed all around the plant boundary and other locations described later. The sources of air pollution and the control methodologies are summarized in Table-5.1. Table-5.1: Sources of Air Pollutants and Control Methods Source Pollutants Control Method Raw Material Handling Fugitive Dust Dust Suppression System, Yard Green Belt DRI process gas Dust,SO2 ESP, Lime & Dolomite Blast Furnace Stock Dust Bag Filter House Blast Furnace Stove SO2, NOx Burner Design, Stack of adequate height Blast Furnace Dust in Top Gas Gas Cleaning Plant Lime Plant Dust, SO2, NOx Bag Filter, Stack of adequate height Steel Melting Shop Dust Bag Filter Ferro-Alloys Plant Dust Bag Filter Reheating Furnace NOx Burner Design, Stack of adequate height Coke ovens SO2, NOx Stack of adequate height, gas cleaning in by-product recovery unit Sinter plant Dust,SO2 & NOx ESP and stack of adequate height Following are the list of pollution control equipment provided in the plant.
Table-5.2: LIST OF AIR POLLUTION CONTROL EQUIPMENT
5-6

Name of the unit Sinter Plant Complex 1. Sinter Plant-Main Stack 2. Sinter Plant Cooler Stack 3. Sinter Plant De-dusting Stack Coke Oven Complex 4. Coke Oven Plant Stack1 5. Coke Oven Plant Stack2 Blast Furnace Complex 6. Bf Stove Stack 7. Bf-Dry Gas Cleaning 8. Bf-Stock House Pollution control system
ESP ESP ESP Tall Stack Bag House Bag Filter
9. Bf-Cast House Dry Fog Dust Suppression System DRI Process Stacks after Waste heat Recovery Boilers 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. DRI Process Stack -I DRI Process Stack -II DRI Process Stack -III DRI Process Stack -IV DRI Process Stack -V DRI Process Stack -VI DRI Process Stack -VII DRI Process Stack -VIII DRI Process Stack -IX DRI Process Stack -X DRI Process Stack XI DRI Process Stack XII DRI Process Stack XIII DRI Process Stack -XIV DRI Kilns - De-dusting stacks DRI KILN-1 & 2-in plant de-dusting DRI KILN-3 & 4-in plant de-dusting DRI KILN-5& 6-in plant de-dusting DRI KILN-7& 8-in plant de-dusting DRI KILN-9 & 10-in plant de-dusting DRI KILN-11& 12-in plant de-dusting DRI KILN-13& 14-in plant de-dusting SMS Complex SMS-1 EAF+LF Fume Extraction-I ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP ESP Bag Filter Bag Filter Bag Filter
32. SMS-1 EAF+LF Fume Extraction -II 33. IF+LF Fume Extraction -I
5-7

34. IF+LF Fume Extraction -II 35. SMS-II EAF+LF Fume Extraction-I 36. SMS-II EAF+LF Fume Extraction -II Hot Strip Mill 37. RE-HEATING STACK-1 38. RE-HEATING STACK-2 39 RE-HEATING STACK-3 Captive Power Plant 40. BFG gas fired Boiler of CPP Lime & Dolo Plant 41. LIME PLANT KILN1 42. LIME PLANT KILN2 43. DOLO PLANT KILN5 Raw Material Preparation Plant 44. RMP CRUSHER Bag Filter Bag Filter Bag Filter Bag Filter Bag Filter Bag Filter Bag Filter
5.2.2 Wastewater Management The prevention and control of water pollution aim at conserving make-up water by recycling the wastewater after treatment. During the operation of the plant, three major categories of wastewater, viz. blow down water from the cooling tower, ash slurry water and sanitary waste water streams would be generated.
Wastewaters are expected to be generated from different facilities of the proposed plant. Water Balance Diagram is given in Drg No BSSL/0/ISP/71 sheet 1 of 1. Efforts are made to reuse most of the water in the plant itself.
The wastewater likely to be generated from the integrated steel plant is:
Underflow from Raw Water Clariflocculator Backwash Waste from Filtration Plant DM Plant Regeneration Waste 2007 MECON Limited. All rights reserved 5-8

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Run-off water from Raw Material Storage Yards Waste water from gas cleaning system in BF Phenolic effluent in Coke oven complex Waste Water from Hot Strip Mill Cooling Tower Blow-down Boiler Blow-down Sewage & Canteen Effluents
Sludge from Raw Water Clariflocculator and Backwash from Filtration Plant will be led to a thickener for removing suspended solids. The overflow from the thickener will be reused in the plant water system. The sludge from the thickener will be dried and dumped. During the monsoon season, this treated effluent along with run-off will be discharged to nearby natural drainage system. Since this treated effluent will contain only solids present in the raw water drawn from Brahmani River, the discharge of this treated effluent will not affect the quality of Brahmani River by any appreciable degree.
Water from coal washery will be treated in thickener. Overflow from thickener (clarified water) will be reused in the plant. The coal washery shall maintain close circuit operation.
Water from the BF GCP will be sent to a clarifier / thickener. The overflow from the thickener will be re-circulated. The underflow from the thickener will be sent to a press filter and recovered cake will be recycled in sinter plant.
5-9

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Acidic and Alkaline effluents will be generated at the DM Water Plant. These effluents will be properly neutralized and reused in the plant through ash pond.
Effluents from the slab caster and hot strip mill complex are likely to contain suspended solids and oil & grease. These effluents will be routed to settling pits fitted with oil & grease trap. The clarified water will be reused in the plant.
Cooling Tower Blow-down from various recirculation systems will be cascaded for reuse in other qualitatively compatible systems as shown in enclosed water balance drawing.
Thus, proposed plant will recycle water to the maximum extent possible. However in abnormal cases periodically small quantities (50 m3/h max) of effluents if and when required to be discharge to prevent build up of excess dissolved solids into natural drainage channels through
stabilization in pond and will be well within the stipulated norms of quality.
Efforts will be made to harvest rainwater in the plant. Run-off water from the office areas, shop roofs will be collected and stored for future use.
oil sewer will collect water from areas where there are possibilities of contamination by oil (transformer yard, fuel & lubricating oil storage areas, and workshop) and the drains from such areas will be routed through an oil-water separator. The collected oil shall be sold to re-refiner approved by SPCB.
All storm water drains from the raw materials and solid waste handling areas will be routed through garland drains into catch pits of sufficient 2007 MECON Limited. All rights reserved 5-10

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) volume to settle out suspended solids present in the storm water run-offs. The clear water will be discharged into natural drainage channels. This type of effluent is anticipated only in monsoon season.
The sewage from the Plant, Township and Canteen waste water will be treated in sewage Treatment Plant. The treated sewage will be diverted for irrigation of green cover.
5.2.3 Solid Waste Management/Disposal The principal solid waste produced by any steel plant is slag, scrap, scale and dust. The dust from dust catcher of DRI unit, dust from SMS section will be recycled to the extent possible in the plant itself or sold to outside parties.
SMS slag from EAF will be used in land fill at low-lying areas. Slag from Blast furnace will be granulated and sold to the cement plants for slag cement. Scrap from SMS and other areas will be recycled in the steel plant to the extent possible. Scale and debris from HSM will be recycled to the maximum extent possible in the plant itself. The solid waste generated and their probable uses are indicated in the Table-5.2. Table-5.2: Quantity of Solid Waste Generated in the 3.1Mtpy Steel Plant
Sr. Solid Waste No.
1. DRI SECTION: DRI fines
Nature of Solid Waste
Quantity (tpy)
Disposal methodology
2.
3.
Iron fines:33% coal fines in the form of solids as fixed C: 9% Ash:58% Char Ash:60% C:35% H2O : 3.5% VM:1.5% Transfer point dust Solid dust from ESP
714000 100% will be utilize within plant in sinter making & steel making
749700 100% will be sold to BEL who is setting up CFBC based Power Plant within plant boundary. 324655 100% will be utilized within plant in sinter making
5-11

Sr. Solid Waste No.
4.
Nature of Solid Waste

-
Quantity (tpy)
Disposal methodology
Kiln Accretion and miscellaneous waste COKE OVEN COMPLEX Coke Breeze SINTER PLANT
42273 Dumped in low lying area and may be used in clay making for various purposes in steel plant 127000 Will be reused in sinter making within steel plant
5.
6.
Sinter dust BLAST FURNACE
solid
11607 Will be recycled in sinter plant
7.
Dust from GCP
8. 9.
Granulated Slag Usable in plant scrap
Fe:50% CaO:20% SiO2:2% Al2O3:3% MgO:8% Al2O3:22%
50430 Will be reused in sinter making
401000 Granulated and 100% sold to cement plant 47619 Will be recycled in SMS.
SMS SECTION: 10. Slag
11. Dust
12. Scales
CaO:40-60% SiO2:12-18% MgO:4-7% Fe2O3:5-7% FeO:70% MgO:9% CaO:6% Fe:>90%
445032 will be used in the land fill, Boulder soling of plant roads and may be used partly in sinter making . 22888 To be reused to the sinter plant
15894 100% reused in sinter plant 82000 100% Reused in steel making 38700 100% Reused in steel making 24600 100% reused in sinter making 1458600 100% reused in sinter plant 1118000 100% sold to Bhushan Energy Limited who is setting CFBC based power plant within steel plant boundary
13. Usable Scrap HSM (Mill) 14. Return Scrap 15. Scales Fe:>90% ORE CRUSHING 16. Iron Ore fines COAL WASHERY: 17. Middling from coal Ash : 45% washery Carbon : 24% O2:2.9% H2:1.6% S:0.5%
5-12

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) The iron ore fines and BF GCP Sludge will be recycled in sinter plant. Since the proposed plant envisages such a facility, the iron ore fines will be used for sintering. The GCP Sludge will be recycled in sinter plant.
Sludge from water treatment plant and dust recovered from dust extraction systems will be dumped in sludge pond. The slag from the Blast Furnace will be granulated and sold to cement manufacturers. The SMS slag will be sold to parties engaged in building roads.
Other solid wastes, which will be generated in the proposed steel plant, include waste refractories, scrap, scales, waste lubricants etc. Waste refractories will be sold as road building material or dumped in landfills. All the scrap will be recycled fully. Waste lubricants will be sold to reprocessing units. Scales will be recycled. The used batteries shall be returned back to the manufacturer in lieu of the new batteries of equivalent numbers.
Hazardous wastes from by product plant will be reused and balance will be disposed / sold as per Hazardous waste rules of Indian government.
5.2.4 Noise Level Management In integrated steel plant crusher area, furnace area, the power generating sets, fans and pumps will be the major sources of noise.
Noise generation levels will be considered while selecting equipment. Equipment should not generate noise more than 85 dB (A) at 1m distance. Wherever required noisy equipment will be placed on vibration isolators or housed in a separate enclosure or surrounded by baffles covered with noise absorbing material. As the operator would be stationed in the control room, there is 2007 MECON Limited. All rights reserved 5-13

