proposed 3.5 mtpa integrated steel plant & 295 mw...

AARESS IRON & STEEL LIMITED

PROPOSED 3.5 MTPA INTEGRATED STEEL PLANT & 295 MW

CPP AT HALAVARTHI, KOPPAL, KARNATAKA

ENVIRONMENTAL IMPACT ASSESSMENT (EIA) &

ENVIRONMENTAL MANAGEMENT PLAN (EMP)

POLLUTION & ECOLOGY CONTROL SERVICES NAGPUR – INDIA

FINAL EIA REPORT

vivek

Stamp

i

INDEX

Sl.

NO.

PARTICULARS PAGE

CHAPTER 1 : INTRODUCTION 1-6

1.0 Introduction 1

1.1 Purpose of the Report 1

1.2 Identification of Project & Project Proponent 2

1.2.1 Nature of the Project 2

1.2.2 Size of the Project 2

1.2.3 Project Proponent 2

1.2.4 Importance of the Project 2

1.2.5 Location of the Project 2

1.3 Scope of the Study 3

1.4 Basic Data Generation, Field Studies and Data Collection 3

1.5 Report Coverage 3

CHAPTER 2 : PROJECT DESCRIPTION 7-40

2.0 Project Description 7

2.1 Introduction 7

2.2 Type of Project 8

2.3 Need for Project 9

2.4 Location 10

2.5 Size or Magnitude of Operation 10

2.6 Proposed Schedule for Approval and Implementation 10

2.7 General Layout and Transportation 11

2.8 Technology & Process Description 12

2.8.1 Coke Oven Batteries 12

2.8.2 Sintering Plant and Auxiliaries 13

2.8.3 Iron Ore Fine Beneficiation Plant 15

ii

Sl.

NO.

PARTICULARS PAGE

2.8.4 The Blast Furnace Complexes 17

2.8.5 Steel Making Facilities 19

2.8.6 The hot rolling Mills 25

2.8.7 Cold rolling complex 28

2.9 Captive Power Plants and Turbo Blower Stations 30

2.9.1 Captive Power Plants: 30

2.9.2 Turbo-blowers 31

2.10 Cryogenic Oxygen Plant 31

2.11 Pollution Control and Environment Management 31

2.12 Instrumentation, Automation & Controls 34

2.13 Water supply and treatment facilities 35

2.14 Steam facilities 36

2.15 Compressed air facilities 36

2.16 Fuel Oil Facilities 37

2.17 Inter Plant Gas Pipeline 37

2.18 Industrial Safety and Fire Protection Services 38

2.19 Ventilation, Air Conditioning & De-dusting Facilities 38

2.20 Construction Planning 38

2.21 Manpower & Training 39

2.22 Capital Cost & Economics of the project 40

CHAPTER 3: DESCRIPTION OF THE ENVIRONMENT 41 - 108

3.0 Introduction 41

3.1 Environmental Monitoring Program 43

3.1.1 Micro Meteorology 44

iii

Sl.

NO.

PARTICULARS PAGE

3.1.2 Air Environment 49

3.1.3 Water Environment 65

3.1.4 Noise Environment 75

3.1.5 Soil Environment 78

3.1.6 Land Environment 88

3.1.7 Geology 91

3.1.8 Flora & Fauna 93

CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS

&MITIGATION MEASURES

109 - 189

4.1 Introduction 109

4.1.1 Impacts and Mitigation Measures Due To Project Location 109

4.1.2 Impacts and Mitigation Measures Due To Project Design 110

4.1.3 Impacts and Mitigation Measures during Construction Phase 111

4.1.4 Impacts and Mitigation Measures during Operation Phase 113

4.1.5 Impacts and Mitigation Measures because of Accidents 147

4.2 Measures for Minimizing and / or Offsetting Adverse Impact 148

4.3 Irreversible and Irretrievable Commitments of Environmental Components 149

4.4 Assessment of Significance of Environmental Impacts 150

4.4.1 General 150

4.4.2 Criteria For Determining Significance 152

4.4.3 Environmental Significance Against Predictability Criterion 155

4.4.4 Manageability Criterion 157

4.4.5 Issues Under Manageability Criterion 158

4.4.6 Environmental Significance Against Manageability Criterion 159

4.4.7 Environmental Significance 162

4.5 Technological Details Of Environmental Mitigation Measures 165

4.5.1 Introduction 165

4.5.2 Carbon Credit Technology or CDM Projects Envisaged 165

iv

Sl.

NO.

PARTICULARS PAGE

4.5.3 Air Pollution: Mitigation Measures 168

4.5.4 Water: Mitigation Measures 176

4.6 Rain Water Harvesting 179

4.7 Energy Conservation Measures 179

4.8 Solid Waste: Mitigation Measures 179

4.9 Green Belt Development: Mitigation Measures 182

CHAPTER-5.0: ANALYSIS OF ALTERNATIVE 190

CHAPTER 6: ENVIRONMENTAL MONITORING PROGRAMME 191 - 215


6.1 Environmental Aspects to be Monitored 191

6.1.2 Regular Maintenance of Drainage System 192

6.1.3 Meteorology 193

6.1.4 Major Stack Emissions Monitoring 193

6.1.5 Solid / Hazardous Waste Generation & Utilisation 194

6.1.6 Green Belt Development Plan 194

6.1.7 House Keeping 194

6.1.8 Occupational Health and Safety 194

6.1.9 Socio-Economic Development 195

6.1.10 The Waste Water Quality 195

6.1.11 Work Zone Air Quality 195

6.1.12 Work Zone Noise 195

6.1.13 Ambient Air Quality(AAQ) 196

6.1.14 Wastewater Discharge from Plant 196

6.1.15 Ambient Noise Level 197

6.1.16 Ground Water Monitoring 197

6.2 Monitoring Plan 197

6.2.1 General 197

6.2.2 Performance Indicators(PI) 198

v

Sl.

NO.

PARTICULARS PAGE

6.2.3 Environmental Monitoring Programme 198

6.2.4 Reporting System for Progress Monitoring 204

6.2.5 Emergency Procedures 205

6.2.6 Budgetary Provisions for Environmental Monitoring Plan 205

6.2.7 Budgetary Provisions for Environmental Protection Measures 205

CHAPTER 7: ADDITIONAL STUDIES 207-242

7.1 Risk Assessment 207


7.2.2 Process Description 207

7.2.3 Applicability of the Rule 210

7.2.4 Description of Hazardous Chemicals 211

7.2.5 Hazard Identification 215

7.2.6 Hazard Assessment 216

7.2.7 HAZOP Study 217

7.2.8 Consequence Analysis 217

7.2.9 On-Site Emergency Plan / Disaster Management Plan 219

7.2.10 Industrial Safety And Fire Fighting 220

7.2.11 Safety Of Personnel 220

7.2.12 Fire Protection Facilities 220

7.2.13 Plant Disaster Control 221

7.3 Social Impact Assessment 230


7.3.2 Objectives 230

7.3.3 Methodology adopted for the study 231

7.3.4 Profile of Koppal District 232

7.3.5 Conclusions 239

7.3.6 Corporate Social Responsibility 240

7.4 Public Consultation 241

vi

Sl.

NO.

PARTICULARS PAGE

7.5 Corporate Environmental Responsibility 242

CHAPTER 8: PROJECT BENEFITS 243-244


8.1 Employment Potential 243

8.2 Other Tangible Benefits 243

CHAPTER 9 : ENVIRONMENTAL MANAGEMENT PLAN 245-253

9.1 Environmental Management Plan (EMP) : Administrative Aspects 245

9.2 Organization Policy 245

9.3 Implementation of Mitigative Measures 246

9.4 Organization Structure 246

9.4.1 Administrative Setup 246

9.4.2 Laboratory Set Up 247

9.4.3 Functioning 250

9.5 Implementation Arrangement 251

9.5.1 Institutional Implementation Arrangements 251

9.5.2 Co-ordination with Other Departments 252

9.5.3 Interaction with State Pollution Control Board /CPCB / MoEFCC 252

9.5.4 Training 252

9.6 Environmental Auditing 253

9.7 Water And Energy Conservation Measures 253

9.8 Other Measures 253

CHAPTER-10: SUMMARY AND CONCLUSION 254-270


10.1 Need for the Project 255

10.2 Plant Capacity, Cost and Implementation Schedule 255

10.3 Project Site and its Environs 255

10.4 Site Selection 256

10.5 Salient Features of the Project 256

vii

Sl.

NO.

PARTICULARS PAGE

10.6 Land 256

10.7 Water 256

10.8 Environmental Impact Assessment Study 256

10.8.1 Baseline Status 256

CHAPTER 11: DISCLOSURE OF CONSULTANT 261-262

viii

LIST OF TABLES

Table No. Names Page

3.1 Environmental Setting of Plant Site 41

3.2 Schedule of Environmental Monitoring Program 44

3.3 Environmental Attributes & Frequency of Monitoring 44

3.4 Temperature & Humidity Recorded During Sampling Period 46

3.5 Description of Ambient Air Monitoring Stations 50

3.6 Techniques& Instruments Used For Monitoring of Ambient Air

Quality

51

3.7 AAQ Observations Project Site One At Proposed Steel Plant 52

3.8 AAQ Observations Adjacent From One Pellet Plant 53

3.9 AAQ Observations Allangara Village 54

3.10 AAQ Observations Hira Baglani Village 55

3.11 AAQ Observations Kunikeri Tanda Village 56

3.12 AAQ Observations Huvinahalu Village 57

3.13 AAQ Observations Koppal Village 58

3.14 AAQ Observations Belanalu Village 58

3.15 AAQ Observations Basapur Village 60

3.16a Summarized Report of Ambient Air Quality 61

3.16b Summarized Report of Ambient Air Quality 61

3.16c Summarized Report of Ambient Air Quality 61

3.17a Percentile Distributions of Various Parameters in Ambient Air Quality 62

3.17b Percentile Distributions of Various Parameters in Ambient Air Quality 62

3.17c Percentile Distributions of Various Parameters in Ambient Air Quality 62

3.18 National Ambient Air Quality Standards 63

3.19a Descriptive Listing of Ground Water Sampling Stations 65

3.19b Descriptive Listing of Surface Water Sampling Stations 66

3.20 Methodology for sampling and analysis of water & wastewater 67

3.21a Analysis Report of Ground Water Samples 69

3.21b Analysis Report Of Surface Water Samples 71

ix

3.22 Details of Sampling Stations of Noise Level Measurement 75

3.23 Measured Noise Levels At Monitored Stations 77

3.24 Details of Soil Sampling Locations 78

3.25 Analytical Techniques for Soil Analysis 80

3.26 Barren Land Project Site (S-1) 81

3.27 Agriculture Land In Hira Baglani Village (S-2) 82

3.28 Waste Land In Kunikeri Tanda Village (S-3) 83

3.29 Barren Land In Huvinahalu Village (S-4) 84

3.30 Agriculture Land In Belanalu Village (S-5) 85

3.31 Standard Soil Classification 86

3.32 Land Use / Land Cover in 10 Km Radius 90

3.33 List of Major Industries in 10 Km Radius 91

3.34 The Rock Types Found in the Study Area 92

3.35 Stratigraphic sequence observed around Koppal & Ginigera 92

3.36 List of Plant Species Recorded From the Study Area 96

3.37 List of Fauna in the Study Area 104

4.1a Stack emission details for AISL 3.5 MTPA Steel Plant phase-1 119

4.1b Stack emission details for AISL 3.5 MTPA Steel Plant phase-2 120

4.2 Meteorological data used as input for Air quality modeling 122

4.3a Prediction of GLC’s at 3.5 MTPA (Phase-1) Proposed steel 123

4.3b Prediction of GLC's at 3.5 MTPA (Phase-2) Proposed steel 124

4.3c Prediction of GLC's at 3.5 MTPA (Phase-1+2 combined) 125

4.4a Source of Generation / Characterization of Solid Wastes 138

4.4b Solid Waste Generation and Disposal 141

4.5 Charter of Corporate Responsibility shall be as followed 147

4.6 Potential Impacts Verses Mitigation Measures Adopted 148

4.7 Events and their Environmental Consequences 151

4.8 Issues Considered under Predictability Criterion 152

4.9 Level of Certainty in the Prediction of Activity Events and their

Associated Consequences

153

x

4.10 Predictability Criterion Significance Score 155

4.11 Predictability Criterion Table 155

4.12 Issues Considered under Manageability Criterion 157

4.13 Questions for Addressing Issues under Manageability Criterion 158

4.14 Manageability Criterion Significance score 159

4.15 Manageability Criterion Table 161

4.16 Matrix for Determining Level of Environmental Significance 163

4.17 Activity Environmental Significance Table 163

4.18 Emission Norms for Air Pollution Control (APC) Measures 175

6.1 Major Stacks to be monitored after the Implementation of the Project 193

6.2 Monitoring of Effluent Outlet & Inlet of ETP 195

6.3 Noise Level monitored after Implementation 196

6.4 Ambient Air to be monitored 196

6.5 Environmental Monitoring Programme 199

6.6 Performance Indicators (PI) for Environmental Monitoring Plan 202

6.7 Reporting System for Environmental Monitoring Plan 204

6.8 Cost of Environmental Protection Measures (Rs. Crores) 206

7.1 Threshold Quantity & the Chemicals Stored and Handled 211

7.2 Type Of Hazards 215

7.3 Over Pressure generation from vapour cloud explosion 218

7.4 Effect of Different Overpressure 218

7.5 Heat radiation intensity at different distances for 50 t 219

7.6 Relation between Heat Radiation Intensity, Time and Effect on Man 219

7.7 The village wise demographic data 235

9.1 Monitoring / Analytical Equipment / Usage for proposed plant 248

9.2 List of Coordinating Agencies, which may be involved for specific

Environmental Activities

251

xi

LIST OF FIGURES

Figure No. Names Page No.

1.1a Location of Site 5

1.1b Location of Site ( Total village are Halavarthi, Basapura, Koppal,

Kidadal, Ginigera ) 6

3.1 Key Plan 43

3.1a Wind Rose Diagram for Period during AAQ Monitoring 45

3.2 Temperature variations during study period 49

3.3 Relative Humidity Variations during Study Period 49

3.4 Locations of Ambient Air Quality Monitoring Stations 50

3.5 Figure Showing Of Ground & Surface Water Sampling Locations 66

3.6 Figure Showing Locations of Noise Level Monitoring

76

3.7 Figure Showing Locations of Soil Sampling Locations 79

3.8 Figure showing satellite imagery 89

3.9 Figure Land Use / Land Cover Map of 10Km Radius. 90

4.1 Isopleths for PM Concentration Due to proposed steel project 126

4.2 Isopleths for SO2 Concentration Due to proposed steel project 127

4.3 Isopleths for NOx Concentration Due to proposed steel project 128

4.4 Steps for Assessment of Significance of Environmental Impacts 154

9.1 Organization Chart (Proposed) of Environment Management

Department 247

xii

LIST OF APPENDICES

Appendices Description

1 Copy of TOR

2 List of Raw Materials, their Source and mode of transport

3 Photograph of proposed plant site

4 Water Permission

5 GLCs of Phase I & Phase II

LIST OF DRAWINGS

Sl. NO.

Description Drawing No.

1 General Layout ENV/AISL/FR/GL/001(R-2)

2 Material Flow Sheet AISL/FR/MFS R-1(4 SHEETS)

3 Water Balance ENVIRO/AISL/FR/17/01 (2 SHEETS)

4 Project Implementation AISL/FR/24/01 (2 SHEETS)

5 Utilization of By Product Gases

ENVIRO/AISL/FR/14/01 (2 SHEETS)

AARESS IRON & Steel Limited (AISL)

EIA/EMP study for 3.5 MTPA Integrated Steel Plant including 295 MW CPP at Village Halavarathi, tehsil-Koppal, State: Karnataka

Page 1 of 14 Compliance of TOR

Terms of Reference (TOR)

The following Terms of Reference (TOR) has been finalized by the Expert Appraisal Committee (EAC) and issued vide letter

F.no- J-11011/161/2015-IA II (I) dated 22/07/2015 for preparation of EIA/EMP report. The TOR issued for EIA/EMP study for

3.5 MTPA Integrated Steel Plant including 295 MW CPP at Village Halavarathi, tehsil-Koppal, State: Karnataka. The approved

TOR is attached as Appendix-1. The point wise compliance of TOR is indicated below:

Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

1. Executive Summary - - Attached with EIA Report

2. Introduction

I. Details of the EIA Consultant including NABET accreditation.

II. Information about the project proponent.

III. Importance and benefits of the project

Chapter-10

Chapter-1

Chapter-1

Page-261-262

Page-2

Page-2

3. Project Description

I. Cost of project and time of completion

II. Products with capacities for the proposed project

III. If expansion project, Details of existing products with

capacities and whether adequate land is available for

expansion, reference of earlier EC if any

IV. List of raw materials required and their source along with

mode of transportation

V. Other chemicals and materials required with quantities and

storage capacities

VI. Details of Emission, effluents, Hazardous waste generation

and their management.

Chap-2

Chap-2

N.A.

-

N.A.

Chap-2

Page-38 & 40

Page-9

-

-

N.A.

Page-32-34

Proposed project

Appendix-2




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

VII. Requirement of water, Power, with source of supply, status of

approval, water balance diagram, man power requirement

(regular and contract)

VIII. Process description along with major equipment’s and

machineries, process flow sheet (quantitative) from raw

material to products to be provided.

IX. Hazard identification and details of proposed safety systems.

X. Expansion/modernization proposals:

a. Copy of all the Environmental Clearance(s) including

Amendments there to obtained for the project from

MOEF/SEIAA shall be attached as annexure. A certified copy

of the latest monitoring report of the regional office of the

Ministry of Environment and Forests as per circular dated

30th May, 2012 on the status of compliances of conditions

stipulated in all the existing environmental clearances

including Amendments shall be provided In addition. Status

of consent to Operate for the ongoing /existing operation

of the project from SPCB shall be attached with the EIA –

EMP report.

b. In case the existing project has not obtained environmental

clearance, reasons for not taking EC under the provisions

of the EIA Notification1994 and/or EIA Notification 2006

shall be provided. Copies of Consent to Establish/ No

objection Certificate and consent to Operate (in case of

Chap-2

Chap-2

Chap-7

-

N.A.

Page-32 to 34

Page-12 to 31

Page-207-242

-

This is new proposal for

project

N.A.




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

units operating prior to EIA Notification 2006, CTE and CTO

of FY 2005-2006 ) obtained from the SPCB shall be

submitted, Further compliance report to the conditions of

consents from the SPCB shall be submitted.

4. Site Details

I. Location of the project site covering village, Taluka/ tehsil.

District and state, justification for selecting the site,

whether other sites considered.

II. A topo sheet of the study area of radius of 10km and site

location on 1:50,000/1:25,000 scale on an A3/A2 sheet.

(including all eco-sensitive areas and environmentally

sensitive places)

III. CO- ordinates (lat – long) of all four corners of the site.

IV. Google map- Earth downloaded of the project site.

V. Layout maps indicating existing unit as well as proposed

unit indicating storage area, Plant area, greenbelt area

utilities etc. if located within an Industrial

area/Estate/Complex, layout of Industrial Area indicating

location of unit within the Industrial area/Estate.