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) minimum chance of exposure to high noise levels. However Personnel working in high noise zones will be issued with personal noise protection equipment (e.g. ear muffs, ear plugs) and their duty hours will be regulated to control noise exposure levels. In addition green belt will be developed all around the plant boundary and around various shops and offices to prevent the spread of noise produced inside the plant.
5.2.5 Green Belt Development Plan Green belt is an important sink for air pollutants. Trees also absorb noise and by enhancing the green cover, improve the ecology and aesthetics and affect the local micrometeorology. Trees also have major long-term impacts on soil quality and the ground water table. By using suitable plant species, green belts can be developed in strategic zones to provide protection from emitted pollutants and noise.
Plant species suitable for green belts should not only must be able to flourish in the area but must also have rapid growth rate, evergreen habit, large crown volume and small / pendulous leaves with smooth surfaces. All these traits are difficult to get in a single species. Therefore a combination of these is sought while selecting trees for green belt. The green belt should be planted close to the source or to the area to be protected to optimize the attenuation within physical limitations.
In the proposed plant, green belt will be developed in vacant areas, around office buildings, around stores, along the side of roads, along the plants boundaries and around the waste dump area. Plant species suitable for green belts should not only be able to flourish in the area but must also have rapid growth rate, evergreen habit, large crown volume and small / pendulous leaves with smooth surfaces. All these traits are difficult to get in a single 2007 MECON Limited. All rights reserved 5-14

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) species. Therefore a combination of these is sought while selecting trees for green belt. The green belt should be planted close to the source or to the area to be protected to optimize the attenuation within physical limitations. A total of approximately 33% area will be developed as green belt or green cover. Green belt will also be planted in township. The widths of the belt will 50 m to 100 m as per the space availability all along the boundary. Whereas, around waste dumps site an area of about 100 acre will be under green belt with a width ranging from 30 m to 50 m as per the availability of space. A total of about 1200 - 1500 per ha plants will be planted. The species for green belt development will be selected in consultation with the State Forest Department. The following species are suitable for planting in the area as recommended by Central Pollution Control Board in their publication Guidelines for Developing Greenbelts (PROBES/75/1999-2000):
A very elaborate green belt development plan has been drawn for the proposed plant. The areas, which need special attention regarding green belt development in the industrial area, are:
Along Plant Boundary Along Road Side Around Various Shops Around Office and Other Buildings Stretch of Open Land In and Around Township
5-15

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Selection of Species
The species for plantation have been selected on the basis of soil quality, place of plantation, chances of survival, commercial value (timber value, ornamental value, etc.), etc. It is to be noted that only indigenous species will be planted. Exotic species such as Eucalyptus and Australian Acacia will not be planted. The species will be selected in consultation with State Soil Conservation Department. Mixed plantations will be done keeping optimum spacing between the saplings.
Along Plant Boundary
The row of plants facing plant should be smaller species and those facing outside should be taller species. The species suggested for plantation is:
Small Species Kaneer (Nerium sp.) Prosopis (Prosopis juliflora) Bougainvellea (Bougainvillea spp.) Ber (Zizyphus spp.) Gulmohar (Delonix regia) Duranta (Duranta sp.) Kamayani (Murriya exocitica) Bilayati Babool (Prosopis juliffera) Babool (Acacia arabica)
Tall Species Amaltas (Cassia fistula) Siris (Albizzia lebbeck) Neem (Azadirachta indica) 2007 MECON Limited. All rights reserved 5-16

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Druping Ashok (Polyalthia longifoila) Mango (Mangifera indica) Peepal (Ficus religiosa) Arjun (Terminalia arjuna) Jackfruit (Artocarpus heterophylla) Palash (Butea spp) Cassia (Cassia siamea) Bottle brush (Callistemon lanceolatus)
Road Side Plantation
Avenue plantation should include the following species:
Siris (Albizzia lebbeck) Gulmohar (Delonix regia imli (Tamarindus indica) Siris (Albizzia lebbeck) Neem (Azadirachta indica) Druping Ashok (Polyalthia longifoila) Mango (Mangifera indica) Peepal (Ficus religiosa) Bargad (Ficus bengalisis) Arjun (Terminalia arjuna) Cassia (Cassia siamea)
Around Various Shops
As there will be limited space (in height) due to various over head pipelines, thus small and medium sized species are suggested and they should be planted 2007 MECON Limited. All rights reserved 5-17

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) depending on the vertical height and lateral space available for the plant growth. The species selected will be from among the following:
Small Species Ber (Zyziphus sp.) Sharifa (Annona squamosa) Prosopis (Prosopis sp.) Cassia (Cassia auriculata) Duranta (Duranta sp.) Kamayani (Murrya exotica)
Medium Size Species Kaner (Nerium sp.) Amaltas (Cassia fistula) Subabool (Leucaena leucocephala) Cassia (Cassia alata) Babool (Acacia arabica)
Around Office and Other Buildings
Plantation will be done around various shops, stores and other buildings, along the side of connecting roads. Species suggested for plantation are as follows which are mostly ornamental plants:
Cassia (Cassia javanica) Amaltas (Cassia fistula) Cassia (Cassia siamea) Amaltas (Cassia fistula) Arjun (Terminalia arjuna) 2007 MECON Limited. All rights reserved 5-18

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Lagerestromea (Lagerestromea flosregennae) Peltophorum (Peltophorum feruginium) Gulmohar (Delonix regia) Druping Ashok (Polyalthia longifoila)
Stretch Of Open land
In the proposed plant, green belt will be developed in vacant areas. Species suggested for such areas are:
Siris (Albizzia lebbeck) Pakur (Ficus racemosa) Gulmohar (Delonix regia Imli (Tamarindus indica) Peltophorum (Peltophorum feruginium) Gulmohar (Delonix regia Siris (Albizzia lebbeck) Neem (Azadirachta indica) Mango (Mangifera indica) Peepal (Ficus religiosa) Bargad (Ficus bengalisis) Arjun (Terminalia arjuna) Cassia (Cassia siamea)
Mixed plantation will be done to take care of different heights and rates of growth.
5-19

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) In and Around Township
In the proposed township plantation will be done in following areas:
Along the township boundary Along the roads Stretch of open land
For the above areas the plants to be planted will be from among the list given above for respective areas in the plant premises.
Phase Wise Green Belt Development Plan
Green belt will be developed in a phase wise manner right from the construction phase of the proposed plant. In the first phase (in the first and second year of construction) along with the start of the construction activity the plant boundary, the township boundary, around the proposed waste dumps, and the major roads will be planted. In the second phase (in the third year of construction) the office building area will be planted. In the third phase (in the fourth year of construction) when all the construction activity is complete plantation will be taken up in the plant area, in stretch of open land, along other roads and in the township will be taken up.
The trees may be watered using the effluent from the sewage treatment plant. They will be manured using sludge from the sewage treatment plant. In addition kitchen waste from the town-ship and plant canteen can be used as manure either after composting or by directly burring the manure at the base of the plants.
5-20

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Kitchen waste from plant canteen can be used as manure either after composting or by directly burying the manure at the base of the plants.
5.3
Rainwater Harvesting BSSL is planning to have a system of rainwater harvesting at plant in Meramandali. Rainwater harvesting is primarily dependent on various site characteristics such as soil properly, catchments characteristics; rainfall characteristic, and ground water table etc.
There are artificial as well as natural rainwater harvesting system. The recharging system can be implemented for
i) ii)
Individual units Centralized collection system
Scheme I: Collection of rainwater harvesting from individual building units and construction of filter beds at individual building unit. Rainwater falling on other open area is to be collected, through constructed drainage system and discharge system and discharge to surface out-fall (by passed for rainwater harvesting)
Scheme II: Construction of rainwater filter bed at centralized place where water from individual unit as well as storm water from open area shall be diverted
The rainwater carries suspended solids as washed out from open area. A filter bed filters the particles thus prevent them from reaching / contaminating ground water.
5-21

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) The first layer of filter bed shall be coarse sand the second layer shall be pebbles and third layer shall be gravel. The filtrate thus collected from the bottom of filter bed shall be piped to recharge bed.
5.4
House Keeping Proper house keeping is an essential part of sound environmental management.
It will be rigorously seen that there is no accumulation of wastes, especially combustible wastes (e.g. Oily rags, oil sludge, wood from packing boxes, etc.) inside the plant area. In summer dry grasses & vegetation growing inside the plant area will be cut and removed. All fire fighting equipment and warning devices will be kept in perfect working conditions.
It will be seen that all personnel are aware of the implications of environmental pollution and simple practices to avoid pollution.
5.5
Occupational Safety and Health Maintenance of occupational safety and health is very closely related to productivity, good employer employee relationships and good relationships among all on board personnel.
The main factors of occupational health in steel plant are dust, heat and noise. Following measures will be undertaken in the installation for occupational safety and health of workers.
Inspection and maintenance of pollution control systems will be undertaken only after checking that the equipment has been properly shut down or with permission of authorised officer. Immediate removal of waste accumulated in working areas. 2007 MECON Limited. All rights reserved 5-22

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Insulation of hot surfaces. All safety measures will be strictly implemented. Fire fighting equipment will be tested regularly to ensure their full serviceability. Contingency plans drawn up to deal with accidents will be rehearsed by all personnel. Training of employees for use of safety appliances and first aid. Regular medical check up of personnel will be carried out.
5.6
Pollution Monitoring The proposed plants Environmental laboratory may be equipped to monitor meteorology, air quality, noise, water quality, emissions from stacks and solid wastes. External laboratories may be contracted to carry out the required monitoring work. The frequency of sampling will be as per Central and State Pollution Control Board guidelines. Continuous on line monitoring facilities will be provided for each major stack. An Environment Management department will be constituted to operate and maintain all pollution control systems, organise necessary environmental monitoring and maintain records & details of monitoring.
5.7
Training Facilities To achieve the objective of pollution control it is essential not only to provide latest pollution control and monitoring systems but also provide trained manpower to operate and maintain such systems. So the Environmental Management department personnel will be provided with additional specialized training to operate and maintain the equipment to be deployed on the installation. All personnel will be trained to deal with pollution emergencies also.
5-23

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 5.8 Community Development Plan BSSL is committed to community development around the steel plant. It has an ambitious plan to adopt 10 villages for community development. A substantial amount has been allocated for the following activities for the social up-liftment of surrounding villages.
An school for children of surrounding villages upto XIIth standard A 50 bedded community hospital for the population in surrounding
villages
Provision of drinking water facilities in surrounding villages BSSL will facilitate the technical training institute such as ITI in
collaboration with state authority.
Provision for training of women folks (sewing, stitching etc) of

surrounding villages for their economic up-liftment. 5.9 Charter on Corporate Responsibility for Environmental Protection (CREP): Integrated Iron & Steel Industry 1. Coke Oven Plants To meet the parameters PLD (% leaking doors), PLL (%leaking lids), PLO (% leaking off take), of the notified standards under EPA within three years (by December 2005). Industry will submit time bound action plan and PERT Chart along with the Bank Guarantee for the implementation of the same. To rebuild at least 40% of the coke oven batteries* in next 10 years (by December 2012). The coke oven plant is expected to be implemented in 2008-09 with all latest technology and shall meet all government guidelines given in CREP.
5-24

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 2. Steel Melting Shop
Fugitive emissions - To reduce 30% by March 2004 and 100% by March 2008 (including installation of secondary de-dusting facilities).
The primary fume extraction system and secondary dedusting facilties will be installed.
3. Blast Furnace
Direct inject of reducing agents by June 2013.
The plant will be installed with latest available technology. Direct injection of reducing agents will be provided.
4. Solid Waste / Hazardous Waste Management
Utilization of Steel Melting Shop (SMS) / Blast Furnace (BF) Slag as per the following schedule: By 2004 - 70%, By 2006 80% and By 2007 100%.
SMS slag will be initially dumped suitably and then will be used for road making and ballast for railway track. BF slag will be granulated and it will be sold to nearby cement plant and the schedule given in format will be followed.
5-25

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Hazardous Wastes
Charge of tar sludge / ETP sludge to Coke Oven by June 2003.
Inventorization of the Hazardous Waste as per Hazardous Waste (M&H) Rules, 1989 as amended in 2000 and implementation of the Rules by Dec. 2003.
(tar sludge, acid sludge, waste lubricating oil and type fuel falls in the category of Hazardous Waste)
Inventorisation of the hazardous waste will be done in line with the notification.
5. Water Conservation / Water Pollution
To reduce specific water consumption to 5 m3/t for long products and 8 m3/t for flat products by December 2005.
The water conservation as per the directives of CREP, when the plant gets stabilised and below 8 m3/t for flat products.
To operate the CO-BP effluent treatment plant efficiently to achieve the notified effluent discharge standards. - by July 2003
The Phenolic effluent shall be treated in BOD plant and treated effluent shall be used for coke quenching after suitable Addison of makeup water. 6. Installation of Continuous stack monitoring system & its calibration in major stacks and setting up of the online ambient air quality monitoring stations by June 2005. 2007 MECON Limited. All rights reserved 5-26

Continuous stack monitoring system & its calibration in major stacks shall be provided. 5 nos. of permanent AAQ monitoring stations around plant is also envisaged.
7. To operate the existing pollution control equipment efficiently and to keep proper record of run hours, failure time and efficiency with immediate effect. Compliance report in this regard is submitted to CPCB / SPCB every three months.
Agreed
8. To implement the recommendations of Life Cycle Assessment (LCA) study sponsored by MoEF by December 2003.
The issue shall be examined & shall be to be done as per the Government directives
9. The industry will initiate the steps to adopt the following clean technologies/measures to improve the performance of industry towards production, energy and environment.
- Energy recovery of top Blast Furnace (BF) gas.
We are committed to adapt best available technology
Use of Tar-free runner linings.
5-27

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Best available indigenous material will be used.
De-dusting of Cast House at tap holes, runners, skimmers ladle and charging points.
Agreed
- Suppression of fugitive emissions using nitrogen gas or other inert gas.
His will be done as per the best available technology
- To study the possibility of slag and fly ash transportation back to the abandoned mines, to fill up the cavities through empty railway wagons while they return back to the mines and its implementation.
It is already envisaged in the project
- Processing of the waste containing flux & ferrous wastes through waste recycling plant.
Committed to adapt best available technology.
- To implement rainwater harvesting.
We have planned for rain water harvesting.
- Reduction of Green House Gases by:
5-28

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Reduction in power consumption
Reduction of power consumption will be done by regular energy auditing.
Use of by-products gases for power generation
It is included in the project and we are using the kiln outlet gases for power generation
Promotion of Energy Optimisation Technology including energy audit
This plant will be one of the best example for promotion of energy optimisation technology.
- To set targets for Resource Conservation such as Raw material, energy and water consumption to match International Standards.
All effort will be made to match international standards
- Up-gradation in the monitoring and analysis facilities for air and water pollutants. Also to impart elaborate training to the manpower so that realistic data is obtained in the environmental monitoring laboratories.
We have already planned for best equipped laboratory for analysis of air, water and other pollutants in addition to on line monitoring of stacks. Training for related employee will be given. The entire activity will be managed by an independent Environmental Management Cell.
5-29

- To Improve overall house keeping.
Agreed
10. Sponge Iron Plants
Inventorisation of sponge iron plants to be completed by SPCBs/CPCB by June 2003 and units will be asked to install proper air pollution control equipment by December 2003 to control primary and secondary emissions.
* As per rebuilding schedule submitted to CPCB/MoEF.
Proper air pollution control equipment shall be employed
5-30

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 6.0 EMP IMPLEMENTATION AND MONITORING
Various measures have been suggested in the environmental management plan for mitigation of impacts. These have to be implemented according to the suggestions and monitored regularly to prevent any lapse.
A large part of the sampling and measurement activity is concerned with long term monitoring aimed at providing an early warning of any undesirable changes or trends in the natural environment that could be associated with the plants operation. A separate department has already been to look after all environmental related matters of the plant.
Quarterly environmental audits will be carried out for expansion plant to check for compliance with standards. This is being carried out by external experts.
Third party environmental audits will be carried out once very year.
BSSL has already taken ISO:14001 EMS certification in many of its plant and will implement Environmental Management System (EMS) in Meramandali also.
The unit is taking all necessary steps to implement the measures suggested by Central Pollution Control Board (CPCB) in the Charter on Corporate Responsibility for Environmental Protection (CREP) for Integrated Iron and Steel Industry.
6-1

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 6.1 Laboratory Facilities
It is imperative to BSSL to have a well-equipped environmental control laboratory inside the plant premises. The Environmental control laboratory shall apply for recognition as per EP Act 1986 and notified in Government of India Gazette. The laboratory shall be running continuously 24 hours in threeshift operation and carrying out all monitoring as specified in their Consent condition.
All
the personnel deployed in the laboratory have been given training by
external experts so to carry out necessary environmental monitoring as well analysis. The equipment will be made available for carrying out environmental monitoring shall be as follows:
Table 6.1: List of Monitoring / Analytical Equipments required with Environmental Lab of Meramandali Steel Plant
Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Item
Description / make/ model
Quantity
High Volume Sampler Respirable Dust Sampler Stack Monitoring Kit HVS Flow Calibrator PM-10 HVS Dry Gas Meter Analytical Balance Digital Balance Anemometer Digital Balance Personal Sampler Nephelo Turbidity meter DR-2000 Spectrophoto Meter COD Reactor Portable Dissolved Oxygen Meter PDV-2000 Digital Voltameter
Vayubodhan APM-4-0 Vayubodhan APM-451 Env. Engg. Nagpur SMK-70 Andersons samplers S-53 Ecotech Pvt. Ltd. Env. Engineers Inc. A-1 The Balance Works (P) Ltd. Sartorious L-22005 Dynalab Sartorious R-200 D Gillian HFS-113 A HACH / 16800 HACH / 44800 HACH / 45600 Toshniwal Process Inc. Ltd. OXI-191 Chemetronics Austria PDV-2000
4 4 1 1 2 3 1 1 1 1 1 2 2 2 2 1
6-2

Sl. No. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. Selective Iron Meter Selective Iron Meter Composite Sampler Visible Spectro Meter BOD Analyser BOD Incubator Ultrasonic Flow Meter Vaccum Pump Vaccum Pump Muffle Furnace Drying Oven Ultrasonic Cleaner Adjustable Digital Pipettes Spectrophotometer Digital Multimeter D.O Meter Hot Plate Muffle Furnace Electronic Balance Digital Conductivity meter Sound Level Meter with calibrator & Octave Pilter Set CEL-275 SLM CEL-177 Precision Acoustic Calibrator CEL-296 Octave Y-3 Octave filter CEL-238 Secondary Processor with Printer UHER 4200 Report Monitor Electronic Balance On-line ambient air monitoring station On-line stack monitoring of major stack Orion Reaserch Inc. AE-940 Orion Reaserch Inc. AE-960 Sigma / 702 Nikal Associates Genway UK/6100 HACH/2173-B Newtronic 10 GRS Polysonics 18408 MST-P Charles Austerm Pumps Ltd. CapesL3C Charles Austerm Pumps Ltd. CapesL2C Okay Scientists Own Concern 360 Lucas Dawe B 3200 E4 HACH (Eriuliben) Toshniwal (BOM) Inst. Pvt. Ltd. Philips Scientific 8050 A ORION 810 Super Heating India Anamed Co AA-2200 Unitech U-31 C Bruael & Kjear 2230 Lucas CEL-275 Lucas CEL 1 1 2 1 1 1 4 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 Lucas CEL UHER 4200 ORTELING 1 1 1 2 15 Item Description / make/ model Quantity
6.2
Meteorology
A meteorological station will be set up at a suitable location within the plant premises. The following parameters will be recorded regularly: 2007 MECON Limited. All rights reserved 6-3

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Wind speed and direction Rainfall Temperature and humidity Evaporation rate
6.3
Primary & Secondary Emissions Monitoring & Air Quality
Ambient air quality shall be monitored regularly in accordance with CPCB / Orissa State Pollution Control Board (OSPCB) guidelines. Work zone air quality shall also be monitored as per directives of OSPCB to assess the levels of particulate matter, NOx and SO2. Efforts will be made to install continuous Ambient Air Quality monitoring systems in accordance with the CREP. All major stacks will be provided with on-line monitoring system. The emissions from all the stacks shall be monitored once a month using the manually operated stack emissions monitoring equipment. However the frequency of monitoring may be increased if required in accordance with the stipulations of OSPCB or other statutory authorities.
6.3.1 Stack Emission Monitoring*
Shop
Nos. of Stacks
Monitoring Frequency per month
1. 2. 3. 4.
Sinter Plants Coke Ovens Blast Furnaces Refractory Material Plant
3 2 3 3
3 2 3 3 6-4