VI. Photographs of the proposed and existing (if applicable)

plant site. If existing, show photographs of

plantation/greenbelt, in particular.

VII. Land use break- up of total land of the project site

(identified and acquired). Government/private –

Chap-1

-

Chap-1

Chap-3

Chap-2

-

-

Page-2-3

-

Page-2-3

Page-89

-

-

-

Other site not considered as

site is allocated by KIDB

Attached as drawing

Attached as Drawing

Appendix-3

Appendix-4




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

agricultural, forest, wasteland, water bodies, settlements,

etc shall be included. (not required for industrial area)

VIII. A list of major industries with name and type within study

area (10km radius) shall be incorporated. Land use details

of the study area

IX. Geological features and Geo-hydrological status of the

study area shall be included.

X. Details of Drainage of the project upto 5km radius of study

area. If the site is within 1km radius of any major river,

Peak and lend season river discharge as well as flood

occurrence frequency based on peak rainfall data of the

past 30 years. Details of flood level of the project site and

maximum flood level of the river shall also be provided. (

mega green field projects)

XI. Status of acquisition of land. If acquisition is not complete,

stage of the acquisition process and expected time of

complete possession of the land.

XII. R & R details in respect of land in line with state

Government policy.

Chap-3

Chap-3

-

-

-

Page-88-91

Table-3.32,

3.33

Page-91

-

-

-

The project is not located in 1

km radius of any major river

A total of 922.1 acres is under

possession & 995.50 acres

under acquision by KIADB

There is no R&R envisaged for

project

5. Forest and wildlife related issues(if applicable):

I. Permission and approval for the use of forest land (forestry

clearance), if any and recommendations of the State Forest

Department, (if applicable)

-

-

There is no forest land

involved, hence clause does

not applicable




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

II. Land use map based on High resolution satellite imagery

(GPS) of the proposed site delineating the forestland (in

case of projects involving forest land more than 40 ha)

III. Status of Application submitted for obtaining the stage I

forestry clearance along with latest status shall be

submitted.

IV. The projects to be located within 10km of the National park,

sanctuaries, Biosphere Reserves, Migratory Corridors of

wild Animals, the project proponent shall submit the map

duly authenticated by Chief wildlife warden showing these

features vis-a-vis the project location and the

recommendations or comments of the Chief Wildlife

warden-thereon

V. Wildlife conservation plan duly authenticated by the chief

wildlife warden of the state Government for conservation of

schedule I fauna, if any exists in the study area.

VI. Copy of application submitted for clearance under the

wildlife (protection) Act, 1972, to the standing committee

of the National Board for wildlife

Chap-3

N.A.

N.A.

N.A.

N.A.

Page-88-90

N.A.

N.A.

N.A.

N.A.

There is no forest land involve

There is National Park,

Sanctuaries, Biosphere

Reserves, Migratory Corridor

of wild life within 10 km radius

of project

6. Environmental status

I. Determination of atmospheric inversion level at the project

site- specific micro-meteorological data using temperature,

Chap-3

Page-45-49




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

relative humidity, hourly wind speed and direction and

rainfall.

II. AAQ data (except monsoon) at 8 locations for PM10, PM2.5,

SO2, NOX, CO and other parameters relevant to the project

shall be collected. The monitoring station shall be based

CPCB guidelines and take into account the predominant

wind direction, population zone and sensitive receptors

including reserved forest.

III. Raw data of all AAQ measurement for 12 weeks of all

station as per frequency given in the NAAQM notification of

Nov.2009 along with min., max., average and 98%values

value for data of all AAQ station should be provided as an

annexure to the EIA Report.

IV. Surface water quality of nearby river (600m upstream and

downstream) and other surface drains at eight locations as

per CPCB/MOEF & CC guidelines.

V. Whether the site falls near to polluted stretch of river

identified by the CPCB/ MOEF & CC.

VI. Ground water monitoring at minimum at 8 locations shall

be included.

VII. Noise levels monitoring at 8 locations within the study area.

Chap-3

Chap-3

Chap-3

N.A.

Chap-3

Chap-3

Page-49-65

Page-49-65

Page-65-75

N.A.

Page-65-75

Page-75-78




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

VIII. Soil characteristics as per CPCB guidelines

IX. Traffic study of the area, Type of vehicles, Frequency of

vehicles for transportation of material, additional traffic due

to proposed project, packing arrangement etc.

X. Detailed description of flora and fauna (terrestrial and

aquatic) existing in the study area shall be given with

special reference to rare, endemic and endangered species.

If schedule-1 fauna with in the study area, a wildlife

conservation plan shall be prepared and furnished.

XI. Socio-economic status of the study area.

Chap-3

-

Chap-3

Chap-7

Page-78-87

-

Page-93-108

Page-230-232

7. Impact Assessment and Environment Management Plan.

I. Assessment of ground level concentration of pollutants

from the stack emission based on site-specific metrological

features. In case the project is located on a hilly terrain.

The AQIP Modeling shall be done using input of the specific

terrain characteristics for determining the potential impacts

of the project in the AAQ. Cumulative impact of all sources

of emissions (including Transportation) on the AAQ of the

area should be well assessed. Details of the model used and

the input data used for modeling shall also be provided. The

Chap-4

Chap-9

Page-109-189

Page-245-253




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

air quality contours shall be plotted on a location map

showing the location of project site, habitation nearby,

sensitive receptor, if any.

II. water quality modeling in case, if the effluent is proposed

to be discharged in to the local drain, then water quality

modeling study should be conducted for the drain water

taking into consideration the upstream and downstream

quality of water of the drain.

III. Impact of the transport of the raw materials and end

products on the surrounding environment shall be assessed

and provided. In this regard option for transport of raw

material and finished products and wastes (large quantities)

by rail or rail-cum road transport or conveyor-cum-rail

transport shall be examined.

IV. A note on treatment of waste water from different plant

operation, extent of recycled and reused for different

purposes shall be included. Complete scheme of effluent

treatment. Characteristics of untreated and treated effluent

to meet the prescribed standards of discharge under E(P)

rules.

N.A.

Chap-4

Chap-4

N.A.

Page-129-131

Page-132-136

Project does not envisage any

waste water discharge from

plant to local drain




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

V. Details of stack emission and action plan for control of

emission to meet standards.

VI. Measures for fugitive emission control.

VII. Details of hazardous waste generation and their storage.

Utilization and disposal, copies of MOU regarding utilization

of solid and hazardous waste shall also be included. EMP

shall include the concept of waste-minimization

recycle/reuse/recover technique. Energy conservation and

natural resources conservation.

VIII. Proper utilization of fly ash shall be ensured as per fly ash

Notification. 2009. A detailed plan of action shall be

provided.

IX. Action plan for the green belt development plan in 33%

area i.e., land with not less than 1,500 tress per ha. Giving

details of species, width of plantation, planning schedule etc

shall be included. The green plant shall be around the

project boundary and a scheme for greening of the roads

used for the project shall also be incorporated.

X. Action plan for rain water harvesting measures at plant site

shall be submitted to harvest rainwater from the roof top

and storm water drains to recharge the ground water and

Chap-4

Chap-4

Chap-4

N.A.

Chap-4

Chap-4

Page-119-121

Page-129

Page137-143

N.A.

Page-182-189

Page-179




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

also to use for the various activities at the project site to

conserve fresh water and reduce the water requirement

from other sources.

XI. Total capital cost and recurring cost/annum for

environment pollution control measures shall be included.

XII. Action plan for post-project environment monitoring shall

be submitted.

XIII. Onsite and offsite disaster (Natural and Man-

Made)preparedness and Emergency Management Plan

including Risk Assessment and damage control. Disaster

management plan should be linked with District Disaster

Management.

Chap-6

Chap-6

Chap-7

Page-206

Page-197-205

Page-207-221

8. Occupational health

Details of existing Occupational & safety Hazards, What are the

exposure levels of above mentioned hazards and whether they are

within permissible Exposure level (PEL). If these are not within PEL,

what measures the company has adopted to keep them within PEL

so that health of the workers can be preserved.

Details of exposure specific health status evaluation of worker, if

the workers’ health is being evaluated by per designed format .

Chest x rays Audiometric, Spirometry, vision testing (Far & Near

Chap-4 Page-145-146




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

vision, colour vision and any other ocular defect) ECG during pre-

placement and periodical examinations give the details of the

same. Details regarding last month analyzed data of above

mentioned parameters as per age, sex duration of exposure and

department wise.

Annual report of health status of workers with special reference to

Occupation health and safety

Plan and fund allocation to ensure occupational health & safety of

all contract casual workers.

9. Corporation Environmental policy

I. Does the company have a well laid down environment

policy approved by its Board of Directors? IF so, it may be

detailed in the EIA report

II. Does the environment policy prescribe for standard

operating process / procedures to bring into focus any

infringement / deviation / violation of the environmental of

forest norms / conditions? if so it may be detailed in the EIA

III. What is the hierarchical system or Administrative order of

the company to deal with the environmental issues and for

ensuring compliance with the Environmental clearance

conditions? Details of the system may be given

Chap-9

Page-245-252




Sl.

NO.

TOR Points Coverage

in Chapter

Page No/

clause no

Remarks

IV. Does the company have system of reporting of non

compliances / violations of environmental norms to the

board of directors of the company and / or share holders

Or stake holders at large? this reporting mechanism shall

be detailed in the FIA report

10. Details regarding infrastructure facilities such as sanitation, fuel

restroom etc To be provided to the labors force during construction

as well as to the casual workers including truck drivers during

operation phase.

- - The facilities shall be made

available, once the works

permission made available

11. Enterprise social commitment(ESC)

i. Adequate funds (at least 2.5% of the project cost )shall be

earmarked towards the enterprises social commitment based on

public heating issued and item wise details along with time bound

action plan shall be included. Socioeconomic development

activities need to be elaborated upon.

Chap-7 Page-241-242

12. Any litigation pending against the project and / or any direction /

order passed by any court of law against the project, if so details

thereof shall also be included. Has the unit received any noticed

under the section 5 of environment (Protection) act 1986 or

relevant section of air and water acts? if so details of and complies

/ATR to the notices and presents status of the case.

N.A. N.A. New Project




ADDITIONAL TORS FOR INTEGRATED STEEL PLANT

1. Iron ore/coal linkage documents along with the status of

environmental clearance of iron ore and coal mines

- - Iron ore shall be available

from captive mines

2. Quantum of production of coal and iron ore from coal & iron ore

mines and the projects they cater to mode of transportation to the

plant and its impact

N.A. -

3. For large ISPS, A3-d view i.e. DEM (Digital Elevation Model) for the

area in 10 km radius from the proposal site. MRL details of project

site and R.L of nearby sources of water shall be indicated.

- - Drawing will be submitted

4. Recent land use map based on satellite imagery. High-resolution

satellite image data having 1 m - 5m spatial resolution like quick

bird. Ikonos, IRS P-6 pan sharpened etc for the 10 km radius area

from proposed site .The same shall be used for land used /land-

cover mapping of the area.

Chap-3 -

5. PM (PM10 and PM 2.5) present in the ambient air must be analysed

for source analyses, natural dust RSPM generated from plant

operation (trace elements) of PM 10 to be carried over.

Chap-3 -

6. All stock piles will have to be on top of a stable liner to avoid

leaching of materials to ground water.

- - All stockpiles shall be on top of

stable liners to prevent

leaching to ground water

7. Plan for the implementation of the recommendations made for the

steel plants in the CREP guidelines

Chap-4 - CREP described

8. Plan for slag utilization Chap-4 - Slag will be granulated and

sold to cement plant




9. Plan for utilization of energy in off gases (Coke oven, blast furnace) Chap-2 - Off gases shall be used as fuel

in mills and remaining used for

power generation

10. System of coke quenching adopted with justification. Chap-2 - Coke dry cooling will be used

11. Trace metals mercury, arsenic and fluoride emissions in the raw

material

- - Shall be submitted to

MOEF&CC once project

becomes operational

12. Trace metals in waste materials especially slag - - -do-

13. Trace metals in water Chap-3 -


PROPOSED 3.5 MTPA INTEGRATED STEEL PLANT & 295 MW

CPP AT HALAVARTHI, KOPPAL, KARNATAKA

EXECUTIVE SUMMARY OF

ENVIRONMENTAL IMPACT ASSESSMENT (EIA) &

ENVIRONMENTAL MANAGEMENT PLAN (EMP)

POLLUTION & ECOLOGY CONTROL SERVICES NAGPUR –, INDIA


Executive Summary of 3.5 MTPA Integrated Steel Plant & 295 MW CPP At Halavarthi, Koppal,

Karnataka

ES- 2

CONTENTS

SN. Description Page No.

1.

2.

3.

4.

5.

6.

7.

8.

9.

INTRODUCTION

PROJECT DESCRIPTION

DESCRIPTION OF THE ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION

MEASURES

ENVIRONMENTAL MONITORING PROGRAMME

ADDITIONAL STUDIES

PROJECT BENEFITS

ENVIRONMENTAL MANAGEMENT PLAN - ADMINISTRATIVE

ASPECTS

SUMMARY AND CONCLUSION

ES-1

ES-1

ES-3

ES-6

ES-12

ES-13

ES-13

ES-13

ES-14



Karnataka

ES- 3

1.0 INTRODUCTION

The national steel policy has set a target of 110 million tons of steel production by

2020 and to increase it to a level of 300 million tons by 2030. In view of the above,

AISL intends to establish the Integrated Steel Plant of 3.5 MTPA along with 295 MW

power from waste gases. The proposed plant will be built within the company

acquired land.

In pursuance of Environmental (Protection) Act, 1986 and Notification of 14th

September 2006, new projects or steel plant of any existing plant necessitates

statutory prior environmental clearance by conducting an Environmental Impact

Assessment (EIA) study. AISL entrusted PECS to conduct an EIA/EMP study for their

proposed steel plant.

2.0 PROJECT DESCRIPTION

2.01 Location

The GPS coordinate as observed for the plant centre is given below: Longitude: 760

14’ 45’’ E Latitude: 150 20’ 25’’ N, near Koppal district in the state of Karnataka. The

site is at a distance of 5 km WNW from Koppal, 30 km from Hospet and about 320 km

from Bangaluru by road. Nearest railway station to the steel plant is Ginigera about

3.5 km. Broad gauge railway lines between Guntakal and Hubli are passing through

this station. The western port of Goa is 320 km.

2.02 The Project

The product mix of the proposed project is presented in Table ES.1

Table ES.1: Proposed Product Mix for Steel Plant

The product mix envisaged for Phase-1 stage

Sl. Type of Product Grades Size range

(mm)

Annual production

(Metric tons)

1 Bar Mill

Wire rod in coils DQ, BBQ, CHQ, BQ,

FCS, Spring steel

5.5-16 200,000

Bars in straight length ACS, CCS, BQ,

Spring Steel

16-69 400,000

Sub Total (a) 600,000

2 Billet Mill

Round bars ACS, CCS, BQ, 60-200 150,000



Karnataka

ES- 4

Spring Steel

Squares (RCS) ACS, CCS 60-200 50,000

Flats ACS, CCS, BQ,

Spring Steel

60-140 50,000

Sub Total (b) 250,000

Grand Total 850,000

The suggested product mix at phase-2

The tentative annual product mix at full rated capacity will be:

(1) Hot rolled coils for sale: 990,000 t

(2) Hot rolled cut Plates/sheets: 485,000 t

(3) Cold rolled coils and sheets: 567,000 t

(4) Galvanized coils and sheets (saleable): 180,000 t

(5) Colour coated coils and sheets: 190,000 t

----------------

Total saleable steel products at Phase-2: 2,412,000 t

The project is needed to increase Steel Production in the country as per National Steel Policy

to bridge the gap between demand and supply.

The details of proposed facilities, products and their production capacities are presented in

consolidated manner in Table ES.2.

Table ES.2: DETAILS OF PROPOSED FACILITIES AND PRODUCTION

CAPACITIES

Sl.

No.

Plant Units Phase-I Phase-II Final Plant

Configuration

1 Coal Washery 1x3.0 MTPA - 1x3.0 MTPA

2 Ore Beneficiation Plant 1.2 MTPA - 1.2 MTPA

3 Pellet Plant with coal

gasifier unit

1x1.2 MTPA - 1x1.2 MTPA

4 Sinter Plant 1x144 m2

1.29 MTPA

1x324 m2

3.8 MTPA (1x144)+(1x324) m

2

5.09 MTPA gross sinter

5 Coke Oven 1x0.68 MTPA

2x55 Ovens 5.5

m tall

1x1.5 MTPA

2x65 Ovens 7.0 m

tall

2.1 MTPA Coke Oven

battery

2x55 ovens 5.5 m tall




Karnataka

ES- 5

6 Blast Furnace 1x1681m3 BF

1.2 MTPA

1x3814 m3 BF 2.6

MTPA

1x1681m3+1x3814 m3

BF 3.8 MTPA hot metal

BF slag 343,000 788,000 1,131,000 tpa

7 SMS

a)

EOF(EnergyOptimizing

Furnace)/BOF (Basic

Oxygen Furnace)

2x65 t EOF 2x180 t BOF

furnaces

(2x65)t EOF+ 2x180t

BOF

b) LF (Ladle Furnace) 2x65 t 1x180 t 2x65 t +1x180 t

c) VD / RH Degasser 2x65 t VD 1x180 t RH

Degasser

2x65 t VD +1x180 t RH

Degasser

f)

Billet Caster/ Bloom

Caster

2x3 Billet

Caster +1x2

Bloom caster

- 2x3 Billet Caster +1x2

Bloom caster

h) Slab Caster - 2x1 strands slab

caster

(2x1) Strand

8. Billet & Bar Mill 0.25 MTPA - 0.25 MTPA

9. Bar & Rod Mill 0.60 MTPA - 0.60 MTPA

10. Hot Strip Mill - 2.5 MTPA slab

input

2.5 MTPA slab Input

11. Cold Rolling Mill with

continuous Pickling Line

- 1.00 MTPA hot coil

input

1.00 MTPA hot coil

input

12. Hot Dip Galvanizing /

Galvalume Unit

- 0.4 MTPA CR coil

input

0.4 MTPA CR coil input

13. Colour Coating Unit - 0.2 MTPA

Galvanizing Coil

Input

0.2 MTPA Galvanizing

Coil Input

14. Oxygen Plant 1x550 TPD 1x1100 TPD 1650 TPD

15. Lime Plant (Out

Sourced)

2x300 TPD 1x600 TPD 1200 TPD

16. Dolo Plant (Out

Sourced)

1x300 TPD _ 300 TPD

17. Captive Power

Plant(CPP)

1x70 MW from

CFBC based

Boiler+ 6 MW

TRT from BF-1

2x100 MW

conventional

based on washed

coal + 12 MW TRT

+ 7MW WHRB

based

295 MW CPP from

CFBC/WHRB/TRT/coal

reject/middling/washed

coal

18. Material Handling Plant

for both phase

Matching Matching Matching



Karnataka

ES- 6

3.0 DESCRIPTION OF THE ENVIRONMENT

3.01 General

The study area has been taken as 10km radius around the project site. The baseline

environmental data were generated during March 1, 2016 to May 29, 2016 covering

Summer season

3.02 Meteorology

A meteorological station was set up at existing MSPL administrative building. In

summer season the predominant wind directions observed from SW direction. It has

been observed that the temperature varied between a minimum of 19.2°C to a

maximum of 38.9°C indicating significant temperature changes. Relative humidity

was in the range of 20 to 96 %. The observed value of Relative humidity indicates

moist weather condition.