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Shop Nos. of Stacks Monitoring Frequency per month 5. 6. 7. Steel Melting Shop Hot Strip Mill DRI Units 6 3 17 6 3 17
* Parameters = TPM, SO2, NOX 6.3.2 Ambient Air Quality Monitoring*
Description 1. AAQ Monitoring
Nos. of Stn 5
Monitoring Frequency Once per Week
* Parameters = SPM, SO2, NOX 6.3.3 Water Quality Monitoring*
Description 1. Outlets
Nos. of Locations 2
Monitoring Frequency Once a Week
* Parameters = pH, SS, Phenol, Cyanide, COD, BOD, DO, NH3-N, Temp. O & G
6.3.4 Noise Monitoring
Description 1 Ambient Noise
Nos. of Locations 10
Monitoring Frequency Once in 3 months
The suggestions given in the EMP shall be implemented by the EMD by following an implementation schedule. 2007 MECON Limited. All rights reserved 6-5

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Along with the performance and guarantee test of main plant equipment, performance and guarantee test of pollution control equipment will be made before taking over the expansion plant. EMD shall also be a party in preliminary and final acceptance tests.
A detailed maintenance schedule shall be drawn for all pollution control systems. The maintenance shall be done strictly as per schedule and guidelines furnished by plant manufacturer.
Ground level concentration in ambient air, stack emission and work zone monitoring results shall be discussed in the EMD and any variance from norms shall be reported to the Executive Director for immediate study and rectification action
6.4
Drainage System
The effectiveness of the drainage system depends on proper cleaning of all drainage pipes/channels. Regular checking is being done to see that none of the drains are clogged due to accumulation of sludge/sediments. The clogged drains are cleaned as soon as possible, preferably the same day. The catchpits linked to the storm water drainage system from the raw material handling areas are regularly checked and cleaned to ensure their effectiveness. This checking and cleaning is rigorous during the monsoon season, especially if heavy rains are forecast.
6.5
Water Quality
Effluents from outfall, Sewage treatment plant from Township and Plant are 2007 MECON Limited. All rights reserved 6-6

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) monitored and tested in Environmental Control Laboratory at least once a month as per CPCB guidelines / directives. However the frequency of monitoring may be increased if required in accordance with the stipulations of OSPCB or other statutory authorities. In addition to above BSSL shall also carrying out monitoring of certain parameter in some of the plant equipment/area as a quality measures for measurement of pollutants going to outfall
6.6
Noise Pollution
The EMD shall monitor and keep the record of noise levels and take necessary organisational actions like rotation of workmen, availability and use of personal protective devices, damage to enclosures or insulation layers over enclosures and piping.
6.7
Green Belt Development
As discussed in EMP chapter BSSL shall plant trees in almost all possible locations and continuously encourage others to plant trees in their garden, locality etc. However following plan shall also be made for future program
o Annual plans for tree plantation with specific number of trees to be planted shall be made. The fulfillment of the plan shall be monitored by the EMD every six months.
o A plan for post plantation care will be reviewed in every monthly meeting. Any abnormal death rate of planted trees shall be investigated.
6-7

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) o Watering of the plants, manuring, weeding, hoeing will be carried out for minimum 3 years
6.8
House Keeping
The EMD shall be keeping a very close monitoring of house keeping activities and organising regular meetings of joint forum at the shop level (monthly), zonal level (once in two months) and apex level ( quarterly). The CED (Civil Engineering Department) shall take care for the house keeping of shops.
6.9
Occupational Health
Routine medical examination of personnel shall be carried out as a systematic programme at plant.
6.10
Interaction with State Pollution Control Board (SPCB)
EMD shall be in regular touch with OSPCB and send them quarterly progress report on EMP. Any new regulations considered by State/Central Pollution Control Board for the Industry are been taken care of.
6-8

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 7.0 DISASTER MANAGEMENT PLAN
An Emergency Plan has been formulated to take care of any disaster in the existing integrated steel plant and surrounding areas and is detailed as under:
In order to prevent occurrence of any disaster, the plant will be provided with various safety and disaster control facilities. Normally, in the steel plant, no major disaster affecting nearby population areas are foreseen. However, accidents inside the plant affecting workplace in vicinity cannot be ruled out. Work-force inside the plant shall be exposed to various high pressure system pipelines and vessels, acids and chemicals, fuel such as coal and furnace oil and other process equipment which, if not properly operated and maintained, can cause serious accidents affecting life and property in the vicinity of accident site. In addition to these, numerous material handling systems, heavy road transport, high-tension electric lines, level crossings, overhead cranes and various other handling and transport systems always have chances of accidents.
Definition of Disaster
A situation will be called a `Disaster' if it entails any one or more of the following factors:
i) ii)
Risks of loss of human lives - ten or more in one single situation. Loss of property as a consequence of the incident is over Rs.1 crore and/or bears a potential to the above.
iii)
A situation which goes beyond the control of the available resource of the plant.
iv)
A situation apparently may not have much loss but its long-term severity can affect loss of life, production and property.
7-1

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) The types of possible disaster are given below:
Type of disasters
i)
Disaster due to emergencies on account of:
Fire Explosion Oil spillage Spillage of toxic chemicals Electrocution
ii)
Disaster due to natural calamity on account of:
Flood Earth quake / cyclone / Storm / Cloud burst / lightning
iii)
Disaster due to external factors on account of:
Food poisoning / water poisoning Sabotage
Objectives
Objectives of disaster control/management plan for existing Steel Plant are:
i) ii)
To identify type of major disasters which may occur in the plant? To collect data on type of disasters which has happened already in other steel plants?
7-2

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) iii) An action plan to handle disaster.
Identification of Hazardous Process/Area
1. Furnaces area - Explosion 2. Fuel Oil tanks - fire & spillage 3. Turbine Hall Explosion 4. Boiler Explosion
Electrical premises
1. Electrical Rooms - Fire & Electrocution 2. Transformer area - Fire & Electrocution 3. Cable Tunnel - Fire & Electrocution
Other premises
Storage facilities for coal and fuel oil -Fire/spillage
Level of Accident
If there is any disaster in any part of the plant /work place due to any reason the area which may be affected can be classified in the following four classes.
1. Level I - Operator level 2. Level II - Local/community level 3. Level III - Regional/ national level 4. Level IV - International level
2007 MECON Limited. All rights reserved 7-3

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) There is only level I and II class of accidents can be considered for the steel plant.
Level I
Under this level, disasters may happen due to fire, explosion, oil spillage and spontaneous ignition of inflammable materials.
This level has probability of occurrence affecting persons inside the plant. The various shops, which have been mentioned as potential hazard areas, will be affected during this level of accident.
Level II
In case of sabotage/complete failure of all automatic control/warning systems for example in fuel oil storage area the oil kept in tanks and covered by tank bund may leak out. However, the probability of this is very low due to adequate security and training of persons of the plant operating such system.
Disaster Preventive Measures
If any disaster takes place it is not easy to control if contingency plans are not available. For effective control of disaster adequate manpower, technical know-how, alertness and internal help are necessary. It always betters to take preventive measures to avoid any disaster. In proposed plant following prevention measures will be taken to prevent disaster.
7-4

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Plant layout: i) Design, manufacture and construction of all plant and machinerys and buildings will be as per national and international codes as applicable in specific cases and laid down by statutory authorities. ii) Provision of adequate access ways for the movement of equipment and personnel are kept. iii) Minimum two numbers of gates for escape during disaster shall be provided. iv) Siting of fuel oil storage shall be in protected fenced area inside tank bend. v) Water spraying in coal storage area.
Fire Fighting The existing plant is having a well-equipped fire-fighting group for the existing steel plant with 5 Officers, 25 Workers trained in this field. Following fire-fighting equipment shall be in place when the plant fully commissioned:
Fire Tender Jeep Portable Extinguishers Foam generator Static tanks
2 No. 4 Nos Lot Lot Lot
List of Fire Extinguishers Required at Different Locations
Name of site Kiln Area CO2 Foam type
Type
Dry Chemical type


EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Name of site IF & EAF Area CO2 Foam type Dry Chemical type Caster Area CO2 Foam type Dry Chemical type Turbo generator Area CO2 Foam type Dry Chemical type Type
Cable galleries
CO2 Foam type Dry Chemical type
High voltage pannel
Various control rooms
Various MCC rooms
Various pump houses
Fuel Tank Area
CO2 Foam type Dry Chemical type Sand Baskets
Guest Houses & offices

Dry Chemical powder type

7-6

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Name of site Godowns Foam type Type
Crusher House
However before installing fire station & safety equipment, an experienced fire officer would be appointed who carry out an in-depth study and shall decide about the selection of equipment.
Safety
The existing steel plant when fully commissioned will have a safety department manned by experienced engineers and staff whose main job will be to bring about safety consciousness amongst the work force in the plant. The safety department will conduct regular safety awareness courses by organizing seminars and training of the personnel among the various working levels.
Safety awareness will also be created by the various posters highlighting the safe working practices in different shops, hazards in working area, public places and roads etc. Safety engineers of the plant will conduct regular checks and mock exercises on the safe working of their department and report will be given to departmental head for corrective measures to improve the safety conditions.
Training
A department of training will also be set up to train officers. They will arrange training on safety accident prevention, first aid, hazard control, house keeping

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) and environmental management. Special emphasis with mock drills in disaster control will also be planned.
Communication
During the proposed modification-cum-expansion of steel plant there will be an up-to-date communication facilities with telecommunication and wireless, walkie-talkies, telecommunication and loud speakers in each shop, office and gate to warm workers in case of an accident.
Organization to combat contingency
The contingency plan is prepared from the experiences of accidents that have occurred in various other Steel plants. The contingency plan being a dynamic plan will need periodical reviews and modifications with new experiences. Even with all precautionary measures taken to avoid disaster, disaster may occur. To tackle situations during and after disaster, a well-defined contingency plan is a must. A Disaster Control Room (DCR) will be set up having links with all plant control rooms. An officer will be manning the DCR. On getting information about any accident, the officer will verify from the affected plant control room and inform the Disaster Controller (DC) and/or other co-ordinators immediately.
The responsible officers of Disaster Control Group will assemble in the DCR and formulate control procedures as per the contingency plans. The functions of the various officers of the Disaster Control Group will be as follows:
7-8

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Functions of Disaster controller
To declare "Disaster Emergency" after consulting the Sr. officer available and inform Fire Station Control Room to sound the sirens accordingly and arrange to convey the message in public address system
To report to DCR immediately.
To receive messages from the communication center.
To take decisions in consultation with the Commanding Officers of different services and convey them to the disaster point.
To be responsible for planning and provisions of assistance from township and from local authorities.
To keep higher authorities informed about the situation.
The decision of the Disaster Controller on any matter to meet the objective of disaster control plan will be final.
Functions of Officer In-charge:
Disaster Controller will nominate an officer whose functions will be as follows:
To be responsible for the operation of DCR and for the dispatch of messages.
To decide on the priority of dispatch of messages.

7-9

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) To keep liaison with all activities and give up to date and accurate appreciation of the situation.
To be responsible for the efficient organization of the Disaster Control Room.
Functions of Commanding Officers of various services:
The Commanding Officers of various services are designated Coordinator (services), Coordinator (Operation) and Coordinator (external services). The following are their functions:
To report to the Control Post immediately on hearing "Disaster Siren".
To keep Disaster Controller posted with the up-to-date information regarding manpower and material available concerning their respective services.
To advise Disaster Controller on all matters arising out of disaster.
To assist Disaster Controller for provision of material and man power concerning his service.
To convey message to his service teams through communication centre after consulting Disaster Controller.
To consult between themselves on matters related to more than one service and to decide on the action to be taken.
7 - 10

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Casualty services
The Commanding Officer of Casualty Services will be medical officer.
Functions
First aid service by first aid parties on the spot.
Ambulance service for transport of casualties from the spot to township hospital and from township hospital to outside, if required.
Procedure for treatment
On getting a signal from the Disaster Control Room or information on telephone or hearing siren, the Sub-Commanding Officer of the Casualty service will report to hospital and doctor on call duty and first aid personnel will report to Disaster Control Room. The Ambulance with the driver will report to Disaster Control Room. First aid parties will render first aid to casualties at the place of occurrence and those requiring further treatment would be transported to the nearest hospital by ambulance.
In case of extra help from outside or within CMO would contact Co-ordinator (Planning) for help in areas such as:
Extra medical helps from neighboring hospital or main hospital. Evacuating the casualties. Essential assistance in first aid.
7 - 11

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) First Aid
It is necessary to give first aid to the persons injured in disaster. There will be two first aid posts to meet the workload, one post will be near the Disaster Control Room and the other post will be in the township hospital. At each post 3 first aid parties shall be kept in rotating shifts of 8 hours.
Equipment
Each member of the first aid will be provided with the following personnel equipment.
Helmet Water bottle Torch First aid box
1 no. 1 no. 1 no. 1 no.
Rescue and repair services
The responsibility of effective working of Rescue and Repair Services are with Co-ordinator (Services) and Sub-Commanding Officers as follows:
Rescue services
To extricate persons from the debris of collapsed building and save human lives.
To hand over the dead bodies and injured persons to first aid parties.
7 - 12

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) To take immediate steps as may be necessary for the temporary support or demolition of buildings and structures, the collapse of which is likely to endanger life or obstruct traffic. To cut of supplies of water, steam & gas, electricity to damaged buildings / structures.
Each rescue party will be provided with the following equipment:
1. 2. 3. 4. 5. 6. 7. 8. 9.
Gas mask respirator Fire proximity suits Resuscitators Petromax lamp, Torches Axes/hand saw Fire entry suits Fire blankets Ropes Ladders
10. Rubber glove (Tested up to 25,000 voltage) 11. Blankets 12. Rubber shoes or Industrial shoes.
Repair services
To take up quick repairs of the damaged machinery. To take up repair of damaged building roads and culverts. To maintain essential public utility services viz. water, electricity and sewage system.
7 - 13

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Fire fighting services
Fire officer will be the Commanding Officer of Fire Fighting Services. Additional strength for fire fighting which is beyond the control of fire station will come from security and maintenance personnel and if required form outside fire stations.
Functions
To co-ordinate fire fighting activities To enforce all regulations for prevention of fire. To request neighboring industries and District Authority for rendering services of their fire fighting crew under mutual aid schemes, if necessary.
Traffic control
The free movement of the fire vehicles and ambulance at the scene of fire/emergency is very important and therefore, the security personnel on duty must ensure that all the roads at the scene of fire/emergency are kept clear and free from obstruction. Persons arriving by motor transport at the scene of fire/emergency must not park their vehicles within 100 meters of fire, near fire hydrants, at road junction and at access roads. The ignition key should be left in the vehicles.
Training services Functions
To arrange training of volunteers/employees nominated by Commanding Officers of various services.
To arrange refresher training courses once in a year.

7 - 14

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) To arrange mock drills, twice in a year. To make a list of employees trained in various specialized disasters so that they can be easily contacted to handle a particular type of disaster. The person concerned will immediately report to Disaster Control Room.
Faculty
Faculty will be consisted of commanding officers/sub-commanding officers and/or their nominated officers.
Depot and Transport services
Functions:
Dispatch of vehicle to the place of incident as per orders from the DCR. To get back the vehicle as soon as the work is completed. General administration of the depot including repair and maintenance of vehicle.
Storage maintenance and inspection of equipment. Maintenance of discipline and moral. Ensuring adherence to the depot duties. Welfare of personnel in the depot.
Vehicle repair
The Sub-Commanding Officer and his staff will promptly attend to all major repairs of the essential vehicles under his supervision.
7 - 15

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) For carrying out minor repairs, vehicle repair party will be detained at the depot. The party will be provided with a vehicle for quick movement.
Commanding Officer will evolve a system such that he is apprised of the conditions of the vehicles scheduled at 1500 hrs. daily during peace time. This is required so that the vehicles are available at a short notice.
Fuel
The Commanding Officer will contact Coordinator external services for arrangement of fuel for vehicles during fuel crisis and stop supplying fuel to vehicles other than those, which are in use for disaster control.
Supply services
A senior person will head supply service from stores department.
Functions:
To be responsible for planning, organizing and procuring necessary equipment/materials.
To be responsible for storage of equipment/materials at accessible location and for quick distribution on demand.
To obtain the requirement of equipment / materials from Commanding Officers of various services for their respective services.
To co-ordinate with Commanding Officer of Depot and Transport Services for transports required for distribution of equipment / materials in consultation with DCR.
7 - 16

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Salvage service
The salvage services will be under the charge of Committee. This committee will be formed taking one person from stores and one from production.
Functions:
To salvage properties from debris To take care of such properties To return the properties to respective shop in-charges. To co-ordinate patrolling with the help of, police and security personnel for the safeguard of valuable properties till the same are removed to a safe place.
Welfare services
Management of proposed Steel plant will nominate one person from administration side and he will be the Commanding Officer of welfare services.
Vacant buildings, schools complex and club will be used for housing those rendered homeless. Emergency camps will be set up only in exceptional cases on playing ground. For this purpose necessary material will be brought from nearby market.
Functions:
To provide shelters to affected persons. To arrange enough stock of essential commodities through co-operative society.
7 - 17

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) To arrange cooking of food in canteen supply to place where people are given shelters in township. For plant people, food will be supplied within battery area by mobile vans. If canteen is affected by disaster, the food will be cooked at school complex and will be served as indicated above. To arrange clothing and medicines to affected persons. Doctor(s) will assist for giving medicines.
To arrange drinking water, if supply is disrupted, with the help of District Authorities.
Mobile canteen
One mobile canteen in a motor van/truck will be made available in the plant area. The mobile van will be stationed in Depot.
Co-operative Society
There will be one cooperative society in township, which will be dealing in essential commodities. The District authorities during any emergency will further supplement the resources of this society.
Security services
Chief Security officer will be Commanding Officer, Security Services.
Functions:
Security services will be primarily responsible for the security of the plant.
7 - 18

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Commandant in consultation with co-ordinator (external service) will keep a close liaison with local police and district authorities. To control the vehicular traffic inside the plant. To help local police in patrolling the area of plant and outside the battery area, necessary. To assist Fire fighting services in fighting fires. To assist in transporting injured persons. To assist local police in patrolling in township and work out adequate arrangement for protection of property.
One jeep and one motor cycle will always be kept as reserve to cope up with emergency demand and for immediate mobility of security personnel.
Crash shut down of Units
Section head will be the Commanding Officer for Crash Shut down of the units, which are affected and may further aggravate disaster.
Function
To shut down the unit(s) affected and which may cause further disaster.
Public Relation Service
The Officer-in-Charge of Public Relation Services will look after this job.
Functions
To consult DC before communication, if required with outside agencies.

7 - 19

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) PRO will be the official spokesman for the steel plant with outside agencies. PRO will arrange for photography and filming of the whole disaster as photography and filming of such incidents are of immense value for the purpose of investigation, training and education. . Contingency Plan
The following contingency plan shall be followed:
Fire and Explosion
Plant fire fighting is activated.
Disaster Controller along with Commanding Officers takes overall charge of the situation.
DC will assess the situation for possible after effects of the fire in the plant and the surrounding areas likely to get affected.
DC will inform local authorities to send fire tenders, if necessary.
DC will inform the people of likely affected areas through communication system to leave the area and move to other areas earmarked, if necessary.
DC will inform co-ordinator, external services to inform the District authorities of the disaster and request them for help.
To evacuate people from the affected areas outside the plant.