3.03 Water Environment

Five ground water samples and Five surface water samples were taken and

analysed. Summary description is as follows:

The pH values for all ground water samples are ranging between 7.1 to 7.7, whereas

pH values for all surface water samples are ranging between 6.8 to 8.2. These

values are within desirable range of 7.5 to 7.9 as per IS 10500:2012 standards for

drinking water.



Karnataka

ES- 7

All surface water samples have Dissolved Oxygen levels ranging from 5.6 to 6.8

mg/l. The Surface water samples have BOD values ranging from 15.0 to 29.0 mg/l.

These results indicate very low organic pollution load. All BOD values are within the

prescribed limit (< 30.0 mg/l) as in IS 2490:1982. All surface water samples have

COD values in range between 45.0 to 104.0 mg/l. All water samples are indicating

very low organic pollution load in terms of COD. All COD values are well below the

prescribed limit (< 250.0 mg/l) as in IS 2490:1982).

The total solids in ground water are in the range of 486.2 to 663.2. All surface water

samples have dissolved solids ranges from 196 to 727 mg/l which are well below

Permissible limit of 2000 mg/l as per IS 10500:2012.

The chloride concentrations in all ground water samples have ranged between 70.3

to 256.7 mg/l and all surface water ranges from 41.2 to 220.2 mg/l these values are

below permissible limit of 1000 mg/l as prescribed in IS 10500:2012.

The Sulphate concentrations for all ground water samples are ranging between 21.2

to 143.4 mg/l, and all surface water samples ranges from 14.3 to 128.6 mg/l these

values are below acceptable limit of 200 mg/l as prescribed in IS 10500:2012.

All ground water samples have hardness in the range of 272 to 428 mg/l and all

surface water samples ranges from 154 to 267 mg/l which are below the permissible

limit of 600 mg/l

All the ground water and surface water samples have fluoride content within the

range of 0.1 to 0.3 mg/l which are much lower than acceptable limit of 1.0 mg/l as

per in IS 10500:2012. .

All ground and surface water samples have low nitrate concentrations ranged

between 0.2 to 21.7 mg/l, and much below the acceptable limit of 45 mg/l as per in

IS 10500:2012.

Heavy metals, Boron and other trace elements in all water samples are either absent

or wherever present were below their respective permissible limits.

3.04 Ambient Air

Nine AAQ monitoring stations were monitored. The results of PM10, PM2.5, SO2,

NOx, CO & NH3 at all the monitoring stations were well within the respective

permissible limit for industrial, residential, rural and other areas (Table ES.3).



Karnataka

ES- 8

Table ES.3: Average Values of AAQ in Summer Season as Compared with CPCB

Norms

AAQ Station/CPCB

Standards PM 10

(µg/m3)

PM 2.5

(µg/m3)

SO2

(µg/m3)

NOX

(µg/m3)

NH3

(µg/m3)

Proposed Steel Plant

Site

53.2 24.2 12.5 21.1 BDL

Adjacent to Pellet

Plant

44.6 23.5 11.8 19.5 BDL

Allangara Village 47.3 24.9 13.1 23.2 BDL

Hire Baglani vi llage 44.8 24.9 13.1 23.2 BDL

Kunikeri Tanda

Vil lage

41.3 25.8 16.1 27.2 BDL

Huvinahalu Vil lage 47.2 26.2 19.8 28.3 BDL

Koppal Village 41.6 19.8 13.8 24.2 BDL

Belanalu Village 40.2 23.7 15.5 27.8 BDL

Basapur Village 46.6 25.9 12.9 21.9 BDL

Industrial, Residential,

Rural & other Area Norm

(24hr./*1hr.Av)

100 60 80 80 400

Samples of air were collected and analysed for CO content. All sampling stations

have very less CO content (< 0.2 mg/m3) in comparison of stipulated annual

average 2 mg/m3 limit recommended for sensitive area in revised NAAQ Standards

from MoEF&CC.

Representative samples from all sampling stations were collected and analysed for

gases and compounds i.e. Ozone, Ammonia, Benzene &Benzo (α) Pyrene. The

concentrations of these gases & compounds were absent.


Toxic Metals i.e. Lead, Arsenic & Nickel. The concentrations of Toxic Metals were

below detectable limit.

Overall Ambient Air Quality of the plant area and its buffer zone is good and there

are no any abnormal values recorded.

3.05 Soil

Soil samples were analysed from five locations. The soils are more or less in the

region of neutral pH. Aavailability of Nitrogen, Phosphorus and Potassium were high

to low in most of the soils Organic carbon content is low to medium in most of the

samples. Overall the soil in the area is good for plant growth.



Karnataka

ES- 9

3.06 Ambient Noise

The noise monitoring was conducted at nine (9) locations all around the study area. It

has found that in the proposed plant buffer zone, noise levels are in the range of 38.0

– 55.5 dB(A) at all nine stations. Maximum levels of noise have recorded in day

hours which are natural as our most of activities have done in day hours.

3.07 Ecological Features

The study area, falls under Semi Arid climate region, sparsely populated and is

undulated and interspersed with small hillocks and hilly terrain. The study area is

predominantly rural with sparse patches of rural settlement. The study area contains

some degraded forest patches, containing scattered thorny scrubs. Extensive

grazing, biotic pressure and water scarcity are the main contributors to the present

stage of vegetation degradation. Due to lack of suitable habitat, bio–diversity of

mammals is low, only the common animals found in rural area are found. The

proposed plant is planned within the acquire land of the AISL premises and no forest

land is involved in the proposed plant.

3.08 Socio-economic Status

Basic Socio-economic Conditions and Land-use in the study area are as follows:

Population density in the area is high due to the dominance of urban areas.

Individual land holdings are small. Cotton constitutes the major crop of the area,

being cultivated in about 56.0% of the gross cropped area (GCA).

The employment rate is moderate many people are engaged in service and other

activities but agriculture still plays an important role in rural economy.

People spend major portion of their disposable income on food items. However

there is a growing tendency of higher expenditure allocation on non-food items.

4.0 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 Impact During Construction

The proposed plant will have sufficient land and all of the construction activity will be

limited within the AISL acquire land, with all infrastructural facilities. As such no

impact on land use and pollution generation during construction phase are expected.

Further, the impact of such activities will be temporary and will be restricted to the

construction phase only.



Karnataka

ES- 10

4.2 Operational Phase Impact

4.2.1 Air Environment

Impact on Air Environment

AISL will be a green field integrated steel plant capacity of 3.5 MTPA including 295

MW power generating from waste gases. Accordingly, the emissions are estimated

for 3.5 MTPA ISP. The prediction of Ground level concentrations (GLC) of pollutants

emitted from the stacks have been carried out using ISCST-3 / AERMOD Air Quality

Simulation model. It is expected that after the implementation of integrated steel plant

RPM, SO2 and NOx will increase. The predicted GLC values at different receptor

points is given in Table ES.4.

Table ES.4: Prediction of GLC's at 3.5 MTPA combined phase 1+2 (μg/m3)

Location

Code

AAQM location RPM (PM10)

Back Ground

value

From stack

prediction

Total

A1 Project Site 56.5 4.06 60.56

A2 Adjacent to Pellet Plant 49.5 4.06 53.56

A3 Allangara Village 53.0 8.12 61.12

A4 Hirabaglani Village 48.6 4.06 52.66

A5 Kunikeri Tanda Village 45.3 0.00 45.30

A6 Huvinahalu Village 50.5 4.06 54.56

A7 Koppal village 46.5 8.12 54.62

A8 Belanalu Village 44.5 8.12 52.62

A9 Basapur Village 49.6 16.24 65.84

Norm 100

Location

Code

AAQM

location

SO2 NOX

BG* Phase-

1+2

Total BG* Phase-

1+2

Total

A1 Project Site 16.3 0.00 16.3 27.7 0.00 27.7

A2 Adjacent to

Pellet Plant 13.9 0.00 13.9 23.3 0.00 23.3

A3 Allangara

Village 18.0 2.16 20.16 29.5 3.95 33.45

A4 Hirabaglani

Village 17.8 2.16 19.96 31.4 3.95 35.35

A5 Kunikeri Tanda 20.7 2.16 22.86 31.7 0.00 31.7



Karnataka

ES- 11

Village

A6 Huvinahalu

Village 24.4 2.16 26.56 31.1 3.95 35.05

A7 Koppal village 21.6 4.33 25.93 28.7 3.95 32.65

A8 Belanalu

Village 18.5 4.33 22.83 33.4 3.95 37.35

A9 Basapur

Village 15.4 6.49 21.89 26.3 11.85 38.15

Norm 80 80

Mitigation Measures

Air pollution control measures envisaged will be designed suitably so as to meet

the air emission norms as given by MOE&F and CPCB Stack monitoring to

ensure proper functioning of different major stacks

Air monitoring in the Work-zone will be to ensure proper functioning of fugitive

emission control facilities.

Monitoring of ambient air quality will be as per KSPCB directives.

Workers will be provided with adequate protective measures to protect them from

inhaling dust.

4.2.2 Water Environment: Impacts

The requirement of water for the integrated steel plant will be 4170 m3/Hr (22.24

MGD) considering about 6% loss of water during treatment, which will be met

from the Tungabhadra Reservoir located at a distance of about 20 Km from the plant

site, from where raw water will be pumped to the plant storage reservoir. No impact

on ground water is envisaged as no ground water will be drawn.

Mitigation Measures

Re-circulating water in the process whereby discharged volume is minimum.

Clarifier and sludge pond for removal of suspended solids.

Neutralisation of acidic water by lime.

Removal of oil and grease from the contaminated water by means if oil traps,

skimming devices, etc.

Effluent quality monitoring at inlet and outlets of different effluent treatment plants

to ensure proper functioning of different effluent treatment facilities.

Use of treated wastewater in different shops and for plantation development as

far as practicable.



Karnataka

ES- 12

4.2.3 Solid Waste Disposal: Impacts

Solid waste generated from different units and disposal is given in Table ES.5.

Table ES.5: Solid Waste Generation and Disposal

Solid Waste Total generation at

full capacity (tons)

Utilization and mode Disposal as

wastes

Phase-1 Phase-2

Coal/coke dust 11,854 12,653 100% utilized in coal blend

charge in the coke oven

complex

Nil

Undersize coke 26,000 59,200 100% utilized in sintering

plants as a bed material for

heat energy

Nil

Tar sludge 240 256 To be used along with coal

charge in the coke ovens

Nil

Acid sludge from

by-product units

100 100 - To be neutralized

and disposed as

landfill.

Lime sludge from

PCM

450 To be used as neutralizing

agent

Nil

Iron bearing dusts

from dust

catchers/ESPs/Ba

g filters

232,980 556,669 To be used along with the

charge mix in the sintering

plants. The design has

provisions to use these.

Nil

Blast Furnace

granulated slag

362,208 822,298 To be sold to cement plants

for making blast furnace slag

cement

Nil

Steel making slag 150,000 324,000 Only iron bearing portion of

the steel slag would be

recovered and iron to be

used in steel making. A

small % of the steel slag can

be used in Blast furnace as

source of lime.

These would be

used as landfills

either inside the

plant or in the

neighborhood

Iron oxide from

acid regeneration

plant of Cold

rolling mills

40,000 To be sold to users like

Ferro magnet industry, iron

powder industry etc.

Nil



Karnataka

ES- 13

Power plant fly

ash

127,360 490,758 To be sold to fly ash brick

makers and cement plants

making fly ash cements

Nil

Power plant

Bottom ash

31,840 122,689 Cannot be used in the

processes adopted.

To be used as land

fill

Arising of

skull/scraps

94,197

(114,197)

*

191,315 To be used in steel making

for re-melting.

Nil

Rejects after Two

stage WHIMS

treatment in the

fine ore

beneficiation

plant.

4,44,188

(Dry)

To be temporarily stocked at

the designated site in the

plant and later transported to

a nearby ore mine pit for re-

filling and green

development.

Phase-1:

Phase-2: 4,44,188 t

Refractory wastes 10,880 26,849 Un-contaminated (80%)

bricks will be sold (for

construction) or crushed to

be used as mortar.

About 20% of the

waste bricks which

are contaminated

with slag/skull etc.

would have to

discarded and

dumped in landfills.

Muck/sludge/wast

es

5,050 7,750 Cannot be re-used

Total arising 1,053,159 3,098,723 174,066 (16.53%) 870,968 (28.2%)

Mitigation Measures:

All attempts to utilise solid waste as per the guidelines given in CREP.

4.2.4 Noise Levels: Impacts

During plant operations noise generated will be close to the compressors and blowers

and will be confined within plant boundary, thus will not have any impact out of the

plant boundary.

Mitigation Measures: The following measures will be undertaken to mitigate noise

and its impact:

Plugging leakages in high-pressure gas/air pipelines.

Reducing vibration of high speed rotating machines by regular monitoring of

vibration and taking necessary steps.



Karnataka

ES- 14

Design of absorber system for the pulpit operator's cabin.

Noise absorber systems in pump houses.

Noise level at 1m from equipment will be limited to 85 dB (A).

The fans and ductwork will be designed for minimum vibration.

Periodical monitoring of work zone noise and outside plant premises..

Un-manned high noise zone will be marked as "High Noise Zone".

In shops where measures are not feasible, attempts shall be made to provide

operators with soundproof enclosure to operate the system.

Workers exposed to noise level will be provided with protection devices like

earmuffs as per present practice and will be provided with rotational duties.

Regularly check-up of workers for noise related health problem and if detected

proving alternative duty.

4.2.5 Ecological Features: Impact

Since the change in ambient air quality due to emissions from the proposed

integrated steel plant will be small, vegetation in study area will not be damaged. The

effluent discharge from the plant will not be allowed beyond the surface water

discharge norm, thus there will be no impact on the ecological components of surface

water bodies in the area.

Mitigation Measures: Green Belt Development

The green belt which works as sink for emission shall be well planned covering

boundary and surrounding various shops. This will mitigate dust emission generating

from operational plant.

4.2.6 Occupational Safety and Health: Impacts

Working operation of integrated steel plant is cumbersome and negligence in plant

operations may cause risk to safety and health problems of employees.

Mitigation Measures

Proper control of fugitive dust from sources inside plant including open

stockyards. The dedusting systems provided in shops will be regularly monitored

for proper functioning and the level of dust in working zone will be reported to the

management and ensure necessary control action.



Karnataka

ES- 15

Keeping ventilation systems of premises in perfect working order and regular

cleaning of air filters.

Based on the environmental monitoring for dust, gases, noise & vibration, the

workers exposed to these shops will be regularly checked in medical unit and

results will be intimated to management.

Spot cooling facilities will be provided for workers exposed to high heat generating

shops and will be checked periodically.

House Keeping Measures

Regular cleaning and watering of plant roads to avoid accumulation of

dust/garbage

Regular cleaning of shop floors

Avoiding accumulation and dumping of wastes and damaged equipment and

items anywhere inside the plant affecting aesthetics.

Developing a positive outlook in the employees for keeping the work place, both

in factory, office or laboratory, clean and well maintained.

Mitigation Measures

The community development efforts of AISL for its stakeholders will continue to

fulfill their aspirations.

AISL will have structured interactions with the community to disseminate the

measures taken by the steel plant and also to elicit suggestions for overall

improvement for the development of the area.

4.2.7 Technological Mitigation Measures

Air Pollution

Pollution control measures envisaged in the proposed steel plant units will be

designed for emission levels of less than 50 mg/Nm3 and the details for different units

shall be as follows:

Coke Oven Batteries

a. High Pressure Liquor Aspiration (HPLA) System

b. Efficient Charging Cars

c. Hydro Jet Door Cleaners

d. Leak Proof Oven Door

e. Pushing Emission Control (PEC)



Karnataka

ES- 16

e. Dry-fog Dust Suppression System in Coke Cutter / Coke Conveyor

Sinter Plant

For sinter plant, dry type electrostatic precipitator (ESP) will be provided. Further,

there will ESP systems for plant de-dusting for different material transfer points.

Waste heat utilization has been envisaged for the preheated sinter mix before feeding

to sinter bed.

Blast Furnace

The measures envisaged for the blast furnaces, viz.

Coal Dust Injection (CDI).

Gas Cleaning System

Cast House Dedusting System:.

Mixer and De-sulphurisation Unit: A fume extraction system comprising of bag filter,

centrifugal fan etc will be provided for dust generated during mixing and

desulphurisation.

Steel Making and Primary Refining: Basic Oxygen Furnace (BOF): Gas cleaning plant

will be provided. Secondary Refining: A fume extraction system will be provided

comprising of suction hood, associated duct, bag filter and centrifugal fan etc for the

dust generated during secondary refining.

Raw Material Handling Area: In RMH area dust extraction system will comprise of one

set of pulse jet type bag filter & centrifugal fan. Dust suppression system will also be

provided at various junction houses.

5.0 ENVIRONMENTAL MONITORING PROGRAMME

The environmental aspects will be monitored to ensure proper implementation and

effectiveness of various mitigative measures envisaged / adopted for the proposed

steel plant are:

Maintenance of Drainage System

Meteorology observations

Plant Stack Emissions Monitoring

Solid / Hazardous Waste Generation & Utilization inventorisation



Karnataka

ES- 17

Green Belt Development implementation schedule

Occupational Health and Safety and House Keeping records

Effluent Quality report

Work Zone Air Quality and Work Zone Noise

Ambient Air Quality and Ambient Noise

Ground Water and Soil Monitoring

The estimated capital cost of the steel plant of AISL will be around Rs. 17,979 Crores

and the item wise estimated cost towards environmental protection and enhancement

measures are given in Table ES.6.

Table ES. 6: Cost of Environmental Protection Measures (Rs. Crores):

S

N

Environmental Protection Measures Recurring Cost per

annum

Capital Cost (Rs.

Crores)

1 Air Pollution Control 50 400

2 Water Pollution Control 15 80

3 Noise Pollution Control Included in item

no.1

Included in 1

4 Environment Monitoring Programme 0.46 5.0

5 Green Belt 0.10 8.0

6 Others (Solid waste management,

ventilation / air conditioning, fire fighting

etc.)

42 307.0

Total 107.56 800

Training Facilities

To achieve the objective of pollution control, training will be given to employees to

cover, Awareness of pollution control & environmental protection / management;

Operation and maintenance of specialised pollution control equipment; Field

monitoring, maintenance and calibration of pollution monitoring instruments;

Occupational health/safety, Disaster management, etc.



Karnataka

ES- 18

6.0 ADDITIONAL STUDIES

Risk Assessment

AISL will be having a well-documented "On Site Disaster Management Plan".

Hazards shall be listed and risk assessment shall be carried out for complete plant

setup. SOP shall be prepared for preventive measures.

Socio-economic Assessment

People are happy with the peripheral developmental activities carried out by

AISL/MSPL & are looking for the same in future also. Overall peoples’ perception on

the project is good.

7.0 PROJECT BENEFITS

There shall be Improvements in physical & social infrastructure of the region.

There will be a positive employment and income effects, both direct as well as

indirect.