7 - 20

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) To control the traffic and law and order.
To arrange medical aid for the affected people.
DC will arrange inspection of affected areas to get first hand knowledge of damages occurred.
Alarm System
On receiving the message of `Disaster' from Disaster Controller, fire station control room attendant will sound SIREN WAILING TYPE FOR 5 MINUTES. DC will arrange to broadcast disaster message through Public Address System.
On receiving the message of "Emergency Over" from DC the fire station control room attendant will give All Clear Signal by Sounding Siren straight for two minutes. The features of the alarm system will be explained to one and all to avoid panic or misunderstanding during disaster.
Actions to be taken on hearing the warning signal
On receiving the message of "Disaster" the following actions will be taken.
All the co-ordinators will report to the Disaster Control Room even if not contacted by the Cell :
The Commanding Officers and Sub-Commanding Officers will report to the place of accident.
7 - 21

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) The Process Unit persons will remain ready in their respective units for crash shut down on the instruction from the co-ordinator.
The persons from other sections will report to their respective officer.
The concerned section (Civil, Engineering Services, Mechanical, Project etc.) will take immediate action to remove contractors personnel outside the plant gate.
The residents of the township will remain alert.
Disaster due to natural calamity and external factors
Most of the measures & processes shall be same as given under in-house disaster except that the disaster controller will contact the state / district authorities for necessary instructions to co-ordinate with them.
Chemicals/Oil spillage
The possibility of large chemical/oil spillage in the final effluent discharged in reservoir is remote. However, DC will arrange to inform the following:
State Pollution Control Board
District authorities and request them to arrange patrolling of the area along with security personnel.
District authorities, to warn people in the affected area against fire/hazard that may occur and against the adverse effect of using water for any purpose.
7 - 22

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Disaster Controller along with Commanding Officers takes overall charge of the situation.
DC will inform the people of likely affected areas through communication system to leave the area and move to other safe areas earmarked.
DC will inform co-ordinator, external services to inform the District authorities of the disaster and request them for help.
To evacuate people from the affected areas outside the plant. -To control the traffic and law and order.
To arrange medical aid for the affected people.
DC will arrange inspection of affected areas to get first hand knowledge of damages occurred.
Cloud burst/lightning
Cloud burst/lightning may lead to a situation, which could be minor to major emergency. In such emergency, actions indicated under fire and explosion will be initiated.
Food poisoning
In case of food poisoning in plant canteen the following actions will be taken:
DC will inform the medical officer of steel plant health center for immediate first aid.
7 - 23

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) DC will contact District Authorities and seek their help, if necessary.
Security Personnel and employees will help in evacuating the affected people to various hospitals.
7 - 24

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 8.0 SOCIO-ECONOMIC IMPACT ASSESSMENT
8.1
General
Present Scenario
Socio-economic development is closely linked with the growth of industrialization. This necessitates the development of various types of industries as the economy passes through different stages of development. A project is a cash flow which in fact puts a break in investment flow of a region. Such investment may be widespread impact on the socio-economy of the area surrounding it, through multiplier and linkage effects. At the same time possibility of some adverse impact can not be ruled out. Therefore, a thorough socio-economic impact assessment is required for any such project / investment. Bhusan Steel & Strips Limited has proposed to modify and expand the existing steel plant near Angul, Orissa. The project involves substantial investment to which the local people have strong adherence due to some obvious impact on their socio-economic conditions. Accordingly, it is necessary to carry out a detailed socioeconomic impact assessment of the project. On this backdrop, the present study is directed towards the following objectives:
Objective
To assess the impact of the project on agricultural situation; To examine the impact of the project on pattern of demand; To assess the in impact of the project on consumption pattern; To examine the employment and income effects of the project; To explore the possibility of local industrialization as an offshoot of the project; To examine the effect of the project on education status of the people in the study
8-1

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) area; and To judge peoples' perception regarding the project.
8.2
The Study Area & Analytical Framework In the present investigation, the study area is considered as the circle with 7 km with centre at the project site. Major portion of the study area falls under the Dhenkanal district while the smaller part is in Angul district. Table-8.1 depicts a synoptic view of the basic statistics of the study area. The population of the area is around 23293 with a density of 151 persons per square km.
Table-8.1: Estimated Population and Occupational Pattern of the Study Area (Nos) Item up to 0.5 kms 0.5 - 3 kms 3 - 7 kms Total
1. Population Total Including Male Female SC ST 2. Households 3. Literate 4. Occupational pattern a) Main workers i) Cultivators ii) Agricultural labourers iii) Workers in household industry 2007 MECON Limited. All rights reserved
94
3713
19486 23293
49 46 16 11 17 49
1912 1801 624 434 675 1913
10035 11996 9451 11297 3274 2280 3543 3913 2725 4235
10041 12003
35 13 12 2
1366 505 486 59
7171 2650 2553 312
8572 3168 3051 373
8-2

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Item up to 0.5 kms 0.5 - 3 kms 3 - 7 kms Total
iv) Other workers b) Marginal workers Total working population (4)
8 5 40
316 204 1570
1656 1072 8242
1980 1281 9853
Land use pattern of the area is given in Table-8.2. It is observed that forest cover is quite high on around 15.4% of the land in the study area. Net Sown area constitutes about 39% of the area. Among other categories misc. trees, permanent pastures, barren, fallow are worth mentioning.
Table-8.2: Land use of the study area
Sl. No. 1 2 3 4 5 6 7 8 9 10
Type of land Forest land Misc. trees Permanent pastures Culturable waste Land put to non agriculture use Barren Current fallow Other fallow Net Sown Area Others Total
Study area 23.7 7.7 5.2 4.5 8.6 5.9 2.6 3.4 60.7 31.8 154.0
% of total 15.4 5.0 3.4 2.9 5.6 3.8 1.7 2.2 39.4 20.6 100.0
8-3

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 8.3 Analytical Framework Sampling
The study area is divided in to three strata --- (i) within 0.5 km radius circle centering the project site, (ii) area between 0. 5km radius circle and 3 km radius circle and (iii) area between 3 km radius circle and 7kms radius circle. A sample of 40 respondents is selected using two-stage stratified random sampling technique. In the first stage villages are selected and in the second stage, the respondents are selected at random from the selected villages.
Respondents have been interviewed with the structured questionnaire specially designed for this study keeping in view the objectives. Major constituents of the questionnaire are as follows:
1. Cropping pattern 2. Crop productivity 3. Cost of cultivation 4. Net return from crops 5. Household budget 6. Consumption pattern 7. Peoples' perception about the project etc.
Methodology
The major methods used as tools of analysis in this study are as given below:
1. Regression:
Simple linear regression of the following type in considered
8-4

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Yi = a + b Xi + Ui
(Where, U is the stochastic error term having its usual properties)
The model is fitted to data applying
Ordinary Least Square (OLS) to obtain
estimated demand and consumption functions.
2. Fitted regression models is used to work out
i)
Elasticity of demand with respect to disposable income (e) in case of
demand functions :
e = (dy / dx) . (y/x)
ii) Marginal propensity to consume (MPC) from consumption function :
MPC = dC / Dy
3. Frequency distribution of peoples' perception, educational status, land etc
holding
8.3.1 Agriculture Situation Agriculture is a major source from which people of the area derive their income. However, the climatic condition and the quality of soil of the area are not suitable for developed agriculture. Table-8.3 represents the cropping pattern in the study area. From the table it is evident that paddy is the main crop produced. Paddy is grown on about 67% the Gross Cropped Area (GCA). Other than paddy, maize is grown on 1.4% of the area.
8-5

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Table-8.3: Cropping Pattern & Cropping Intensity Sl No 1 2 2 Crop Paddy (Kharif) Maize Others TOTAL Area covered in GCA (%) 66.8 1.4 31.8 100.0
Table-8.4 depicts productivity of crops. The productivity figure for paddy is found to be quite low and much below state average. Productivity of maize is 0.1 qtl/ac. Table-8.4: Crop Productivity Sl. No. 1 2 Paddy Maize Crop Productivity (Qtl./ac.) 9.5 0.1
Table-8.5 presents average investment in agriculture, net return and cropping intensity. It is observed that agriculture is still profitable in this area as net return from agriculture is positive (Rs 3230 per acre). The cropping intensity is quite low (128.5%). This indicates backwardness of agriculture. Scanty rainfall, scarcity of irrigation water and low quality soil permitted them to produce only a few crops Table-8.5: Cost of Cultivation, Net Return And Cropping Intensity Sl No 1 2 3 Item Investment in agriculture (Rs/acre) Net return (Rs/acre) Cropping intensity (%) Quantity 1145 3230 128.5
8-6

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 8.3.2 Consumption Behaviour
Table-8.6 presents the source-wise distribution of average family consumption. It is observed that the major portion of consumption (65.8%) goes to meet the need for food items while clothing constitute 14.0% and medical expenses 3.9% of the total consumption. Table-8.6: Source-Wise Distribution of Family Consumption
Total Average family consumption (Rs/yr) Percentage Distribution 58.1 2.4 14.1 5.7 19.7 100.0 Food 21643 Education 878 Clothing 5250 Medical 2629 Others 7357 Total 37257
8.4
Anticipated Socio-Economic Impacts The survey reveals that the respondents spend major portion of their disposable income on food items. However, there has been a growing tendency among the respondents, of higher expenditure allocation on non-food items although their basket of consumption has only few items other than food. To go to the details of their pattern of demand, income elasticity of demand is calculated by fitting demand functions. Table-8.7 presents the results of the regression analysis conducted for fitting the demand functions. It is observed that all the demand functions give uniformly good fits to the data because R2 in all the cases is found to be quite high. Moreover, as indicated by t-test, the relevant parameter of the demand functions is found to be statistically significant at 1% level. The income elasticity of demand as measured from the fitted functions are 0.83 and 0.86 for food and non-food items respectively. The inelastic demand for food and non-food items indicates their strong necessity of these items. The higher magnitude of elasticity in case of non-food items is indicating their tendency to shift the demand in favour of non-food items as their income increases.
8-7

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Table-8.7: Demand Functions For Food And Non-Food Items Form of the fit Dij = a * Ybj * U (Where, Dij = Demand for the ith item by Nonjth respondent. Yj= Disposable income of the jth food 0.371 Item Regression parameters ln a Food 0.336 b 0.834 (17.05)* 0.857 (21.3)* 0.9743 R2 0.9604
respondent
Figures in ( ) indicate t - values * Significant at 1% level.
Hence, the impact of the project on the pattern of demand can be reasonably predicted as a shift from food to non-food items i.e., a consumer behaviour which may closely follow the Engel law. This is not a bad indication provided considerable income is earned by them; otherwise, if the shift is a substitution of necessary food requirements then it is not desirable in true socio-economic sense.
8.4.1 Agriculture Situation Overall assessment of the agricultural situation of the area reveals that agriculture is still quite backward in this area. Constraints of such backwardness as reported by the farmers are scanty rainfall, lack of irrigation water, unproductive soil and the major one is lack of credit. Majority of the farmers opined that unproductive land is the most important among these constraints. Keeping this in mind, it can be concluded that even if some irrigation facilities are provided/extended in this region, agriculture will still continue to be traditional.
Given the persistent nature of backwardness of agriculture, it can reasonably be argued that the project is not going to cause significant damage to it. Hence, the project will not have much of adverse impact on the existing agricultural situation of 2007 MECON Limited. All rights reserved 8-8