Peoples’ interest towards education will increase due to the expectation of getting

jobs.

There will be change in pattern of demand among people by way of shift from

food items to non-food items.

Increase in industrialisation in the vicinity of AISL, which will bring more skill

diversification among local people.

8.0 ENVIRONMENTAL MANAGEMENT PLAN – ADMINISTRATIVE ASPECTS

The implementation and monitoring of effectiveness of the environmental mitigation

measures during the operation phase will be assigned to the Environmental

Management Department of AISL. An Environmental Management Unit, comprising

of senior management level officers will periodically assess and monitor the

implementation of mitigation measures and environmental monitoring programme,

and tackle the bottlenecks of the implementation of mitigation measures.

9.0 SUMMARY AND CONCLUSION

In the plant design itself latest state of art technology has been envisaged so as to

achieve the air emissions and noise levels from plant operation and the effluent

quality below statutory norms. Further, maximum re-use and re-utilisation of



Karnataka

ES- 19

generated solid waste and wastewater has been envisaged. The plant shall work on

zero discharge philosophy.

The EIA report has thoroughly assessed all the potential environmental impacts

associated with the project. The environmental impacts identified by the study are

manageable. Site specific and practically suitable mitigation measures are

recommended to mitigate the impacts. Further, a suitably designed monitoring plan

shall be provided to monitor and control the effectiveness of envisaged mitigation

measures during the operation phase.


EIA/EMP for 3.5 MTPA Integrated Steel Plant & 295 MW CPP At Halavarthi, Koppal, Karnataka

Page 1 of 262

CHAPTER-1: INTRODUCTION

1.0 INTRODUCTION

M/s AARESS IRON & STEEL LIMITED (AISL), is a flag ship company of Baldota

group of companies. The proposed integrated steel plant at Koppal shall be the most

modern, technologically efficient and eco-friendly integrated steel plant in India.

AISL intends to establish the Integrated Steel Plant of 3.5 MTPA along with 295 MW

power from waste gases. The proposed plant will be built within the company

acquired land. With this, AISL will be in a stronger position to supply a wide variety of

steel products to the consumers in South and Central India. The product mix that will

be offered by AISL will include flat products, long products, wire rods, re-bars,

besides the semis like billets, blooms and HRC.

This is an EIA / EMP report for the proposed Integrated Steel Plant of 3.5 MTPA

along with 295 MW power generating facility. The report is prepared as per the

procedure specified in 14th September 2006 Notification of Ministry of

Environment and Forests (MoEF&CC).

1.1 PURPOSE OF THE REPORT

In pursuance of Government of India policy vide Environmental (Protection) Act,

1986, any project necessitates statutory prior environmental clearance in

accordance with the objectives of National Environmental policy as approved by

the Union Cabinet on 18th May, 2006 and MoEF&CC EIA Notification dated

14.09.06, by preparing Environmental Impact Assessment (EIA) report. All the Steel

plants are kept at S.N. 3(a) under Category A and are appraised at the Central level.

In view of the above, the EIA report has been prepared taking into consideration the

requirement and guidelines of statutory bodies and also client’s requirement.

The objective of the EIA study report is to take stock of the prevailing quality

of environment, to assess the impacts of proposed industrial activities on

environment and to plan appropriate environmental control measures to minimize

adverse impacts and to maximize beneficial impacts of proposed project. The

following major objectives have been considered:

Assess the existing status of environment.

Additional impacts, due to the proposed project

Suggest pollution control and ameliorative measures to minimize/reduce the impacts

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 suggested environmental control plans.

Clearances from statutory authorities



Page 2 of 262

1.2 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

1.2.1 Nature of the Project

The proposed project falls under Category ‘A’ (Sl. No. 3 (a) of Schedule: "Primary

and Secondary Ferrous Metallurgical Industries"). It intends to maintain production of

long and flat products based on BF-EOF/BOF route.

1.2.2 Size of the Project

AARESS IRON & STEEL LIMITED (AISL), is a flag ship company of Baldota group

of companies and has proposed to establish an Integrated Steel Plant capacity 3.5

MTPA including 295 MW CPP from waste gases to meet growing domestic demand

of long/flat products in today’s market conditions. Further, size of the project is of

crucial importance for making it economically viable. At the same time the proposed

project will help in long term development of the region and the state of Karnataka.

1.2.3 Project Proponent

AARESS IRON & STEEL LIMITED(AISL) intend to establish an Integrated Steel

Plant at Koppal, Karnataka based on BF-EOF/BOF process route for steel making

and 295 MW CPP. MSPL a group company operates a 1.2 MTPA Pellet Plant on

adjacent land.

1.2.4 Importance of the Project

The Indian steel industry is poised for faster growth in the decades ahead as the

industrial and economic development of the country gains pace. The total steel

consumption of finished steel has been estimated to touch 120 MTPA in the year

2022 from the current level of over 100 MTPA compared to China’s (Our neighbor)

steel production of >500 MTPA. Even after approximately doubling the production

capacity, the per capita domestic consumption would continue to be substantially

below the world average of 197 Kg. Therefore, there is a good prospect of domestic

steel consumption growing at about 6 – 8% up to the year 2018. The national steel

policy has set a target of 110 million tonnes (MT) of steel production by 2020 and to

increase it to a level of 300 million tones by 2030. AISL is well positioned to fulfill its

role in the nation’s quest for higher growth and development in the new millennium.

The growth of the steel industry significantly contributes to economic growth of the

Nation as well as to the region, as it generates employment both directly and also

due to development of downstream industries. The infrastructural and other social

amenities grow in the region leading to overall development of the region.

1.2.5 Location of the Project

The GPS coordinate as observed for the plant centre is given below:

Longitude: 76o12’9.78” E, 76o13’58.16”E



Page 3 of 262

Latitude: 15o19’34.32”N, 15o20’52.49”N near Koppal district in the state of

Karnataka. The site is at a distance of 5 km WNW from Koppal, 30 km from Hospet

and about 320 km from Bangaluru by road. Nearest railway station to the steel plant

is Ginigera about 3.5 km. Broad gauge railway lines between Guntakal and Hubli are

passing through this station. The western port of Goa is 320 km. Location map is

shown as Fig. 1.1.

1.3 SCOPE OF THE STUDY

The Terms of Reference (TOR) has been finalized during the 2nd- 3rd July 2015

meeting of the reconstituted Expert Appraisal Committee (Industry) of Ministry of

Environment & Forest, Climate Change for preparation of EIA/EMP report for

Integrated Steel Plant (3.5 MTPA) along with Captive Power Plant (295 MW) near

villages Halavarthi, district Koppal, Karnataka.

1.4 BASIC DATA GENERATION, FIELD STUDIES AND DATA COLLECTION

This report has been prepared on the basis of one full season baseline

environmental data monitored and completed during March 2016 to May 2016 by

MoEF&CC recognized M/s Nilawar Laboratory, Nagpur. The data includes

meteorological conditions, ambient air quality, noise, water quality and soil quality.

Site survey has been conducted for studying the flora and fauna, socio-economic

conditions including public consultation, land use, hydrology, geology, ecology etc.

Additional information is also collected from several agencies and departments, both

under State and Central Governments pertaining to above.

The collected data have been analysed in detail for identifying, predicting and

evaluating the environmental impacts of the proposed project. The maximum

anticipated impacts on environment are assessed and suitable environmental

management plan has been suggested.

1.5 REPORT COVERAGE

The report provides information on the existing state of environmental conditions

vis-a-vis contribution of incremental pollution by the proposed plant. These

environmental factors include air quality, surface water & ground water quality, soil

quality, flora & fauna, agricultural pattern, health & welfare facilities, transport &

communication systems, socio-economic patterns etc. The report evaluates the

predicted impact of the proposed project activities on all the above factors. The

report also covers the various remedial measures considered by the plant

management like upgradation to technological processes, air and water pollution

control system, solid wastes re use opportunities, green belt development plans

along with the environmental management system proposed to be adopted by the

Company. A detailed coverage of background environmental quality, pollution

sources, anticipated environmental impacts (including socio-economic impacts) and

mitigation measures, environmental monitoring programme, additional studies,



Page 4 of 262

project benefits, environmental monitoring plan and all related aspects have been

covered in this report.

The report including this introduction chapter, includes:

Project Description

Description of the Environment

Anticipated Environmental Impacts and Mitigation Measures

Analysis of Alternatives

Environmental Monitoring Programme

Additional Studies: (Public Consultation, Socio-economic Studies and

Risk Assessment Studies)

Project Benefits

Environmental Management Plan (EMP)

Summary and Conclusion

Disclosure of Consultant engaged



Page 5 of 262

Fig. 1.1a LOCATION OF SITE



Page 6 of 262

Fig. 1.1b LOCATION OF SITE



Page 7 of 262

CHAPTER 2: DESCRIPTION OF PROJECT

2.0 PROJECT DESCRIPTION

2.1 Introduction

AARESS Iron & Steel Limited is a MSPL Group company and intends to establish 3.5

MTPA integrated steel plant including 295 MW CPP from waste gases at Village

Halavarthi, District Koppal (Karnataka). MSPL Limited is a flagship company of the

Baldota Group of Companies and is one of the largest iron ore mining company and

has the largest installed capacity of green energy in the country.

AARESS Iron & Steel Limited is a new company promoted by MSPL group to install

an integrated steel plant including a captive power plant at Koppal in Karnataka. The

process had started in 2007 itself when the purchase of land through KIADB at

Halavarthi, district Koppal, Karnataka had begun. Today the company is in

possession of 922.19 acres of land in the Ist phase and another 995.50 acres are in

the process of acquisition/purchase out of which about 65 acres purchased. The

company intends to install a 3.5 MTPA Integrated Steel Plant in two phases along

with 295 mw of power from waste gases. The first phase will be with a capacity of 1

million tons of crude steel finishing to long products catering to the alloy and special

steel market of India and abroad. The land required for the Ist phase is already in the

possession of company. The IInd phase will produce 2.5 MTPA of crude steel with a

separate set of facilities for hot rolled coils with downstream facilities of cold rolling,

coil processing and coating facilities. To improve the flexibility of the plant with

respect of fine iron ore, facilities of beneficiation of fine ore will be provided. This

report is for the total 3.5 MTPA integrated steel plant complex to be set up in two

phases.

Facilities Envisaged in the Steel Plant

The list of facilities as envisaged in this Feasibility Report is given below:

Sl.

No.

Plant Units Phase-I Phase-II Final Plant

Configuration

1 Coal Washery 1x3.0 MTPA - 1x3.0 MTPA

2 Ore Beneficiation Plant 1.2 MTPA - 1.2 MTPA

3 Pellet Plant with coal

gasifier unit

1x1.2 MTPA - 1x1.2 MTPA

4 Sinter Plant 1x144 m2

1.29 MTPA

1x324 m2

3.8 MTPA (1x144)+(1x324) m

2

5.09 MTPA gross sinter

5 Coke Oven 1x0.68 MTPA

2x55 Ovens 5.5

m tall

1x1.5 MTPA

2x65 Ovens 7.0 m

tall

2.1 MTPA Coke Oven

battery





Page 8 of 262

6 Blast Furnace 1x1681m3 BF

1.2 MTPA

1x3814 m3 BF 2.6

MTPA

1x1681m3+1x3814 m3

BF 3.8 MTPA hot metal

BF slag 343,000 788,000 1,131,000 tpa

7 SMS

a)

EOF(EnergyOptimizing

Furnace)/BOF (Basic

Oxygen Furnace)

2x65 t EOF 2x180 t BOF

furnaces

(2x65)t EOF+ 2x180t

BOF

b) LF (Ladle Furnace) 2x65 t 1x180 t 2x65 t +1x180 t

c) VD / RH Degasser 2x65 t VD 1x180 t RH

Degasser

2x65 t VD +1x180 t RH

Degasser

f)

Billet Caster/ Bloom

Caster

2x3 Billet

Caster +1x2

Bloom caster

- 2x3 Billet Caster +1x2

Bloom caster

h) Slab Caster - 2x1 strands slab

caster

(2x1) Strand

8. Billet & Bar Mill 0.25 MTPA - 0.25 MTPA

9. Bar & Rod Mill 0.60 MTPA - 0.60 MTPA

10. Hot Strip Mill - 2.5 MTPA slab

input

2.5 MTPA slab Input

11. Cold Rolling Mill with

continuous Pickling

Line

- 1.00 MTPA hot

coil input

1.00 MTPA hot coil

input

12. Hot Dip Galvanizing /

Galvalume Unit

- 0.4 MTPA CR coil

input

0.4 MTPA CR coil input

13. Colour Coating Unit - 0.2 MTPA

Galvanizing Coil

Input

0.2 MTPA Galvanizing

Coil Input

14. Oxygen Plant 1x550 TPD 1x1100 TPD 1650 TPD

15. Lime Plant (Out

Sourced)

2x300 TPD 1x600 TPD 1200 TPD

16. Dolo Plant (Out

Sourced)

1x300 TPD _ 300 TPD

17. Captive Power

Plant(CPP)

1x70 MW from

CFBC based

Boiler+ 6 MW

TRT from BF-1

2x100 MW

conventional based

on washed coal +

12 MW TRT +

7MW WHRB

based

295 MW CPP from

CFBC/WHRB/TRT/coal

reject/middling/washed

coal

18. Material Handling Plant

for both phase

Matching Matching Matching

TYPE OF PROJECT

The proposed project falls under Category ‘A’ (Sl.No. 3 (a) of Schedule : "Primary

and Secondary Ferrous Metallurgical Industries") of the “List of project or activities



Page 9 of 262

requiring prior environmental clearance” of MoEF&CC notification dated 14th

September, 2006 in connection with Environment (Protection) Rules 1986.

NEED FOR THE PROJECT

Steel being a basic commodity for all industrial activities, quantum of its consumption

is considered as an index of industrial prosperity. Since independence, there has

been a substantial growth in the steel production in India from 1.5 Mt in 1950-51 to

about 60 Mt in 2007-2008. Despite the above growth in the steel sector, the per

capita finished steel consumption continues to remain at a level of about 48 kg only,

compared to about 350 kg to 626 kg in the developed countries and 197 kg as world

average. Further, with nearly 20% of the world population, India’s contribution is only

of the order of 3.4% of world steel production. Hence, short-term and long-term

strategies are necessary in planning the development of the steel industry in the

country to improve the level of per capita steel consumption. While modernisation of

the existing steel plants in India may increase steel output marginally, setting up of

new steel plants facilities will be essential to meet the increasing steel demand. The

demand availability projections and product mix has been separately treated for alloy

and special steels in Phase-1 and carbon steel for phase-2.

The product mix envisaged for Phase-1 stage will be:

Sl. Type of Product Grades Size range

(mm)

Annual production

(Metric tons)

1 Bar Mill

Wire rod in coils DQ, BBQ, CHQ, BQ,

FCS, Spring steel

5.5-16 200,000

Bars in straight length ACS, CCS, BQ,

Spring Steel

16-69 400,000

Sub Total (a) 600,000

2 Billet Mill

Round bars ACS, CCS, BQ,

Spring Steel

60-200 150,000

Squares (RCS) ACS, CCS 60-200 50,000

Flats ACS, CCS, BQ,

Spring Steel

60-140 50,000

Sub Total (b) 250,000

Grand Total 850,000

The planned product mix at phase-2 is:

The tentative annual product mix at full rated capacity will be:

(1) Hot rolled coils for sale: 990,000 t

(2) Hot rolled cut Plates/sheets: 485,000 t

(3) Cold rolled coils and sheets: 567,000 t

(4) Galvanized coils and sheets (saleable): 180,000 t

(5) Colour coated coils and sheets: 190,000 t

-----------------

Total saleable steel products at Phase-2: 2,412,000 t



Page 10 of 262

The project is needed to increase Steel Production in the country as per National

Steel Policy to bridge the gap between demand and supply.

LOCATION

The steel plant is proposed to be located adjacent to NH-63 near Koppal and about

26 km from Hospet in Bellary district of Karnataka. It is adjoining the village

Halavarthi. The land profile is undulating and contours vary from lower value of 517.8

to 540.0 m. The area falls in the Survey of India topo sheet No. 57A/3. About 418 ha

of land (approximately 1935 m x 2164 m have already been acquired by the

company for the purpose of the project, which is sufficient for phase-1 project of 1

million ton alloy and special steel plant. For accommodating phase - 2 units

completely, the process of acquiring additional land is in progress. It is anticipated

that a total 775.89 ha of land would be finally available for meeting the entire need of

the 3.5 million ton project.

SIZE OR MAGNITUDE OF OPERATION

The project is of 3.5 MTPA Integrated Steel Plant in two phases along with 295 MW

of power from waste gases. The first phase will be with a capacity of 1 million tons of

crude steel finishing to long products catering to the alloy and special steel market of

India and abroad. The second phase will produce 2.5 MTPA of crude steel with a

separate set of facilities for hot rolled coils with down ward facilities of cold rolling, coil

processing and coating facilities. The process-cum-material flow for the proposed

plant is given in Fig. 2-1.

PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION

It is envisaged to complete the installation and commissioning of the plant equipment

for startup and production in 30 months for Phase-1 facilities. It is envisaged to

complete the installation and commissioning of the plant equipment for startup and

production in 36 months for Phase-2 facilities. The additional time is envisaged on

account of larger % of imported components at phase-2 and relative difficulty in

construction due to presence of an operating plant at the site. The time schedule is

from ZERO date which in this case is the date of placement of order for the major

plant equipment. This period will cover detailed engineering, supply, erection and

commissioning of the units.

The interspacing between the two phases is not certain at the present. It will depend

on the market demand of steel flat product and prices as well as the availability of

funds from institutional sources. Generally a spacing of 2-3 years is expected

between commissioning of one phase and start of construction of the next phase.

From that point of view, the full 3.5 million ton phase of the plant could be completed

in about 8 years’ time from the phase-1 zero date.



Page 11 of 262

2.7 GENERAL LAYOUT AND TRANSPORTATION

The land requirement of the project is summarized below:

Sl. Description Unit Phase-1 Phase1 +2

1 Total area envisaged Ha 418 712

2 Steel plant including CPP Ha 189.3 322.67

3 Green belt Ha 129.17 256.0

4 Water pond area Ha 10.4 23.6

5 Road area Ha 29 38.63

6 Area for rail track,

conveyors etc

Ha 31.9 56.02

7 Total built up area Ha 256.2 432.32

8 Built up area out of total

area

% 63.44 64.04

The proposed general lay out of the steel plant for both the phases is given in the

drawing ENV/AISL/FR/GL/001(R-2) enclosed.

Adjacent to the raw material storage yard, the plant railway yard has been planned.

This 2 km long yard is planned on side of units consuming bulk raw materials roughly

at the centre of the total 3.5 million site running from north to south. Initially, it will

cater to phase-1 and then would be extended to cater to phase-2. The railway yard

will be connected to the present Ginigera railway station (on the Bellary – Hubli line)

which is 17 Km from Hospet. Ginigera station facilities and yards are being expanded

by Railways as a part of doubling of Hospet-Hubli line for ease of connectivity with

Bellary-Hospet area with Goa port.

Road facilities

7.0 m wide (2 lane) road with side shoulders of 2 m width and side drain (11 m ROW)

is proposed around the main plant units and for the raw material storage yard.

2 x 7 m (Four lane) roads with drains and shoulders of 4 m as above and raised

median strip of 1.5 m wide (21 m ROW) is proposed from NH up to the Raw material

storage yard.

The area will also have some minor roads –single lane (7 m ROW)

Trees will be planted on both sides of main roads and in the median of the two main

arterial roads.

The paved areas /hard standing have been planned for storage areas and

approaches to the individual shops/units.

Rail transport equipment proposed to be acquired by the plant is envisages to be as

follows:

(1) 700 HP Diesel Loco 2+2 (Phase-1 & 2)

(2) Internal wagons BOX/BOXN 58 tons: 40 (Phase-2)

(3) Rail weigh bridge 100 t capacity 1

Raw Material Handling & Storage Facilities

The proposed raw material handling plant is located south of the water reservoir and

will be used in both phase-1 and phase-2. It will cover receipt, unloading, storage and

supply of various raw materials to all the units. In order to meet the raw material



Page 12 of 262

requirement for the proposed steel plant, the raw material handling facilities shall be

planned to cater to the present requirement of the 1 million ton stage and will be so

conceived to enable scaling of facilities to cater to the requirement of the 2.5 million

stage of phase-2.

The raw materials of the various units will be received by railway wagons or by

trucks. For unloading of raw materials two number of wagon tipplers are envisaged at

the wagon tippler complex. Two numbers of boom type stacker cum re-claimer are

envisaged at phase -1. One will be basically for ore and the other for coal and lime

stone/dolomite. At phase-2, all the beds will be expanded and would utilize the

available area. A second set of two stackers cum re-claimers will be installed to meet

the increased material handling load. Shovels also will be used at phase-2 for

reclaiming lime stone and dolomite. The tentative capacity envisaged for each of the

stacker cum re-claimer will be: For iron ore and lime stone: stacking 1100 tph and

reclaiming 800 tph. For coal: stacking: 900 tph and reclaiming 500 tph. The locations

of the different beds are indicated in the General layout drawing.

2.8 TECHNOLOGY & PROCESS DESCRIPTION

The material flow charts for the major technological units starting from raw materials

to finished products for both the phases are given in AISL/FR/Material Flow R-1

(sheets 1 through 4). The brief description of the major units and the main

technological indices are given in the sections below:

2.8.1 Coke Oven Batteries:

Top charging by-product recovery type Coke Oven Batteries have been envisaged for

both the phases of the steel plant for supply of coke for the blast furnaces. 2 nos. of 5

m tall batteries at phase-1 and 2 nos. of same size batteries have been envisaged at

phase-2 for uniformity of design & operation and battery machines. The batteries will

be by-product recovery type, twin flue under-jet, regenerative design with fire clay

and silica construction. Dry Quenching of coke with an emergency provision of wet

quenching will be provided for each battery pair at each phase. The following are the

main features of each of the four coke oven batteries.

1. By-Product type Battery size: Two Batteries, 69 ovens each, 5 m tall battery at

each phase.

2. Battery dimensions (Typical):15.04 m x 0.410 m x 5 m

3. Oven useful dimensions 14.3 m x 0.410 (0.39/0.43)m x 4.7 m

4. Useful Chamber volume 27.3 m3

5. Coking time 18 hrs.at phase-1. In phase -2 all the four batteries will operate at

16.9 h coking period.

6. No. of pushing per day per battery: 92 in phase-1 and 98 in phase-2.

7. Dry Coal throughput per day/Battery 1883.7 t (Phase-1); 2000.6 (Phase-1 & 2)

Analysis of blended coking coal: Moisture: 8% (max); Ash: 10-14%; VM: 23-24%;

S: 0.58% (max): FCI: .5-4.5: LTGK: F to G; Fluidity:300-4000 ddpm; Reflectance:

1.12(Min)

8. Dry Coal throughput per year/Battery: 687,550 t (Phase-1) 732,391t (Phase-1&2)



Page 13 of 262

9. Gross coke yield from imported coking coal blend 72.4% (Phase-1); 72.7%

(Phase-2)

10.Gross coke per year /battery 4,97,787 t (Phase-1) 5,32,448 t (Phase-1&2)

11 BF coke (+25 mm) yield from coal input 63.8% (Phase-1)63.8% (Phase-2) Coke

Quality envisaged: Ash: 16-18%; CSR: 65 (Min); CRI: 21 (max)

12 BF Coke per year /battery 4,38,657 t (Phase-1) 4,67,265 t (Phase-1 & 2)

13 By-Products generation:

(a) Coke Oven gas: 25,150 Nm3/Hr per Battery in Phase-1; 26,778 Nm3/Hr per

Battery in Phase-2

(b) The annual generation of other by-products is given below:

Sl. Item Unit At Phase-1 At Phase-2

Per battery For the twin

Battery

Per battery For the twin

Battery

1 Ammonium

Sulphate

t/yr 7,563 15,124 8055 32,220

2 Crude tar t/yr 21,314 42,628 22,774 91,096

3 Sulphur Cake t/yr 820 1640 873 3492

2.8.2 Sintering Plant and Auxiliaries

2.8.2.1 The Blast furnaces of the steel plant in both the phases will use about 77% of iron

bearing materials as iron ore sinter. The rest will be lump ore in phase-1 and large

quantity of the lump ore will be replaced by acid pellets at phase-2 with the

commissioning of the new pellet plant proposed as a part of the steel plant complex.

It is proposed to install one sinter plant at each phase to take care of the input

requirement of the blast furnace installed and the size/ capacity of the sinter plant has

been envisaged to match the blast furnace requirement.

2.8.2.2 Technical Characteristics of the sintering plants

The following are the main characteristics of the sintering plants proposed at Phase-1

and Phase-2.

Sl.

No.

Parameter Phase-1: (SP-1) Phase-2: (SP-2)

1 Sinter machine type Dwight Lloyd type

with circular cooler

Dwight Lloyd type

with circular cooler

2 Sintering machine grate area 144 m2 360 m2

3 Productivity 1.4 t/m2/h 1.35 t/m2/h

4 No. of days working per year 330 330

5 No. of hours/day working 24 24

6 Gross Sinter production per

year

1,596,000 t 3,850,000t

7 Ignition energy from mixed gas 15,000 Kcal/t of

sinter

15,000 Kcal/t of

sinter



Page 14 of 262

8 Under grate suction 1650 mm WC 1650 mm WC

9 Height of the sinter bed 700 mm 700 mm

10 Cooler Circular with heat

recovery system

11 Maximum Dust in exhaust gas

going to stacks attached to

ESPs and bag filters.

40 mg/Nm3 40 mg/Nm3

12 Temperature of cooled sinter < 100 Degree C < 100 Degree C

13 Sinter returned from BF 10% max 10% max

14 Air pollution measured to be

taken

4/5 field ESP for

the main sinter

machine ; 4 field

ESP for extracting

dust from fugitive

emissions in the

sintering area and

separate bag filter

systems for

extracting dust

from isolated dusty

areas.

4/5 field ESP for the

main sinter machine;

2 Nos. 4 field ESP

for extracting dust

from fugitive

emissions in the

sintering area and

separate bag filter

systems for

extracting dust from

isolated dusty areas.

2.8.2.3 Technical Parameters of the sintering machines

Sl. No. Item Specification

Phase-1 Phase-2

1 Sintering area (m2) 144 360

2 Pallet width (m) 3m 4 m

3 Side wall height (mm) 700 (max. bed height

650 mm)

730 (max. bed height

700 mm)

4 Speed of the machine

(m/min)

0.5 to 1.7 1.5 to 6.0

5 Ignition Furnace length

(m)

3m 5m including extended

hood

6 Burners 2 rows of roof mounted

burners

As per selected m/c

design.

7 Fuel Mixed gas (2000

Kcal/Nm3)

Mixed gas (2000

Kcal/Nm3)

8 Under grate suction (mm) 1400 1650

2.8.2.4 Pollution Control arrangements at the Sintering plant

4 or 5 Field ESP to de-dusting of the main sintering plant waste gas to the off gas

chimney – 80 m installed for each machine at each phase.

4 Field ESP for de-dusting of all transfer points, proportioning building, sintering

building, circular cooler and screen room points where dust is generated and are

covered with dust collection hoods to 50 m chimney for each unit of sintering.



Page 15 of 262

Units located at further points like FFC unit and FS unit and underground hoppers to

have separate dust extraction systems comprising of bag filters, exhaust fan and 30

m chimneys with attached dust humidifiers.

The chimney outlet waste gases will have less than 40 mg/Nm3 of dust content.

All collected dust from hoppers below the ESPs and bag filters will be moistened and

reused in the sintering process.

Water will be recycled after passing through settling and oil removal.

2.8.3 Iron Ore Fine Beneficiation Plant

(1) It has been decided subsequent to preparation of the PFR for the project to

skip the new pellet plant of 1.2 million ton capacity in the final FR. The total lump

ore/pellet requirement of the plant after completion of both the phases at 3.5 million

ton stage will be about 1.5 million tons. The capacity of the pellet plant already

installed in the project site through a group company is 1.2 million ton per annum

which can be increased marginally also. In view of this, the entire lump ore required

by the plant at both stages can be more or less met through acid pellet input from this

sister unit. However, the quality of fines (in terms of Fe %) is generally poor in

Karnataka. It will be imperative therefore to use low grade fines at least partly as

input iron ore for sintering process after beneficiation. At the same time, the cost and

space required to process the discards in iron ore beneficiation unit (materials with

less than 40% Fe) are constraints to increase the capacity of beneficiation operation.

(2) As a compromise, it is envisaged that for the fine ore feed of the plant at both

the phases 50% of the input fines will of grades lower than 60% which will be

beneficiated and blended with better grade fines (around 64% Fe) to obtain an

average Fe% in the sinter feed fine ore at 62.1% as envisaged in the sinter plants. .

(3) The annual fine ore requirements (net and dry) for the sinter plants at

planned production levels at rated capacity for both the phases are given below:

Phase-1: 1,292,760 t

Phase-2: 2,949,748 t

Total 4,242,508 t

It was also noted that the group operates two mines in the Hospet sector: Viom High

grade deposit (Fe: +65%) output around 1.6 million tons per year and Iyli (captive

mine) a comparatively poorer grade deposit (Fe- 56-60%) 0.5 million tons production

per year. But the present rule of selling iron ore in Karnataka through open auction,

does not guarantee the AISL plant to receive ore supply from captive group sources.

Further, the reserves in both the deposits are limited and cannot cater to the need of

the plant for a very long period. So even for phase-1 facilities, AISL plant will have to

procure iron ore from the neighborhood and include poorer ores also to keep the

landed cost of ore at economic levels.

(4) It is therefore envisaged that the fines to be used would be a blend of direct

use fines and beneficiated low grade fines. A 50:50 ratio is envisaged. The reduction

in the beneficiated fines in the total ore fines will also reduce the extent of rejects.

The rejects (with Fe <40%) as per environmental requirement need to dewatered,

relocated to assigned dumps and treated for green cover.

(5) It is therefore envisaged to procure about 2.3 million ton fines with +64% Fe

and 3.361 million ton fines of Fe% in the range of 55-56%. The lower grade ore to be

beneficiated to yield maximum of sinter grade fines (2.2 million tons) and a small



Page 16 of 262

quantity will be further beneficiated through magnetic separation to yield pellet grade

beneficiated fine ore which can be converted to pellets at the pellet plant run by the

group company. It may be seen that the scheme proposed is flexible enough to

beneficiate the Iyli ore to sinter grade and pellet grade feeds if required.

It may be seen from above that the capacity of the beneficiation process after phase-

1 and Phase-2 has been envisaged as 3.361 million ton of fine ore throughput. The

input will be Fine iron ore (-) 10 mm with Fe% ranging between 55-56%. This ore will

be primarily upgraded to sinter grade fines of about 60% Fe and the small quantity of

the tailings of the primary beneficiation process will be upgraded to +64% Fe pellet

feed concentrate in the secondary magnetic concentration plant with or without ball

mill grinding. It is envisaged that the both the beneficiation plants would operate

312.5 days in a year and 24 hours a day giving 7500 operating hours in a year.

A. Inputs and Outputs (In terms of dry ore) after phase-1 and 2 facilities.

Item Annual tons Tons per hour % Fe

Input Ore

(-)10 mm low grade ore 3361,000 448.1 56.5

Output ore

+ 8 mm fraction to lump

stock

336,000 44.8 56.5

Beneficiated fines 2,252,250 300.3 60.12

Tailings for further

beneficiation

772,500 103 49.88

It is envisaged that the sinter fine beneficiation unit will be able to upgrade fine ore

from an average analysis of Fe 56.5 to 60% with about 23% as tailings with less than

50% (49.88% Fe has been tentatively calculated) Fe. Such material however cannot

be discarded now as per current mining regulations and the net quantity of discards

needs to be limited to keep disposal costs of discards at a reasonably low level.

So treating these discards with Wet High Intensity magnetic Separation (WHIMS)

process is envisaged. The product of such separation would be essentially fine

grained and can be employed as pellet making feed only. For up gradation of 49.88%

Fe fine ore to a minimum 64% Fe material for pellet plant feed proper liberation of the

Fe bearing mineral will be needed. In the absence of any test report of the material to

be actually used, it is difficult to say whether it would be possible to upgrade to this

extent without grinding. However, recent tests with slimes derived from the tailing

ponds of fine washing plants of several iron ore mines have shown that generally it is

possible to upgrade the slimes without any further grinding. Even then it is desirable

to provide flexibility in the magnetic beneficiation unit. So in this report two circuits of

beneficiation have been envisaged. The first circuit uses the slimes without any

further grinding. The steps are de-sliming with hydro cyclones, followed by magnetic

separation in two WHIMS machines. The concentrate as well as tailings are

thickened in separate thickeners and the thickened products are dewatered to 10%

maximum moisture in two separate filter presses. In the second circuit, the slimes are

first ground in a ball mill and then de-slimed in hydro cyclone followed by two stage

concentration with WHIMS.



Page 17 of 262

The concentrate after de-watering in a press filter will be converted to pellets. The

tailings which would contain less than 40% Fe will also be dewatered in press filters

and temporarily dumped in the assigned area inside the plant. But for environmental

reasons, these would have to be subsequently shifted to mine site to fill in abandoned

mine areas.

2.8.4 The Blast Furnace Complexes

2.8.4.1 The Blast furnace complexes in the two phases will comprise of:

Phase-1: Blast furnace of 1680 m3 useful volume along with auxiliaries.

Phase-2: Blast furnace of 3814 m3 useful volume along with auxiliaries.

In phase-1 the blast furnace will operate with sinter, lump ore or partially pellets,

coke, coal dust, fluxes and other additives. In phase-2, depending on the

commissioning of the pellet plant (1.2 million ton capacity), the lump ore will be

mostly replaced with pellets.

2.8.4.2 Technological Parameters of the Blast Furnaces

The technological parameters envisaged in the two blast furnaces as envisaged in

the two phases are summarized in the table below:

Sl.

No.

Parameter Phase-1 Phase-2

Blast Furnaces Envisaged

1 Useful volume (m3) 1680 3814

2 Productivity envisaged (t/m3/day) 2.0 2.0

3 Production per day (tons) 3360 7628

4 No. operating days per year 350 350

5 Gross Hot metal production per

year (tons)

1,176,000 2,669,800

6 Coke rate dry at belt/skip

(Kg/THM)

420 420

7 Screening loss from BF coke to

skip coke (%)

10 10

8 CDI rate (Kg/THM) 150 155

9 Slag rate (Kg/THM); dry

granulated

280 280

10 Gross granulated slag (10%

moisture) Kg/THM

308 308

11 Slag basicity 0.96 0.96

12 Top pressure (Atmosphere) 1.5 2.0

13 Hot blast temperature Deg. C 1200 maximum

(operating 1050-

1100 Deg. C)

1250 maximum

(operating 1100 -

1150 Deg. C)

14 Blast humidity (gm/Nm3) 40-45 45-50

15 Blast volume Nm3/THM 1030 1030



Page 18 of 262

16 Blast furnace gas generation

(Nm3/THM)

1680 1680

17 CV of BF gas 810 800

18 Stoves 3 4

19 Stove type Vertical, ceramic

vertical burners,

silica dome.

Vertical, ceramic

vertical burners,

silica dome.

20 Skull and ladle loss from gross to

net hot metal

2.5% 2.5%

21 PCM yield from net Hot metal 92% 92%

22 TRT rating 6 MW 12 MW

2.8.4.3 The specific and quantitative consumption of major raw materials in the two blast

furnaces are given below:

Sl.

No.

Parameter Phase-1: BF-1 Phase-2: BF-2 Total

requirement at

Phase-2 (t/yr)

1 Iron Ore Lump/Pellets

(Kg/THM)

390 (458,640) 390(1,041,222) 1,499,862

2 Skip Sinter(Kg/THM) 1290(1,516,200) 1289(3,441,372) 5,017,572

3 Skip/Belt Coke (Kg/THM) 420(493,920) 420(1,121,316) 1,615,236

4 CDI Coal (Kg/THM) 150(176,400) 150(400,470) 576,870

5 Lime stone (Raw) (Kg/THM) 85(99,960) 85(226,933) 326,893

6 Dolomite (Raw) (Kg/THM) 70(82,320) 70(186,886) 269,206

7 Mn Ore (Kg/THM) 6(7,056) 6(16,018) 23,074

8 Quartzite (Kg/THM) 24(28,224) 24(6,405) 34,629

The details of technological characteristics of the input raw materials and the

products from the blast furnace complex Viz. Hot metal (Liquid iron); granulated slag

and blast furnace gas as plant fuel are given in Chapter.

Both the blast furnaces will have coal dust injection systems with oxygen enrichment

of blast to support higher coal injection rates and top recovery turbines to recover the

energy of the high pressure top gases before scrubbing and reducing to near

atmospheric pressure.

2.8.4.4 Environment control measures envisaged in the Blast Furnace Complexes

(a) Air Pollution Control

Blast furnace off gas is a valuable fuel. It is removed of its dust load first at the dust

catchers, which is basically a cyclone separator to precipitate bigger dust particles.

The gas is further washed at the gas cleaning units. The cleaned blast furnace gas

(with dust content less than 5 mg/Nm3) is fit to be a fuel for use in gas burners and is

used in stove heating and as a general plant fuel for reheating of as mixed gas after

mixing with coke oven gas and Converter gas (after phase-2). The off gases of

furnaces using these gases burnt with air do not require any further dust separation

units.



Page 19 of 262

The Blast furnace hot metal and slag runners are planned to be covered with

retractable covers as now internationally practiced. The cast house and the area

around tuyeres would have de-dusting hoods to suck the ambient air and to clean

those in ESPs or bag filter houses. Both are possible and used and would depend on

the final economics. The other dusty areas of the blast furnace like the stock house,

junction houses etc. will have suction hoods leading to Bag filters and 40 m height

chimneys. Closed dusty areas which are wide and are difficult to cover with hoods will

be kept dust free by employing dry fog process. In some open areas simple spray de-

dusting can keep dust away.

Each of the slag granulation boxes will have a stainless steel 40 m chimney to let out

the granulation stream.

The solid dust recovered from the blast furnace complexes (called flue dust) are

collected and used as source of iron and fluxes in the sintering machine charge mix.