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) this area. Instead, the industrial project is likely to provide the farmers with supplementary income, which appears to be essential for raising the standard of living of the people of the study area.
8.4.2 Consumption Behaviour To investigate the consumption behaviour of the respondents in detail, Marginal Propensity to Consume (MPC) is calculated by fitting the consumption function. The results of the regression analysis performed for fitting the consumption function are presented in Table-8.8. It is observed that the function gave uniformly good fit to data because R2 is high and parameters are also found to be statistically significant at 1% level. The MPC worked out on the basis of the fitted consumption function is 0.642. Table-8.8: Fitted Consumption Function Form of the fit Regression parameters a Cj = a + b Yj + Uj Where, Cj = Consumption of the jth respondent Y = Gross income of the jth respondent Figures in ( ) indicate t-values * Significant at 1% level 5039.7 b 0.642 (22.5)* R2 0.977
Effort is taken here to work out the multiplier effect of investment on the people of the study area. The calculations are done using the following model:
Let us consider that the consumption behaviour of the respondents closely follow the following type of consumption function:
8-9

8 - 10

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) C = a + bY We know that, in equilibrium Y=C+ I Where, Y I = Gross income, C = Investment = Consumption and (2) (1)
Putting (1) in (2) one gets, Y = a + bY + I => Where, Y = ( 1 / (1-b) * [ a +I ] 1 / (1-b) is the multiplier . (3)
Assuming that consumption behaviour of the people in the study area closely follow this fitted consumption function, one can easily see that existing size of the multiplier is 2.8. Hence, investment on this project and the consequent generation of additional income will have strong multiplier effect in raising average consumption.
The proposed project is going to have positive income effect and consequently, the multiplier effect is expected to lead to an overall increase in average consumption of the people of the study area. Therefore, one can conclude that the impact of the project on consumption behaviour of the local people is likely to be satisfactory and positive.
8.4.3 Employment and Income effect
Direct employment
During the construction period, the project is going to create substantial employment and income. A large portion of these is likely to trickle down to the local people. Besides this, some persons from the study area may get employment on permanent basis for actual operation of the plant in the form of skilled or semi-skilled, or 2007 MECON Limited. All rights reserved 8 - 11

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) unskilled labour. Thus, substantial amount of employment and income are expected to be generated for the local people. Hence, it can be ascertained that the project is going to have significant employment and income effects. Indirect employment
In the case of indirect employment also, the effect is quite strong and widespread. Besides direct employment, the project is expected to generate substantial indirect employment in other sectors. So far indirect employment is concerned, the effect is very strong and widespread specifically, in ancillary industries, service and transport sectors. In view of the above, it can be justifiably concluded that the present project has tremendous positive employment and income effects.
Overall assessment of the employment and income effects indicates that the project has strong positive direct as well as indirect impact on employment and income generation.
8.4.4 Educational status The existing educational status of members of the sampled households is depicted in Table-8.9. The table revealed that about 55% of total members in the sample are illiterate. This figure includes the non-school going children also. About 13% of the members have education at primary level. Middle school level educated people constitute around 14%. Persons with high school and intermediate level education are observed to be around 9%. The study area has some highly educated persons (i.e., Graduate, PG and technical).
As reported by the respondents during field survey, their interest towards education has been increasing due to hope of getting employment which may come up especially in the non-agricultural sectors in this region, as an indirect impact of this 2007 MECON Limited. All rights reserved 8 - 12

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) project. The general awareness towards the importance of education is expected to increase as a result of the new project and hence, it can be said that the project has a strong positive impact on the level of education of the people of the study area.
Table-8.9: Educational Status of the people of the Study Area
Sl. No 1. 2. 3. 4. 5. 6 6 Illiterate* Primary
Level of education
No (% in total) 169 (54.9) 39 (12.7) 42 (13.6) 30 (9.7) 17 (5.5) 5 (1.6) 4 (1.9) 308 (100.0)
Middle school level High schooling and intermediate Graduation PG Technical Total * Includes non-school going children
8.4.5 Peoples' perception Peoples' perception regarding a project is as important as the impact of the project. So, it is worthwhile to examine what people perceive about the project. To fulfil this objective, an opinion poll was conducted. The results of the poll are analysed and furnished in Table-8.10 It is observed that 85.0% of them have identified the direct and indirect employment opportunity due to the project. Opportunities of business development is pointed out by about 32.5% of the respondents. 15 % of them have identified industrialisation in the area as an advantage. Along with the growth of industrialisation the entire area will be more urbanised. 10% of the respondents feel increase in urbanizatin of the area.
8 - 13

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) On disadvantages, about 55% of the respondents have cited pollution as the major factor. Around 45% of the respondents seem worried about adverse impact of the project on health of people. The problem related to scarcity of water and displacement of people are pointed out by around 27.0% and 23.0% of the respondents respectively.
Table-8.10: Peoples' Perception Perception Respondents
ADVANTAGES 1 2 3 4 5 Employment Business development Industrialisation Urbanisation Development of the area 34 (85.0) 13 (32.5) 6 (15.0) 5 (12.5) 6 (15.0)
DISADVANTAGES 1 2 3 4 Pollution Health damage Scarcity of water Displacement 22 (55.0) 18 (45.0) 11 (27.5) 9 (22.5)
[ Figures in ( ) indicate % in total no. of respondents. Individuals have spelt out more than one advantages / disadvantage ]
8 - 14

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 8.5 Conclusion On the basis of the overall results of the present impact assessment the following conclusions are drawn:
i)
The project is not going to cause any damage to the existing agricultural situation. Instead, it is likely to provide the farmers with supplementary income which, in turn, may be invested back on agriculture.
ii)
The project is going to have positive impact on pattern of demand which can be reasonably predicted as a shift from food to non-food items i.e., a consumer behaviour which may closely follow the Engel law. This is not a bad indication provided considerable income is earned by them; otherwise, if the shift is a substitution of necessary food requirements then it is not desirable in true socio-economic sense.
iii)
The project has strong positive impact on average consumption standard of people and also has intensive multiplier effect.
iv)
The project has good impact on employment and income generation, both direct as well as indirect. This will lead to diversification of skills.
vi)
The project has strong positive impact on the level of education of the people of the study area.
vii)
Peoples perception on the project is positive. Respondents expressed spontaneous support for the project as they foresee relatively more advantages for the people of the study area.
8 - 15

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 9.0 ORGANISATION AND MANPOWER
Bhushan Steel & Strips Limited (BSSL) shall have Environmental Management Division (EMD) at plant level as well as at corporate level for interaction with statutory bodies and managing environmental issues at plant level. Executive Director (works) of plant operation is the head of the plant level pollution control cell with Environmental Engineer, Chemist, etc. The plant level EMD will be provided with well-equipped laboratory for carrying out analysis of the samples of the water, air etc. Plant EMD will carry out the monitoring of the stack emission, noise level, analysis of the water etc. and keep the regional / local statutory body informed about the status of pollution control with intimation to the Corporate office EMD. BSSL will arrange professional training for personnel of EMD at plant level. The proper training shall be provided in area of monitoring and continuous analysis of the pollutants, legal requirement and environmental management system. 9.1 Organisational Set Up
Environmental monitoring and reporting has been designed to provide a close watch on the surrounding natural environment and provide early warnings of any adverse changes that may be related to some dimension of the plants operations. Organisation motto
The importance of environmental control has been recognised by BSSL and it has taken necessary steps to identify and control pollution in the plant, respond to impacts on its own captive population and also in the peripheral areas.
9-1

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) A. The above objective has been intended to be achieved through the following:
i) Improvement in the quality of raw materials. ii) Best available technology for manufacturing operations in steel plant, iii) Using automation & Computer control to have improvement on technology and on working condition, iv) Pollution Monitoring and Control, v) Occupational health set up including regular medical monitoring of employees, vi) A well developed safety management organisation, vii) Preparation of Emergency/Disaster Control plan and a properly trained group to meet the emergency situations, viii) ix) Green belt development inside the plant and township. Development of awareness in employees and public including student population towards environmental preservation, x) R & D activities in regard to specific pollution problems.
B.
The following strategies are being employed to meet the above objectives:
a) All new units coming under expansion would be environmentally audited to meet the pollution control standards. b) As environmental management is also associated with optimum energy utilisation & water conservation, all steps are taken to optimise the conservation of energy and consumption of water. c) The pollution control systems are operated and maintained as per technological norms.
An Environmental Management Division (EMD) will co-ordinate with other departments like Safety Management, Project Engineering, and Community Development under Chief Town Administrator, Water Supply Department etc. and
9-2

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) also do the liaison work with external agencies like State & Central Pollution Control Boards and Corporate Office.
A senior officer of the rank of Deputy General Manager (DGM), shall be the head of the EMD. In his day to day work, he shall be assisted by Environmental Engineers, Chemists and Laboratory Assistants. The DGM (EMD) reports to the General Manager (EMD), who in turn reports to the Executive Director (Works). A tentative Organisation Chart of the EMD is given as Fig. 9.1.
9.2
Man Power
EMD is manned by adequate staff. Services of retired forest officials may be taken for effective implementation of plantation schemes. For development and maintenance of jobs like drainage, settling tanks etc. assistance from the projects civil engineering department shall be taken.
9.3
Training Facilities
For the proposed project, additional training facilities will be developed for environmental control. Specialized courses at various Research/ Educational institutes will be organized. Training will cover the following fields: Awareness regarding Pollution Control and Environmental protection. Operation and maintenance of pollution control equipment. Afforestation / plantation and post care of plants. Field monitoring, maintenance and calibration of pollution monitoring instruments. Chemical analysis of various environmental parameters at laboratory. 2007 MECON Limited. All rights reserved 9-3

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Repair of pollution monitoring instruments. Knowledge of norms, regulations and procedures. Occupational health and safety. Risk assessment and Disaster Management Plan.
Executive Director (Works)
General Manager (Environmental Management Division)
Dy. General Manager EMD(1)
Lab Chemist (05 Nos.) Lab Assistant (03 Nos.)
Field Assistant (AAQ Monitoring Staff) (05 Nos.) Ash Dump Area (06 Nos.)
9-4

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) 10.0 ENVIRONMENTAL COST & PROJECT BENEFITS
10.1
Environmental Cost Component
The project cost has been estimated to be Rs. 63300 Million (Rupees Sixty three thousands three hundred million). The capital cost of environmental mitigation measures is estimated to be Rs. 3481.5 Million, which includes:
Cost Of Air Pollution Control Systems Cost of Water Pollution Control Cost of Solid Waste Management System (Including cost of dust storage with bund) Green belt development Environmental Monitoring Lab Development Social Institutional Development
: : :
Rs. 1393.0 million Rs. 0870.0 million Rs. 1045.0 million
: : :
Rs. 0033.5 million Rs 0070.0 million Rs 0070.0 million
Since Bhushan Steel & Strips Limited will be getting part of necessary environmental monitoring requirement carried out by an external agency, capital cost towards part of environmental monitoring facilities and occupational health of personnel is not required.
The estimated annual cost of environmental mitigation measures for the proposed modification-cum-expansion units has been estimated to be Rs. 350.0 Million. The annual estimated environmental mitigation costs include:
Cost of Air Pollution Control Cost of Water Pollution Control Cost of Solid Waste Management Cost of Green Belt Maintenance 2007 MECON Limited. All rights reserved
: : : :
Rs. 140.0 million Rs. 087.5 million Rs. 087.5 million Rs. 003.5 million 10-1