These are sent to the dedicated areas of the sintering plant.

(b) Water pollution control

(1) The blast furnace and stove cooling water is clean water involved in indirect cooling.

This water is cooled in cooling towers and re-circulated.

(2) The gas cleaning plant water is laden with dust. The dirty water is first clarified in

circular clarifiers and then passed through oil removal unit before re-use.

(3) The granulated slag comes out of the granulation boxes in the form of water slurry.

This slurry is de-watered in rotary filters. The filtrate water is filtered again and cooled

and re-used with addition of makeup water.

The solid recovered from gas cleaning plant water treatment also contains iron oxide

and used in sintering plants and later in the pelletizing plant as charge mix.

(c) Other solid wastes

(1) Most of the scrap, jams and iron muck are sent to the steel melting units for re-

melting.

(2) All blast furnace slag is granulated, de-watered and used in cement plants along with

conventional cement clinkers to be ground for making Blast furnace slag cement.

(3) Refractory wastes: Major arising of refractory wastes is at the time of blast furnace or

stove relining and capital repairs. Otherwise major refractory waste arising is from the

ladle repair shop from de-bricking of ladles. Some bricks are re-used, some ground to

mortar and those mixed with slag or muck are dumped for filling.

2.8.5 Steel Making Facilities

For phase-1 facility, Energy Optimizing Furnace (EOF) process of steel making has

been selected along with bloom and billet continuous casting. In phase-2, the steel

making process of choice is Basic Oxygen Converter Furnace (BOF) process with

continuous casting of slabs.



Page 20 of 262

2.8.5.1 Facilities envisaged at Phase-1are:

2 Nos. of 50/55 ton Energy Optimizing Furnaces (EOF)

1300 t inactive mixer or 300 t torpedo ladles (2 Nos.)

Ladle refining furnace of 55 tons capacity

Vacuum degassing unit of 55 ton capacity.

Bloom caster (1 No.)

Billet caster (2 Nos.)

The parameters of the EOF shop are envisaged as

Sl.

No.

Parameter Phase-1 Remarks

1 Nominal heat size 50 t (55 t max)

2 Tap to tap time 45 minutes

3 Heats per day from both the

EOFs

60 ( 64 max)

4 Operating days per year 320-340 15-16 days down time per

year.

5 Annual production of liquid

steel from the shop

960,000-

1,020,000 t

Av. 1,000,000 t

6 Average yield of liquid steel

from metallic inputs.

83.8%

The other facilities in the EOF shop will include:

(a) Hot metal handling system including the mixer, the open top ladles/torpedo

ladles and the de-sulphurization station.

(b) Scrap storage and handling yard

(c) Flux and Ferro-alloy handling system including the overhead bulk material

bunkers and Ferro-alloy bunkers.

(d) Steel handling in steel ladles placed on self propelled transfer cars for passing

to the LRFs and VD and then to the Continuous casting bay.

(e) Slag handling by dumping on the ground, cooling of slag and removal with

dozers.

(f) Gas cooling and cleaning.

The specific consumption of incoming materials in the EOF furnace is given

below:

Sl.

No.

Parameter Specific Consumption

1

Hot Metal (Kg/TLS) 824

Steel /Cast Iron scrap (Kg/TLS) 185

DRI/Sponge iron (Kg/TLS) 185

Calcined lime (Kg/TLS) 80

Calcined Dolomite (Kg/TLS) 25

Oxygen (Nm3/TLS) 70



Page 21 of 262

Petroleum coke (Kg/TLS) 2

De-oxidant Ferro-alloys (Kg/TLS) 10

Aluminum (Kg/TLS) 1

Ca-silicide (Kg/TLS) 0.2

Alloying elements (Kg/TLS) 10

Refractory (Kg/TLS) 20

The details of the caster to be installed in Phase-1 with the EOF shop are as follows:

Sl. No Item Unit Bloom caster Parameters

Billet caster Parameters

1 Heat size T 55 55

2 Type of CCM - Radial with curved mould

Radial with curved mould

3 Designed section size sq. mm 200 x 200 to 350 x 350 150 x 150 – 250 x 250

4 Basic radius of the machine M 12 9

5 Straightening method Multi radius Multi radius

6 Average section to be cast mm x mm

300 x300 160 x 160

7 Casting speed for average section

m/min 0.6 2.5

8 Casting time Min 45 45

9 Casting practice Sequence casting Sequence casting

10 Heats in a sequence Nos. 4 05/06/16

11 Machine preparation time Min 45 45

12 No. of strands 2 4 for each machine

13 Ladle turret Lift able type Lift able type

14 Tundish Equipped with slide gate

Equipped with slide gate

15 Mould type and length Copper plate assembled mould , 900 mm

Copper plate assembled mould , 900 mm

16 Strand guide Curved, secondary cooling segment.

Curved, secondary cooling segment.

17 Withdrawal and straightening unit

DC drive, Hydraulically operated.

DC drive, Hydraulically operated.

18 Gas cutting unit Automatic oxy acetylene cutting torches

Automatic oxy acetylene cutting torches

19 Dummy bar Flexible type with bottom feeding arrangement

Flexible type with bottom feeding arrangement

20 Run out roll table AC individual driven rollers.

AC individual driven rollers.



Page 22 of 262

21 Marking unit Automatic. Automatic.

22 Bloom cutting length M 7 9/12/16

23 Yield of cast bloom from liquid steel

% 96 (average) 96 (average)

24 Caster working days Days 320 320

2.7.5.2 Steel making and casting facilities envisaged in Phase-2 are:

(1) The BOF shop comprising of

2x1300 t in-active mixers with provision of desulphurization of hot metal.

Scrap storage and handling system including baling press for processing light scraps.

2x150 tons BOF converters with bulk material feeding arrangement to overhead

charging bins, lance handling system, Ferro-alloy addition bins with chutes.

BOF gas collection, cleaning, cooling, recovery system including BOF gas holder.

2x150 t ladle Furnaces for temperature adjustment, desulphurization and trimming

addition for chemistry adjustment.

1x150 ton RH vacuum degassing unit of steel.

The qualities of steel envisaged to be produced in the BOF shop will include: (1) Mild

Steel (2) Low carbon steels (3) Medium carbon steels (4) Deep drawing quality steels (5)

Carbon constructional steels (6) Boiler grade steels (7) Galvanizing quality steels (8) Tin

plate quality steels.

(2) The basic parameters of the BOF shop is given below:

Sl.

No.

Parameter Phase-2

1 Mixers 2 x 1300t

2 Torpedo ladles Yes

3 Converters 2 x 150 t Both operating together

4 Nominal heat size 150 t

5 Tap to tap time 48 minutes

6 Heats per day from the shop 30

7 Operating days per year 300

8 Production of liquid steel 2,700,000

9 Casters : 2 nos. slab casters1650 mm wide

10 Consumption of metallic materials 1127 kg/TLs

11 Lining life with slag splashing 10,000 heats

12 Slag rate 120 kg/TLs

13 BOF gas rate 115 Nm3/TLs

14 BOF gas Calorific value 2000 Kcal/Nm3

15 Yield of cast slab from Liquid steel 95%

Specific Consumption of inputs

1 Hot Metal (Kg/TLs) 965

2 Scrap (Kg/TLs) 72

3 DRI/HBI(Kg/TLs) 90



Page 23 of 262

4 Burnt Lime/Dolo(Kg/TLs) 80

5 Oxygen (Nm3/TLs) 55

6 Nitrogen (Nm3/TLs) 30

7 Argon (Nm3/TLs) 1.2

8 Compressed air (Nm3/TLs) 20

9 Make up water (m3/TLS) 0.8

10 Power (KWH/TLS) 60

11 Steam (Kg/TLS) 95

12 Addition of Fe-alloys for de-oxidation

(Kg/TLS)

10

13 BOF gas used in the shop (Nm3/TLS) 2.5

14 Make up water (m3/TLS) 0.8

15 Consumption of desulphurization compound

(Kg/THM) processed Passivated Magnesium

powder Lime Powder

0.6

5.0

(3) The details of the slab casters are given below:

Sl.

No.

Parameter Value

1 No. of casters 2

2 Heat size (liquid steel) 150 t

3 Caster type Multipoint liquid core bending with

straight Mould.

4 No. of strands 1 x 1

5 Machine radius Tentatively 10,500 mm with multi point

unbending)

6 Mould type Vertical mould

7 No. of tundish cars 2 Nos.

8 Slab width (design) 950-1650 mm

9 Slab thickness 200-250 mm

10 Width changing On line changing facility to be provided

11 Slab length 7500 to 10,500 mm

12 Casting time of a heat 35-40 minutes

13 Machine preparation time (re-

stranding)

50 minutes

14 Yield (Liquid to slab) 98.5% (design)

15 Tundish practice Hot tundish

16 Liquid stream protection Refractory shroud between ladle and

tundish. And SEN between tundish and

mould

17 Dummy bar Flexible chain type – bottom fed

18 Mould oscillation Hydraulic mould oscillator suitable to

quick change practice

19 Mould level control Automatic mould level controller (Eddy

current type)

20 Secondary cooling Air mist/spray cooling (as per technology



Page 24 of 262

provider.

21 Soft reduction of strand Dynamic control

22 Gas cutting machine Oxy-Propane gas based

23 Slab identification Automatic slab marking machine

24 Slab discharge Roller table

25 Process control PLC controlled

26 Sequence casting Should be 10 heats approx.

27 Flying tundish Machine should be designed for flying

tundish also

28 No. of working days for Slab Caster 320 days

2.8.5.3 Environmental control measures envisaged in the steel making processes at both the

phases of the steel plant.

2.8.5.3.1 For EOF process, the following measures are envisaged for prevention of air and

water pollution.

The air pollution control measures include:

(1) The cooling and cleaning of the EOF waste gas. This gas has no heating value

and the cooled and cleaned gas is let out through a tall chimney of about 60m height.

The gas cleaning plant is envisaged to be of wet type and comprise of (a) refractory

lined down comer (b) quenching chamber (c) venturi (d) Cyclone separator (e) ID

fans and Chimney. Each of the two EOF furnaces is provided a separate gas

cleaning and cooling system with separate chimney of 50m height. The outlet of the

GCP is dirty water which is further treated.

(2) Maintaining the shop atmosphere and prevention of fugitive dust in the air is done

by installing suction hoods in all dusty places and use of bag filters to clean the dusty

air before release through medium height chimney (40-50 m)

(3) The fumes of the Ladle furnaces and VOD are also collected through a duct,

cooled in air cooled tubes and cleaned in bag filter houses before release through

chimneys.

Water pollution control in EOF shop

The dirty water from the waste gas cleaning plants in EOF shop is conveyed to a

thickener after dozing with chemicals for settling. The clear water from the thickener

is cooled in cooling tower and pumped back to the system. The collected mud has

60-70% Iron and is used in sintering plant and later in the pellet plant.

The cooling water for the furnace parts are clean water which are cooled in cooling

towers and re-circulated.

2.8.5.3.2 BOF shop

The BOF waste gas has valuable heat value and is re-used after cleaning and

cooling of the gas. For this project a dry type of gas cooling and cleaning system has

been envisaged. The system is described before. The cleaned BOF gas with a



Page 25 of 262

residual dust content less than 5mg/Nm3 is used as plant fuel in combination with

Coke Oven gas and Blast furnace gases and can be burnt with air with waste gas let

off without any pre-treatment.

The BOF shop also will have dust collecting hoods in particularly dust stressed areas

like the bulk material handling platform and transfer chutes the dust laden collected

air will be cleaned with bag filters. The areas like BOF furnace hoods and up-comer

will have evaporative cooling systems and would use DM water.

2.8.5.3.3 Pollution control measures at Continuous casting units.

The main treatment is for water. The strand cooling water is dirty laden with mill

scale. The water for each of the bloom/billet casters and the slab casters is collected

in scale pits for the scales to settle and the clear water overflows and is pumped to an

oil removing units after which the water is cooled and re-used. The scale is collected

from the pits with grab cranes and the scales are used in the sintering plants as

valuable Fe input.

The mould and machine cooling water used in the continuous casting machines are

used for indirect cooling and only needs cooling at cooling towers before re-use.

2.8.6 The hot rolling Mills

(1) It is proposed to install two hot rolling mills at Phase-1 to produce special and

alloy steel billets, bars and wire rods in the size range from 6.5 mm dia. to 200

mm dia for meeting the requirement of various special steel consumers and

industries. At phase-2, where flat products would be the line of products, a hot

strip mill to roll cast slabs to strips in the size range of 800-1550 mm and

thickness of 1.6 to 12 mm will be installed.

(2) The major parameters of the two hot rolling mills envisaged to be installed at

Phase-1(1 million ton facility) are given below:

Sl.

No.

Item Unit Bar & Rod Mill Billet & Bar Mill

1 Type of Mill Single strand

continuous mill

Single strand mill

2 Capacity of the Mill t/y 600,000 250,000

3 Rolling (operating ) speed

max

m/s 16 for bar dia. 16 mm,

110 for 5.5 to 8.0 mm

rods

4 No. of operating days in a

year (availability)

Days

/year

300 300

5 Shifts/day 3 3

6 Hot rolling hours Hrs 6000 5000

7 Utilization of available hours % 83 69.5

8 Reheating Furnace (Single) Walking beam type 150

t/hrs nominal capacity

Walking beam type 150 t/hrs

nominal capacity



Page 26 of 262

9 Input billets/Blooms 160 x160 x 12000;

2400 Kg

160-350 mm Square; 4-6 m

10 Fuel for reheating Mixed gas : CV 1900-

2000 Kcal/Nm3

Mixed gas : CV 1900-2000

Kcal/Nm3

11 Annual billet required t 625,000 260,000

12 Finished product size range Straight length

products:

Rounds16-60 mm

Wire rod in coils 5.5 to

16 mm

Bundle weight: 3000-

5000 Kg

Coil weight: 2500 kg

Coil ID: 860 mm ; Coil

OD: 1250 mm

Straight length products:

Rounds/RCS: 60-200mm

dia/sides. Flats 60-140 mm

13 Billet to product yield % 96 96

14 Specific Fuel Consumption GCal/T

of

billets

0.55 0.75

15 Specific Power consumption KWH/t 60 100

(3) The technical parameters of the Hot Strip Mill envisaged to be installed at Phase-2

with 2.5 million ton facilities are given below:

Sl.

No.

Item Unit Parameter

1 Type of Mill - Six stand 4 high finishing train with 4 high

reversing universal roughing stands and a coil

box. Two coilers; facilities of AGC; Work roll

shifting and work roll bending.

2 Capacity of the Mill t/y 2500,000

Based on 1050 mm x 2.8 mm coils; rolling rate at

reversing rougher – 474 tons/hr.

3 No. of operating days in a

year (availability)

Days/year 300

4 Shifts/day - 3

5 Hot rolling hours Hrs 5500

7 Utilization of available hours % 76

8 Reheating Furnace Two Walking beam type 300 t/hrs nominal capacity

each.

9 Input slab size 210 mm thick; 800 to 1550 mm; 10 m max length;

Weight 25.5 t max. .

10 Slab Quality Mild Steel, low Alloy Steel. Medium carbon steel.

(69 Kg/mm2 variety)

11 Annual slab required t 2,577,320

12 Rolled coil specification 1.6 to 12 mm thick

800-1550 mm wide

Maximum coil weight- 25.59 t



Page 27 of 262

Coil ID: 76 mm; OD: 2100 mm

13 Slab to product yield % 96.7

14 Specific Fuel Consumption G Cal/T of

Slabs

0.65

15 Specific Power

consumption in the mill

KWH/t 150

16 Connected load MW 30 MW (Mill proper) + 10 MW coil processing

facilities.

17 Specific consumption of

rolls

Kg/t of

coils

0.54

18 Specific consumption of

guides

Kg/t of

coils

0.52

19 Annual requirement of tying

straps

Tons 2500

20 Steam Tons/Hr 2

21 Compressed air (Dry) Nm3/Hr 5000

22 Lubricating oil Kg/t of

coils

0.06

23 Grease Kg/t of

coils

0.045

24 Hydraulic Fluid Kg/t of

coils

0.028

(4) Environment Control Measures in the hot rolling Mills

Air Pollution: The reheating furnaces in all the hot rolling mills will use mixed gas

(Blast furnace gas mixed with Coke Oven gas and BOF gas (At phase-2). Since

these gases are pre-cleaned before use as a fuel. The fuel gases are fully combusted

inside the furnace and the off gases do not contain any CO. Therefore, these off gas

normally do not require any treatment to remove dusts. These hot waste gases from

the re-heating furnaces are passes to heat re-cuperator to heat the combustion air

and the cooled gas is let out from a tall chimney. The iron oxide dusts carried with the

gases are usually deposited in the outgoing gas path and at the base of the chimney.

Water pollution: The major dirty water comes from the scale breakers; mill stands

cooling waters, bar cooling water post rolling which are laden with mill scale. Every

mill will have a scale pit to collect these water and the heavy mill scale will settle at

the bottom to be collected with grab cranes. The overflow water will pass through oil

removal systems to skim off any oil collected in the water from the mill bearings,

cooled in cooling towers and to be reused in the cooling water system after addition

of makeup water.



Page 28 of 262

2.8.7 Cold Rolling Mill complex

It is envisaged to install a Cold Rolling and Processing complex at the Phase-2 stage

of the steel plant for partly converting the hot rolled coils in the Hot Strip Mill to cold

rolled and processed products. The input capacity of the complex in terms of Hot

rolled coils will be 1 million tons per year. The entire input hot rolled coils will undergo

pickling in a continuous pickling line and cold rolling in a five stand 4 high/six high

tandem cold rolling mill. Out of the cold rolled coils, a part will be sent to the

galvanizing line of 400,000 t /year capacity. CGL will be coat the coils with zinc for

galvanized sheets (plane/corrugated) and the colour coating line and subsequent

slitting and cut to length lines for making colour sheets.

Since galvanizing lines take as rolled cold coils and has annealing and temper rolling

processes in built in the line, the batch annealing furnace section capacity will be

600,000 t of coils per year. The temper rolling mill will also have similar capacity. The

inspection, slitting and cut to length lines will cater to dispatch of about 600,000 t of

uncoated cold rolled coils. These will cater to the needs of smaller coating

installations.

The main sections envisaged in the cold rolling mill complex are:

(1) Hot coil receipt bay to receive and store coils of the following range:

Coil width: 600-1600 mm;

Thickness: 1.6 to 6 mm

Coil ID: 760 mm

Coil OD: 2100 mm

Maximum Weight: 26.6 tons

(2) Continuous Hydrochloric acid Pickling Line with capacity to pickle the entire 1 million

ton hot rolled coil input

(3) Continuous 1600 mm tandem cold rolling mill with five stands (four stands four high,

the fifth 4/6 high) with a combined motor power of 22,100 KW. In this report separate

pickling and separate cold rolling mill has been envisaged. However a coupled

pickling and cold rolling configuration is possible and would be decided at the time of

detailing.

(4) Strip cleaning line

Cold rolled coils meant for dispatch as cold rolled coils/sheets and required to be box

annealed in the subsequent process steps will pass through a Electrolytic Cleaning

Line (ECL) to remove the rolling oils from the strip so that these do not result black

soot patches while box annealing.