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Cost of Environmental Monitoring Cost Towards maintenance of Social infrastructure TOTAL : : Rs. 017.5 million Rs. 350.0 million : Rs. 014.0 million
10.2
Improvement In The Physical Infrastructure
Road Improvement and extension of the existing network is, essential to develop remote areas, better connection between the economic centers of state, and also cross-border transport and for personal mobility of the masses.
Rail Network Railways provided an important mode of transportation in the public sector spreading over the entire country. It contributes to the countrys economic development by catering to the needs of large-scale movement of freight as well as passenger traffic and is a major source of promoting integration among the masses. Railway provides transport facility to people and handles freight above 600 million tons annually. The Indian railway is intended to modernize the vast railway network, keeping both the economic and social dimensions in mind.
10.3
Improvement In The Social Infrastructure The project investment will vastly accelerate the development and use of the countrys irrigation potential. still be rain-fed. But even after this, two-fifths of cultivated area will
The BSSL will launch a special programme so as to ensure each household in the surrounding village will have full access to reliable power in the next two to
10-2

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) three years. The private sector has a crucial role to play in power generation and takes on an increased role in power distribution.
In order to supplement water availability and recharge the countrys groundwater resources, a local community-based Rainwater Harvesting Programme will be launched to capture at least an additional 1% of local rain resources every year. BSSL will launch Social housing schemes in the surrounding village to meet the needs of the local poor.
10.4
Employment Potential It generates employment both directly and also due to development of downstream industries. During the construction period, the project is going to create substantial employment and income. A large portion of these is likely to trickle down to the local people. Besides this, some persons from the study area may get employment on permanent basis for actual operation of the plant in the form of skilled or semi-skilled, or unskilled labour. Thus, substantial amount of employment and income are expected to be generated for the local people. Hence, it can be ascertained that the project is going to have significant employment and income effects. The estimated manpower requirement at the full development stage of the integrated complex has been estimated to be 2827. Category wise breakup of manpower is indicated in the table:
Sl. No. 1 2 3 4 5
Category Managerial Executive Skilled Semi-skilled Unskilled
Requirement 29 310 938 735 775
10-3

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) Sl. No. 6 Category Clerical Total : Requirement 40 2827
In the case of indirect employment also, the effect is quite strong and widespread. Besides direct employment, the project is expected to generate substantial indirect employment in other sectors. So far indirect employment is concerned, the effect is very strong and widespread specifically, in ancillary industries, service and transport sectors. In view of the above, it can be justifiably concluded that the present project has tremendous positive employment and income effects. Overall assessment of the employment and income effects indicates that the project has strong positive direct as well as indirect impact on employment and income generation.
10.5
Other Tangible Benefits The other tangible benefits will be in the form of plant township hospital and schooling facilities which will also help local population to enjoy the fruit of better facilities in nearby.
10-4

11.0
CONSULTANT CREDENTIALS
MECON LIMITED is a Public Sector Undertaking under Ministry of Steel, Government of India, as one of the leading design, engineering and consultancy organizations, with extensive in house and overseas experience. MECON has wide exposure and infrastructure for carrying out detailed design engineering, consultancy and site services or any other technical services for various sectors including iron ore mining and steel.
MECONs services include the whole range of work relating to setting up of projects in the field of infrastructure, power, metallurgy both ferrous & nonferrous, chemicals/ petrochemicals and allied engineering complexes including specialized fields such as hydro engineering, sewerage scheme, sewage treatment, industrial effluent treatment, solid waste disposal including municipal waste disposal system, ports, defense projects, mints/ currency note presses, environmental engineering, system engineering, etc. Because of being under Ministry of Steel MECON has wide exposure in iron ore mining in India and abroad. MECON was involved in the planning stage of a number of important iron ore deposits in India.
MECON is registered with World Bank, ADB, EBRD, African Development Bank, UNIDO, etc. MECON has collaboration agreements with the leading firms from USA, Germany, France, Italy, erstwhile U.S.S.R etc. in various fields and possesses process know-how & intend to make alliances & agreements to pool up and offer the best resources as may be available for specific requirement. MECON is the first engineering & consultancy organization in the country to be accredited with ISO: 9001 by RW TUV of Germany in the field of design, engineering, consultancy, contracting & supplying, inspection and project management services. 2007 MECON Limited. All rights reserved 11-1

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) MECONs Engineering Resources
MECON has a large set up with about 1900 strong workforce, of which about 1600 are graduate/ postgraduate engineers and technical staff in 39 technical disciplines. We possess our own in-house mainframe computer and host of LANS, mini computers, PCs, latest facilities of CAD/ CAM and other design & engineering aids. MECON is equipped with laboratories including electrotechnological laboratory (ETL), environmental laboratory and R & D laboratory and E-Mail connectivity though VSAT of NICNET.
With head office at Ranchi; 6 regional engineering offices at Bangalore, KolKata, New Delhi, Hyderabad, Chennai and Mumbai, 15 project site offices and liaison offices spread all over the country including Pune, Raigad & Mehsana , MECON can assist very effectively in executing projects.
11.1
Environmental Engineering Division of MECON
Environmental Engineering Division of MECON provides specialized services starting from project conceptualization to commissioning of pollution control system. The services include base line data generation, Environmental Impact Assessment studies and formulation of Environmental Management Plan, safety audits & disaster management plan, toxic & hazardous waste inventory & management and solid waste disposal, industrial effluent treatment, domestic sewage treatment & disposal system, dust extraction & dust suppression systems and other air pollution control system.
A large number of our environmental engineers/ scientists have been trained in UK, USA, erstwhile USSR, Canada, Japan and Germany. They have also assimilated the latest knowledge by extensive association with various foreign 2007 MECON Limited. All rights reserved 11-2

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) companies including WYLE Laboratories-USA, Metchem-Canada, Cremer & Warner- UK, WS Atkins- UK, TUV Rheinlnd- Germany etc.
MECON has been rendering comprehensive services in the mining sector for last four decades. MECON offers complete spectrum of consultancy & engineering services in exploration, exploitation, processing and coal washing, material handling and transportation, information technology and environmental
engineering in mining and mineral industry including coal sector. MECON has an experienced group of geologists, mining engineers, mine environmentalists and mineral engineers specialist in exploration planning computer aided geological modeling, deposit evaluation mine designing and planning and production scheduling, mineral beneficiation and coal washing, preparation of EIA/EMP reports etc. The geological sore body modeling and mine planning including production scheduling are carried out by utilizing SURPAC 2000 and Whittle Scheduler software. The above services are supported by in-house engineering departments like Material Handling, Electrical, Hydro-Engineering, Energy Engineering, Civil, Structural, Repair shops and maintenance garage,
Environmental engineering, Information Technology etc. MECON has rendered engineering and consultancy for most of the mechanized iron ore mining in the country.
MECON has prepared more than 250 EIA reports both in public and private sectors Clearances for almost all the reports prepared by MECON have been obtained from MOE&F in the shortest possible time. At present we are carrying out EIA studies for Steel plant of Bhushan Power & Steel limited at Rengali, Orissa, BSSL at Meramandali (Orissa) and Bhilai steel plant at Bhilai, DSP at Durgapur, RSP at Rourkela, Bokaro Steel Limited, BSL, Bokaro; IISCO Steel Plant ISP; Burnpur; JVSL at Torangallu, JSL at Kalinga nagar, Adhunik Steel & Alloy Limited, Kolkata, Ramsarup Loh Udyog, at Khadagpur, etc. 2007 MECON Limited. All rights reserved 11-3

EIA/ EMP Study for Modification-cum-Expansion of Integrated Steel Plant from1.5 to 3.1 Mtpy, at Meramandali, Dhenkanal, (Orissa) MECON does possess a record of successfully undertaken development of clean technology and environmental standards for Coke-oven plants and also development of clean technology in the areas of iron ore beneficiation.
We are confident that with MECONs established track record & long experience in design, engineering & consultancy of various projects and extensive
experience in executing sizable environmental and mining assignments in India and abroad, we shall be able to meaningfully contribute and supplement client team in order to realize their endeavor successfully.
11-4

Bhushan Steels Or.

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Bhushan Steels Or.

Uploaded by

Copyright:

Available Formats

BHUSHAN STEEL AND STRIP LIMITED

BHUSHAN STEEL AND STRIP LIMITED

Bhushan Steel & Strips Limited

PROJECT DESCRIPTION & ANNEXURES

PRESENT ENVIRONMENTAL STATUS & ANNEXURES

ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION 4 1 to 4 28 MEASURES

ENVIRONMENTAL MANAGEMENT PLAN (EMP)

EMP IMPLEMENTATION AND MONITORING.

DISASTER MANAGEMENT PLAN (DMP)

SOCIO-ECONOMIC IMPACT ASSESSMENT

ORGANISATION AND MANPOWER

ENVIRONMENTAL COST & PROJECT BENEFITS

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

SHOWING Drg. No. MEC/Q6BK/11/S2/01

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

Purpose of the Report

Bhushan Steel & Strips Limited

Bhushan Steel & Strips Limited

Project & Project Proponent

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

Project Importance to the Country/Region

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

Bhushan Steel & Strips Limited

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

imported from foreign countries.

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

MEC/11/14/Q6AT/DE/GN/50/001 sheet 1 of 1 REV.-5.

Schedule for Approval & Implementation

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

Table-2.1: The Plant Facilities at 3.1 Mtpy level

11. Rolling Mill (HSM)

12. Lime & Dolo Plant 13. Power Plant

14. Oxygen Plant 15. Raw materials Preparation Plant (RMPP)

1x950 tpd Oxygen Plant Matching the production facilities

2007 MECON Limited. All rights reserved

Bhushan Steel & Strips Limited

Fig-2.1: Process Flow Diagram

Boiler & Power Plant

Coke Oven Iron Ore COLD PIGS

Continuous Slab/Billet Casters

Sinter Plant Hot Strip Mill HR COILS

PRODUCTION FACILITIES PLANNED IN 3.1 MTPA EXPANSION

2007 MECON Limited. All rights reserved