(5) Box Annealing Section

The section is envisaged to be having 40 bases; 20 furnaces and 20 cooling boxes.

The decision to go for only hydrogen annealing process or go for conventional H2 +

N2 annealing atmosphere will be taken at the time of writing detailed specification

depending on the market situation.



Page 29 of 262

(6) DCR skin pass Mill

The envisaged skin pass mill will be a Twin stand Double Cold Reduction (DCR) mill

stand 2 x 4-high cold rolling mill meant for giving a small cold reduction to the fully

annealed coils with the help of twin four high stands.

(7) Cold rolled products – slitting and shearing section.

(8) Hot Dip Galvanizing Line

The CRC is envisaged to process 1000,000 tons per year of input in terms of hot

rolled coils (HRC). Out of these 400,000 equivalent hot rolled coils are meant for

coated products: Galvanized and colour coated. Colour coated sheets require a thin

galvanizing pre-coat for better paint quality and resistance to corrosion in ultimate

use. So it is proposed to galvanize the entire produce of 400,000 tons of hot rolled

coils to zinc/zinc aluminum coated coils and out of that 200,000 tons of equivalent

HRC will be colour coated in two colour coating lines.

(9) Colour coating line.

It is envisaged to install two colour coating lines in the CRC at phase-2. Each line will

be 100,000 tpy capacity. Due to a large number of colour coating facilities installed

recently, it is envisaged to build up the capacity of colour coating progressively.

Product mix at full capacity of the Cold rolling mill Complex:

Cold rolled coils and

sheets

Grades:

O/D/DD/

EDD

Widths: 1000 mm to 1500 mm;

Thickness: 0.25 to 2.5 mm

567,000 tons /year

Galvanized

coils/sheets(Plane

or corrugated)

- Widths: 800 mm to 1000 mm:

Thickness:0.25 mm to 2 mm.

186,000 tons/year

Colour coated

sheets

- Widths: 800 mm to 1000 mm:

Thickness:0.25 mm to 2 mm.

190,000 tons

/year.

Depending on market demand and progress of installation of the colour coating line,

part of the colour coated tonnage may be initially offered as galvanized product.

Environmental control measures

The environmental control measures to be adopted in the cold rolling mill complex

can be summarized as follows:

(1) Air pollution control:

The air contaminated with acid fumes sucked from the pickling line would be treated

in packed scrubbers to ensure less than 10 mg/m3 of acid in the exhaust air. The

sucked air over the cold rolling mills contains oil mist. This mist is removed from the

air with an electro-static mist eliminator to collect the oil before letting the air out. The

outlet air would have oil level less than 10 mg/Nm3. Most of the other places the air

with small size solid particles like scale or zinc dust or paint fumes will be treated in



Page 30 of 262

Bag filters to ensure that the outlet air contains particulate at the stipulated norm

level.

(2) Treatment of waste water:

Waste water within cold rolling mill complex arises due to the process pickling and

cooling/lubrication during the process of cold rolling. Pickling and related processes

(rinsing, gas cleaning operations and acid regeneration) causes acidic waste water

streams. Cooling and lubricating processes in the rolling sections give rise to oil and

suspended solid loaded waste water streams. Depending on the steel grades

processed, several measures are relevant. In general, use of process water in loops

or cascades and the use of coolants/lubricants in loops as far as practical would be

used. But to permit its use in loops, treatment measures are necessary and have

been envisaged. Waste water treatment is separated into processes for acidic

streams and those for oil loaded components.

For treatment of water with acids and acid recovery will be practiced. The two major

processes- Fluidized bed acid regeneration and the Spray roasting acid re-generation

have been used.

In some situations, acid recovery from waste water may not be possible due to

breakdown or maintenance of downstream plants. In that case the acidic water will be

neutralized with milk of lime to bring the pH of water to acceptable level before re-use

inside the plant for spraying etc.

Treatment of water from rolling stands coolants/lubricants

The main components of coolants and lubricants from the cold rolling stands are

water, oil and emulsifying agents. The emulsions can contain stabilizers, antifoaming

agents, rust preventive agents, biocides etc. Coolants/lubricants are to be used in

cascades to maintain their properties as long as possible. The cleaning and treatment

measures to be adopted are as follows:

Removal of solid: several proprietary processes are available involving magnetic

separation, gravity separation, centrifugal separation, and filtration.

Removal of non emulsified oil by skimming

Monitoring of composition, aeration to prevent putrefaction and cooling

Often industrial waste water treatment plants offered combine some or all of the

above steps to result reusable water.

Spent oil emulsions will be given to outside agencies for processing.

2.9 Captive Power Plants and Turbo Blower Stations

2.9.1 Captive Power Plants: To meet the power requirement of the steel plant, it is

proposed to install captive power plants of the following configuration.

Phase-1: Coal/waste gases based CPP- 1 x 70 MW; 1 x 350 tph at 90 bar steam

pressure and 5300 C Circulating Fluidized Bed Combustion (CFBC) type boiler and

70 MW steam turbine with air cooled condensers.

Phase-2: Coal/waste gases based CPP- 2 x 100 MW; Coal/waste gas fired boiler- 2 x

450 tph at 150 Kg/Cm2 and 5400C. The boiler is currently envisaged as pulverized

coal fired but the option of going for CFBC type will be explored at the detailing stage

depending on the choice of available coals. 2 x 100 MW steam turbines with air

cooled condensers. The generation of power from these two captive power plant will

be supplemented by auxiliary generation of power from the Top gas pressure



Page 31 of 262

recovery turbine(TRT) of blast furnace no 1 & 2. The nominal envisaged capacity of

those two units is 6 MW and 12 MW respectively. Further, steam will be available

from the coke dry quenching units of the coke oven complex. While at phase-1, the

steam is proposed to be used for the process but at 3.5MTPA stage (Phase-2)

installation of steam turbine will be considered for a total generation of another 7 MW.

Coal/waste gases is envisaged as the principle fuel. Heavy oil is the support firing

fuel for low loads and LDO/HSD would be fuel for startups. However, all the boilers

will have facility to use spare Blast furnace or mixed gas if surplus is available. This

can happen when some of the consuming mills are down.

2.9.2 Turbo-blowers:

Turbo-blowers will be used to supply cold air to the blast furnaces via stoves. The

Turbo-blower station for both phases is proposed to be located adjoining to the power

plant. Two turbo-blowers will be installed in each phase to cater to the two blast

furnaces envisaged one each in phase-1 and 2. Each phase will have an exclusive

boiler, fired with by-product gases to supply steam to the turbines of the Turbo Boiler

sets. These boilers will also supply process steam at lower pressure to the various

units of the steel plant at each phase. Low pressure steam for coke ovens can be

supplied either from the CPP units or from the Turbo Boiler units as per convenience.

The capacities of the Turbo-blowers envisaged to be installed at each phase with the

capacities of their respective steam generating units are given below:

Item Phase-1 Phase-2

Capacity of each of two

Turbo-blowers envisaged for

each BF.

108,385 Nm3/hr at 2.9

Kg/cm2 and 110 0 C

246,061 Nm3/hr at 3

Kg/Cm2, 110 0 C

Each Turbine capacity 9 MW (approx.) 20 MW (approx)

Process steam or input

steam to turbines

60 Kg/cm2, 485 0 C 60 Kg/cm2, 485 0 C

Process steam envisaged to

be met from the unit

50.5 tons/hr 91 tons/hr.

Extracted steam from

turbines at 16 Kg/cm2

2 x 8 = 16 tons /Hr. 2 x 18 = 36 tons/Hr

Steam required from boiler

via PRDU

50.5-16= 34.5 t/Hr 55 t/Hr

Capacity of the boiler

envisaged

18 X 5 + 34.5= 125 t/Hr. 40 X 5 + 55 = 255 t/Hr

2.10 Cryogenic Oxygen Plant

In order to meet the requirement of oxygen, nitrogen and argon in the various

processes and services in the steel plant, it is envisaged to install an Oxygen Plant

(Cryogenic Air separation and purification unit) at each phase of the project. The

capacity selected is 700 TPD capacity oxygen plant at phase-1 and 900 TPD

capacity at phase-2. Each plant will be complete with all related auxiliary and service

facilities.



Page 32 of 262

2.11 Pollution Control and Environment Management

An Integrated steel plant employs a number of processes each of these has sources

of environment pollution. The pollutants in the form of solids, liquid and gases are

generated from different processes and need to be treated to harmless products

before discharge to nature. Adequate provision has been kept in selecting the

processes, the machinery and the lay out to keep emission pollutants after treatment

within the current acceptable limits. The measures envisaged to treat the polluting

outputs from each process are described. The following is the summary of the steps

envisaged.

(1) Air pollution control measures:

Utilization of by-product gases and waste gases as fuels and also as sources of

energy before letting out to atmosphere.

Utilization of waste gases with sensible heat (like in CDQ) in waste heat boilers

Use of de-dusting equipment like cyclone, bag filters and Electro-static precipitators

to de-dust waste gases before their entry to stacks.

Use of tall stacks (as per CPCB norms) to let out the gases to atmosphere.

Use of water spray/water fogging practice to reduce ambient air dust concentration in

all open transfer /unloading points where dust collection with suction ducts are not

very effective.

Provision of Low NOX burners at the reheating furnaces in the rolling mills.

(2) Water pollution control

Extensive measures have been envisaged to contain water pollution and in general

the plant will adopt a policy of Zero Discharge of water from the plant area to the

adjoining water bodies. However, some discharge/discard of water from the

processes is inevitable. These would be treated to a safe usage level and as far as

possible, would be used inside the plant. The general principle for achieving the aim

of zero discharge would be:

Unit wise recirculation of water will be ensured, after cooling and treatment to reduce

the requirement of makeup fresh water and avoid wastage of water.

Measures will be taken to treat water to remove suspended/colloidal matter and if

acidic, to treat with lime to make it neutral.

For cooling water adequate cooling towers is provided.

Oil and grease from the contaminated water will be removed by skimming and use of

traps.

Installation of sewage treatment plants in all major units for treatment of the faecal

waste and removal as sludge after biological treatment.

Some of the specific measures for treatment of waste water as envisaged in the plant

unit wise.

(3) Solid waste management

The envisaged arising of solid waste at each technological process units and modes

of disposal has been given. The position is summarized below which shows those

after Phase-1 & 2 facilities, 75% of the generated solid wastes would be re-processed

and utilized inside the plant or sold outside as saleable output. Only 25% of the

generated solid wastes including iron ore WHIMS beneficiation plant tailings do not



Page 33 of 262

have any use at present except as land fill/dumps. These would be used as landfills

in nearby mine area.

Solid Waste Total generation at full capacity (tons)

Utilization and mode Disposal as wastes

Phase-1 units

Phase-2 units

Coal/coke dust 11,854 12,653 100% utilized in coal blend charge in the coke oven complex

Nil

Undersize coke 26,000 59,200 100% utilized in sintering plants as a bed material for heat energy

Nil

Tar sludge 240 256 To be used along with coal charge in the coke ovens

Nil

Acid sludge from by-product units

100 100 - To be neutralized and disposed as landfill.

Lime sludge from PCM

450 - To be used as neutralizing agent

Nil

Iron bearing dusts from dust catchers/ESPs/Bag filters

232,980 556,669 To be used along with the charge mix in the sintering plants. The design has provisions to use these.

Nil

Blast Furnace granulated slag

362,208 822,298 To be sold to cement plants for making blast furnace slag cement

Nil

Steel making slag 150,000 324,000 Only iron bearing portion of the steel slag would be recovered and iron to be used in steel making. A small % of the steel slag can be used in Blast furnace as source of lime, or / and for Road Making

90% i.e. 135,000t from phase-1 facilities and 291,000t from phase-2 facilities cannot be reused in the process as per the present technology. These would be used as landfills either inside the plant or in the neighborhood.

Iron oxide from acid regeneration plant of Cold rolling mills

- 40,000 To be sold to users like Ferro magnet industry, iron powder industry etc.

Nil

Power plant fly ash 127,360 490,758 To be sold to fly ash brick makers and cement plants making fly ash cements

Nil

Power plant Bottom ash

31,840 122,689 Cannot be used in the processes adopted.

To be used as land fill: Phase-1: 31,840t Phase-2: 122,689t

Arising of skull/scraps 94,197 (114,197)*

191,315 To be used in steel making for re-melting.

Nil



Page 34 of 262

Rejects after Two stage WHIMS treatment in the fine ore beneficiation plant.

4,44,188 (Dry)

To be temporarily stocked at the designated site in the plant and later transported to a nearby ore mine pit for re-filling and green development.

Phase-1: Phase-2: 4,44,188 t

Refractory wastes 10,880 26,849 Un-contaminated (80%) bricks will be sold (for construction) or crushed to be used as mortar.

About 20% of the waste bricks which are contaminated with slag/skull etc. would have to discarded and dumped in landfills. Phase-1: 2176 t Phase-2: 5370 t

Muck/sludge/wastes 5,050 7,750 Cannot be re-used Phase-1:5,050 Phase-2:7750 t

Total arising 1,053,159 3,098,723 174,066 (16.53%) 870,968 (28.2%)

Including the skull arising at PCM at Phase-1. But after installation of BOF shop at

phase-2, PCM load will drastically come down with combined working. .

(4) Noise pollution:

The major noise polluting areas in the steel plant are captive power plant turbines

and generators, blast furnace air blowing station, compressed air station, oxygen

plant compressors, blast furnace area, hot rolling mills etc. In case of rotating

equipment the noise level will be specified as per international standards at the time

of procurement. Suction side silencers will be specified in all such equipment. The

isolation of working persons from the noise level by placement of acoustic barrier will

be provided. The working personnel exposed to high noise will be provided with

earmuff and their exposure such high noise source will be limited.

2.11 Power requirements of the steel Plant

Power requirement of the steel plant as envisaged is given below.

Item Phase—1 Phase-2 Total Plant after both

the phases installed

Maximum demand 80 MVA 286 MVA 366 MVA

Average demand 60.2 MW

(75.25MVA)

163.64 MW(204.6

MVA)

223.84 MW

(279.85MVA)

Annual Energy

consumption

528 X 106 KWh 1434 x 106 KWh 1961.8 x 106 KWh

2.12 Instrumentation, Automation & Controls

Adequate measurement and control facilities have been envisaged for all the

shops/units of the plant with a view to achieve safe, reliable and efficient operation of

the plant and optimum utilization of the inputs, safety of the plant machinery,



Page 35 of 262

operating personnel and user friendly man–machine interface. For all major

processes level-2 fully automatic process control has been envisaged in line with the

modern practice.

2.13 Water supply and treatment facilities

The water supply for the proposed steel plant is basically for cooling of various solids,

liquid and gaseous intermediate products and also for machinery cooling. Water is

also required to make up boiler water requirement in the DM plants for steam raising.

There is also requirement of water for drinking and other washing/cleaning purposes.

To minimize the fresh water drawn from the source, cooling water re-circulation

systems have been envisaged with facilities for removal of solids and removal of

entrapped oil. Cooling towers have been provided for cooling the re-circulated water.

The blow downs from cooling towers and the neutralized effluent discharged from the

processes are proposed to be utilized for coke quenching, slag granulation, steel slag

cooling, de-dusting/defogging and other direct contact water treatments aiming at

zero discharge.

The fresh water requirement of the steel plant in two phases is estimated as

Phase-1: 1.0 million ton crude steel stage: 1305 m3/h (6.97 MGD)

Phase-2: 2.5 million crude steel facilities: 2615 m3/h (13.96 MGD)

Total Steel Plant after phase-2: 3920 m3/h (20.93 MGD)

Recirculation systems have been envisaged in the plant for reusing the major

quantity of water after treatment in various units. The intake water for the plant from

the water source after phase-2 installation of the whole plant before the water

treatment plant will be 4170 m3/Hr (22.24 MGD) considering about 6% loss of water

during treatment.

The source of water has been identified as the Tungabhadra Reservoir located at a

distance of about 20 Km from the plant site, from where raw water will be pumped to

the plant storage reservoir located on the northern side of the site near the national

highway. The present available low area where the storage tank can be formed is

about 23.6 hectares. It is proposed to develop the eastern part of this area for phase-

1 storage of water. The area is 10.4 hectares. The capacity of the plant reservoir

assuming 80% of the area will have actual water body with 10 m average holding

capacity:

At phase-1: 0.832 million m3 to cater to 20 days storage of phase-1 water

requirement of the plant at rated capacity production.

After phase-2: the storage capacity will be expanded to 1.89 million m3 for about 19

days requirement of the plant at 3.5 million ton rated capacity production.

It is understood that the present agreement of AISL with Karnataka State

Government regarding withdrawal of water from Tungabhadra dam stipulates a

pumping @12.55 mgd for the full year. But pumping will be allowed for 184 days

(after July15th) and not be allowed in the dry season (January to mid-July). This

means though 4809 million gallons of gross water (12.55 mgd x 365 x1.05) can be



Page 36 of 262

withdrawn from the dam during the wet season after allowing for 5% loss during

pumping and 4580 million gallons of net water can be received. The annual

requirement of water at phase-1 as per estimate given above will be = 6.97 x 1.06 x

365 =2696.7. Though it is less than the water withdrawal allowed for the whole year,

the water to be consumed during the non pumping period of 181 days with

evaporation loss added, need to be stored. For phase-1 requirement it amounts to =

6.97 x 1.06 x 181 x 1.03 = 1377 million gallons or 6198 million m3 (1.06 is the factor

for water treatment loss and 1.03 is for evaporation loss of water). The plant water

reservoir has been provided for only 20 days storage at phase-1 which will cater to

only supply and pumping disruptions. The bulk of the water storage is envisaged to

be done by adopting public tanks and bundhs in the area.

For the combined operation of 3.5 million ton plant, the total annual requirement of

water amounts to 8095.7 million gallons which shows that more water need to be

committed by the state Government before Phase-2 facilities can be started.

2.14 Steam facilities

The steam required in the technological units of the plant apart from the captive

power plants is given below:

Sl.

No.

Service Unit Requirements

Phase-1: 1 MTPA Phase-2: 2.5 MTPA

1 Process steam at 6-9 ata. t/Hr. 69.5 101

2 Maximum steam required

for the turbo-blowers

t/Hr. 2 x 45 2 x 100

The captive power plants will have dedicated boilers for generation of steam for the

turbines. The total steam generating facilities envisaged are:

Captive Power Plant-1 (1 million ton phase)

Boiler 1 No with capacity 350 tph of steam at 90 bar and 5350C feeding 1 No Turbo-

generator of capacity 70 MW

Turbo-blowing station -1 (1 million ton phase)

Boiler 1 No. with capacity 125 t/Hr of steam at 60 bar and 4850C feeding the turbines

of the blast furnace blowers and supplying process steam from turbine extraction as

well as direct from boiler through PRDU.

Captive Power Plant-2 (2.5 million ton phase)

Boilers 2 Nos with combined capacity of 2 x 450 t/ Hr of steam feeding 2 x 100 MW

Turbo-generators.

Turbo-blowing station -2 (2.5 million ton phase)

Boilers 1 No. with capacity 350 tph of steam feeding Turbo-blowers of 60 bar and

4850C feeding the turbines of the blast furnace No 2 blowers and supplying process

steam from turbine extraction as well as direct from boiler through PRDU.



Page 37 of 262

2.15 Compressed air facilities

At Phase-1, it is envisaged to install two centralized compressed air stations.

Compressed air station No. 1 will cater to COBPP, Sinter Plant No1 and Blast

Furnace No 1 along with auxiliaries. Compressed air station No. 2 will cater to Steel

melting shop No 1 along with secondary treatment and casters and the two hot rolling

mills envisaged at phase-1. The miscellaneous requirements of minor consumers

also will be met from ACP-1

Air Compressor Plant (ACP) No 1 will have 4 Nos. (3 operating + 1 Stand by) of

centrifugal air compressors each of 5500 Nm3/Hr, 8.5 Kg/Cm2 pressure. This unit will

also supply instrument quality air to the above processes

Air Compressor Plant (ACP) No 2 will have 4 Nos. (3 operating + 1 Stand by) of

centrifugal air compressors each of 5500 Nm3/Hr, 8.5 Kg/Cm2 pressure. This unit will

also supply instrument quality air to the above processes.

At Phase-2, it is envisaged to install two centralized compressed air stations and two

dedicated ACPs for Hot strip mill and cold rolling complex respectively due to their

large consumption. Compressed air station No 3 will cater to COBPP complex-2,

Sinter Plant No 2 and Blast Furnace No 2 along with auxiliaries. Compressed air

station No 2 will cater to steel melting shop No 2 along with secondary treatment and

casters. ACP No 5 and ACP No 6 will be located in the Hot Strip Mill and Cold Rolling

Mill complex areas respectively.

2.16 Fuel Oil Facilities

Fuel oil will be required in the Captive Power Plants as an auxiliary fuel in the coal

fired boilers to aid combustion. In all other units in both the phases of plant, generally

coke oven gas and mixed gas will be used as plant fuel. Fuel oil storages are being

envisaged at sintering plants, steel melting shops and rolling mills basically for startup

and as emergency measure to provide alternative fuel. The annual requirement of

fuel oil and LDO has been estimated as 1070 Kl and 15,097 Kl in phase-1 and 2

respectively. The higher usage of fuel oil at phase-2 is due to usage of oil as auxiliary

fuel in the pellet plant.

The summary of facilities envisaged at both the stages is given below:

Sl. For Unit Fuel No. of tanks with Aux.

facilities

Capacity of tanks

1 Power Plant Furnace oil 2 Nos. Vertical 2 x 300 Kl

HSD/LDO 2 Nos. Horizontal 2 x 10 Kl

2 Steel Melting &

Hot Rolling Mills

LSHS 2 Nos. Vertical 2 x 210 Kl

3 Sinter Plant -1 HSD/LDO 2 Nos. Horizontal 2 x 15 Kl

Sinter Plant -2 HSD/LDO 2 Nos. Horizontal 2 x 15 Kl



Page 38 of 262

2.17 Interplant gas pipe lines

Interplant gas pipe lines are proposed to supply gases like Blast Furnace gas, Coke

oven gas, Mixed gas, oxygen, nitrogen, argon, general compressed air and

instrument air to the various consuming points. The inter-plant gas pipe lines will be

taken over dedicated stockades.

2.18 Industrial Safety and Fire Protection Facilities

Many units and working premises of an integrated steel plant have hazardous and

fire prone environment. To protect the working personnel, equipment & machineries

and raw materials and stores from any damage or loss to ensure uninterrupted

production, adequate safety and firefighting measures have been planned for the

proposed plant at both the phases of plant development.

2.19 Ventilation, Air conditioning and De-dusting facilities

The facilities envisaged under this head will comprise of:

Pressurized mechanical ventilation systems to be provided in all electrical premises,

turbine halls and pump houses. The system provided will ensure a positive pressure in

the room of + 3mm WC to prevent ingress of dust.

At premises of stores, Battery rooms, toilets etc. general exhaust ventilation with wall

mounted axial fans along with cowl and bird screen has been envisaged.

Various PLC rooms, control rooms of processes, office cabins, Laboratories etc. will

be provided with air conditioning arrangements. Package air conditioning system will

be provided in bigger rooms requiring large volume of air handling.

Dust extraction system from the ambient air of the working floors will be basically

collected through collecting ducts with exhaust fans and cleaned with bag filters before

letting out to the atmosphere through 40/50 m self-supporting chimneys. In some

special cases involving heavy dust loads and volume de-dusting with ESPs has been

envisaged. These are described in the individual technological chapters.

Dust suppression measures. These involve water spraying in open dusty areas like

yards and use of defogging devices in close dusty areas, where dust extraction

through ducts is difficult.

In general, the dust suppression system will operate with reclaimed water not fit for

re-cycling in the water system of the individual units.

2.20 Construction planning

A tentative estimate of the construction/erection quantities involved in the setting up

of the 3.5 million ton steel plant is given below for giving an idea of the volume of

work involved.

Item Phase-1: 1 million ton

facilities

Phase-2:2.5 million ton

facilities

Excavation: 4,869,200 m3 10,069,250 m3

RCC: 823,766 m3 1,393,889 m3

Structures



Page 39 of 262

Building 151,424 t 220,163 t

Technological 15,743 t 25,800 t

Mechanical equipment 139,000 t 192,835t

Electrical Equipment 26,387 t 36,685 t

Refractory 74,935 t 84,178 t

It is envisaged to complete the installation and commissioning of the plant equipment

for startup and production in 30 months for Phase-1 facilities.

(2) It is envisaged to complete the installation and commissioning of the plant equipment

for startup and production in 36 months for Phase-2 facilities. The additional time is

envisaged on account of larger % of imported components at phase-2 and relative

difficulty in construction due to presence of an operating plant at the site.

The time schedule is from ZERO date which in this case is the date of placement of

order for the major plant equipment. This period will cover detailed engineering,

supply, erection and commissioning of the units.

The interspacing between the two phases is not certain at the present. It will depend

on the market demand of steel flat product and prices as well as the availability of

funds from institutional sources. Generally a spacing of 2-3 years is expected

between commissioning of one phase and start of construction of the next phase.

From that point of view, the full 3.5 million ton phase of the plant could be completed

in about 8 years’ time from the phase-1 zero date. This is provided the gap of 2-3

years is utilized for placement of order for the phase-2.

The phase -2 units (2.5 million ton complex) can be installed in steps. While the

primary facilities like Coke oven – by product complex -2 (Battery Nos. 3 & 4); Sinter

plant No. 2, Blast Furnace No. 2, BOF-CC shop and Hot strip mill with Power plant

No. 2 can be completed together to get a capacity of 2.5 million tons of hot rolled

coils, the Hot rolled coil finishing facilities, the cold rolling mill complex can be

installed later depending on the market situation. The pellet plant installation and the

installation of the coal washing complex also can be at a time appropriate for these

investments.

2.21 Manpower and Training

The manpower required for phase -1 facility will be 1713 (including 129 managerial

and executive employees) and at Phase-2 the manpower will be 2098 (including 173

managerial and executive employees) giving manpower productivity of 583 tons per

man year and 1191 tons per man year respectively for 1 million ton and 2.5 million

ton facilities, in terms of rated crude steel production. The man power productivity at

the full implementation of the integrated steel plant (3.5 million tons) is envisaged to

be 918 t crude steel per man year very close to international performance for a fully

integrated unit producing from iron ore and having both long and flat products.



Page 40 of 262

It should be mentioned here that the figures given above is only for regular

employees. The plant’s operation and maintenance will need perhaps as many men –

mostly semi-skilled and unskilled for various non perennial jobs. All routine non key

essential jobs like road transport within the works, security, township services,

medical and capital repair of units are expected to be offloaded.

The training needs would be both in India and also abroad. It is desirable that the

technical training is given in units similar to what will be installed at AARESS at least

for some period, for the operating and maintenance persons to get acclimatized.

Some part of this training should be organized by the equipment suppliers in steel

plants outside India while a large part of the training will be organized in India in the

existing steel Companies.

2.22 Capital cost and economics of the Project

(1) Capital cost envisaged for installation of the steel Plant has been computed as

follows:

Phase-1: Rs. 5,325 Crores.

Phase-2: Rs. 12,654 Crores

Total Rs. 17,979 Crores

The expenses include CSR expenses to the extent of 5% of project cost distributed

over a period of 10 years.



Page 41 of 262

CHAPTER 3: DESCRIPTION OF ENVIRONMENT

Introduction

This chapter incorporates the description of the existing environmental setting in

the area encompassed by a circle of 10 km radius around the steel plant.

Environmental Setting of the Plant Site is as below.

Table 3.1: Environmental Setting of the Plant Site

Sl. No.

Part iculars Detai ls

1. Project s ite

Survey no. 295/2, 296/1, 296/2, 297, 298, 299/P, 299, 300, 301, 302, 303, 304, 305/2, 307/2, 308/2, 309/2, 338, 339, 340 of Koppal Vi l lage, Part of 2, 8, 9, 12, 13, 14, 15, 16, 17,18 to 21, Part of 22 to 23, 50 to 53, Part of 130, 142 to 147 , 151, 130/P4 &130/P6, 131 to 132, 136, 3/F1 to 3/F4, 3/F5+6, 3/F7, 4F/A-3, 4F/A2, 4F/B1 to 4FB4, 5/P, 6P, 7P, 9P, 17P, 133/1+9, 133/2+3+6+7+9+10, 133/4+5, 133/8, 134/1 TO 134/3, 134/4+12, 134/5+10+13, 134/6, 134/7+8, 134/9, 134/11, 134/14, 134/15, 134/16+18, 134/17, 135/1, TO 135/3, 135/4+13, 135/5, 135/6, 137/7+8, 135/9, 135/10, 135/11+14, 135/12, 135/15, 135/17 OF Halavarthi Vi l lage, Part of 54 to 55, 76, 80, 89, 90, 121, 122, 128, 147, 154, Sr. No. 77 to 79, Sr. No 81 to 88, Sr. No. 106 to 110, Sr. No. 112 to 120, Sr. No. 122 to 127, Sr. No. 147 to 150, 121/5 to 121/7, 122/6 to 122/8, 127/2, 128/1, 128/2, 129/A, 130, 131, 132, 133, 134/AP1, 135 to 139, 141, 142/1, Sy.No.144 to 146, 148/2, 149/2, 152, 156, 157/3, 157/4, 158, to 168, 170, 171, 172, 122/P, 130/P, 132/P, 133, 140, 150/2, 151, 153, 154/2, 155, 156, 156/P, 168, 168/P, 169, 170, 171, 172, 173, 170/P, 171/P, 172/P, 173 of Basapur Vi l lage 126 to 132 of Kidadal Vi l lage, Part of 264, 269, 270, 271, 272, 273, 275, 276, 277, 278, 279, 280 of Giniger a Vi l lage, Tehsil : Koppal, Distr ict: Koppal, Karnataka.

2. Geographical Coordinates

Latitude Longitude

15o19’34.32”N 76o12’9.78” E

15o20’52.49”N 76o13’58.16”E

3. Toposheet Nos. 57A/3

4. Elevat ion above Mean Sea Level

515m above MSL



Page 42 of 262

5. Climatic Conditions

Annual Average Maximum Temp 440C, Annual Average Minimum Temp 100C Annual Average Rainfall 572 mm, Annual Average Humidity 47-68%

6. Present land use of the project s ite

Land al located for Industr ial use

7. Soil Black Cotton Soil, Red Soil , Red Sandy Soil

8. Nearest Highway NH -63, 1.8 Km : N

9. Nearest Railway Station

Ginigera, 4.5 Km : NE

10. Nearest Airport Hubli, 120 Km : W (Commercial Airport) Baldota, MSPL : 4 Km : N ( Private Airport)

11. Defence instal lat ions None within 10 km radius

12..

Ecologically sensit ive areas like National parks/Wild l ife sanctuar ies/ bio-sphere reserves

None within 15 km radius

13. Nearest City Koppal, 6 Km.: NW

14. Nearest Water bodies/ River/ Sea

Tungabhadra River, 9.0 km : SE

15 Seismicity Seismic Zone I

16 Rehabil itation & resett lement

None

Study Area:

The study area is 10 km radius from the boundary limits of the Project Site.

A key plan indicating Project Area as core zone and 10 km radius buffer zone is

shown below. This figure provides surface features like villages, habitation,

drainages, roads, railways etc.



Page 43 of 262

Figure 3.1: Key Plan

The current site conditions are taken as the baseline conditions for formulation of

the EIA. Field monitoring for measuring meteorological conditions, ambient air

quality, water, soil and noise had been commenced from March 1, 2016 to May 29,

2016 to study the baseline environmental status for one season. In addition, data

related to land use; socio-economic status has been analysed based on the

secondary information like district census reports and remote sensing satellite

imageries.

3.1 Environmental Monitoring Program

The location of the air, water, noise and soil sampling stations were selected for

appropriate monitoring. A monitoring station was positioned at core zone (Project



Page 44 of 262

site) for Micro-meteorological data collection. The schedule of the environmental

monitoring programme is described below in Table-3.2.

Table-3.2: Schedule of Environmental Monitoring Program

Environmental Component

Monitoring period

NO. of sampling Stations

Parameters monitored

Micro -Meteorology

01.03.2016 to 29.05.2016

01 Temperature, Relative Humidity, Rainfall, Wind Speed, Wind direction

Air Quality 01.03.2016 to 29.05.2016

09 PM10, PM2.5, SO2, NOX, CO, NH3, O3, C6H6, B(α)P, As, Lead & Nickel

Water Quality March 2016 05 Surface & 05 Ground

IS-10500:2012 and IS-2490:1982

Noise April 2016 08 Ld, Ln& Ldn

Soil Quality March 2016 05 Physical & Chemical parameters of Indian Standards (IS 2720)

Table-3.3: Environmental Attributes & Frequency of Monitoring

Sr. No

Environmental Component

Sampling Locations

Sampling Parameters

Total Sampling Period

Sampling Frequency

1. Meteorology One Central location

Wind Speed, Wind Direction

3 months Hourly

Rainfall, Cloud Cover

3 months Daily

Temperature and Relative Humidity

3 months Twice & Thrice Daily

2. Ambient Air Quality

Nine locations

PM10, PM2.5, SO2, NOX, O3, CO, NH3, C6H6, B(α)P, Heavy Metal e.g. Lead, Arsenic, Nickel, Hg & Free Sil ica

Two days per week for 13 weeks

24 hourly

3. Water Quality

05 each of Surface & Ground water locations

As per IS:10500:2012 and IS:2490: 1982 for ground water & surface water samples

Grab sampling

Once during study period

4. Noise Eight locations

Ld, Ln 24 hourly composite


5. Soil Five locations

Physical and Chemical constituents, Suitabil ity for agricultural growth

Composite sample




Page 45 of 262

Wind Rose Diagram for Period during AAQ Monitoring



Page 46 of 262

Temperature and Humidity Daily minimum & maximum temperatures were recorded on twice a day basis and relative humidity was measured three times a day simultaneously. The data so collected is given in Table–3.4. Ambient air temperature and relative humidity give useful auxil iary information for the interpretation of ambient air quality data.

Table-3.4: Monthly Temperature & Humidity Recorded During Sampling Period

Date Temperature (o C) Relative Humidity (%)

Minimum Maximum 0600 hr 1400 hr 2200 hr

01/03/2016 22.0 30.5 68 49 69

02/03/2016 20.5 31.1 93 46 63

03/03/2016 19.2 30.7 85 47 57

04/03/2016 19.7 30.6 66 44 53

05/03/2016 19.6 33.5 71 37 47

06/03/2016 21.8 32.9 70 40 62

07/03/2016 23.2 32.2 78 46 73

08/03/2016 20.8 30.9 78 51 83

09/03/2016 21.7 29.9 88 57 82

10/03/2016 22.5 29.7 83 54 72

11/03/2016 21.6 31.4 50 26 45

12/03/2016 21.6 31.1 44 45 57

13/03/2016 22.5 32.2 76 34 44

14/03/2016 22.7 33.0 68 21 58

15/03/2016 22.3 33.3 90 42 56

16/03/2016 23.4 33.2 79 36 51

17/03/2016 24.3 33.4 66 36 44

18/03/2016 24.3 34.2 40 31 43

19/03/2016 23.3 34.2 87 29 43

20/03/2016 23.8 34.9 48 22 30

21/03/2016 23.3 35.1 54 22 30

22/03/2016 23.8 35.1 42 23 28

23/03/2016 23.8 35.7 68 29 32

24/03/2016 23.9 35.7 76 33 35

25/03/2016 24.8 35.6 59 25 36

26/03/2016 23.8 35.2 74 40 35

27/03/2016 23.6 34.7 85 39 35

28/03/2016 23.7 34.7 50 28 28

29/03/2016 22.6 35.2 61 39 35

30/03/2016 24.5 34.8 73 37 45

31/03/2016 25.1 31.7 63 60 52

Minimum 19.2 29.7 40 21 28

Maximum 25.1 35.7 93 60 83



Page 47 of 262

Date Temperature (o C) Humidity (%)

Minimum Maximum 0600 hr 1400 hr 2200 hr

01/04/2016 23.1 34.8 77 47 40

02/04/2016 24.3 35.4 84 38 37

03/04/2016 23.3 35.5 71 32 33

04/04/2016 22.8 36.2 72 22 32

05/04/2016 24.5 35.8 40 25 34

06/04/2016 26.0 37.3 35 20 33

07/04/2016 23.4 36.1 79 31 31

08/04/2016 24.9 36.2 62 42 43

09/04/2016 24.6 35.5 75 41 45

10/04/2016 24.2 35.0 74 47 58

11/04/2016 23.7 33.0 79 52 62

12/04/2016 23.8 28.9 79 64 78

13/04/2016 20.7 31.2 92 51 46

14/04/2016 20.6 31.1 82 50 60

15/04/2016 21.8 31.7 87 56 49

16/04/2016 23.4 32.3 78 37 46

17/04/2016 23.3 31.3 67 75 58

18/04/2016 21.8 33.4 83 35 40

19/04/2016 23.1 36.2 85 36 39

20/04/2016 23.7 36.4 80 31 37

21/04/2016 23.9 35.6 85 47 41

22/04/2016 25.3 36.4 79 38 53

23/04/2016 25.4 35.8 83 51 62

24/04/2016 21.3 33.7 90 58 48

25/04/2016 24.6 35.0 90 53 62

26/04/2016 23.1 34.3 80 38 44

27/04/2016 23.9 34.6 75 43 52

28/04/2016 24.0 36.4 83 40 47

29/04/2016 25.1 37.5 82 36 56

30/04/2016 25.5 36.4 81 38 35

Minimum 20.6 28.9 35 20 31

Maximum 26.0 37.5 92 75 78



Page 48 of 262

Date Temperature (o C) Humidity (%)

Minimum

Maximum 0600 hr 1400 hr 2200 hr

01/05/2016 25.5 37.9 81 34 29

02/05/2016 25.2 37.6 85 37 57

03/05/2016 25.6 37.0 73 40 48

04/05/2016 25.1 35.6 69 49 58

05/05/2016 24.2 34.9 74 43 43

06/05/2016 25.3 35.2 66 40 46

07/05/2016 24.9 35.4 87 42 53

08/05/2016 23.7 36.6 79 42 43

09/05/2016 25.1 37.4 69 41 42

10/05/2016 26.6 36.2 50 36 33

11/05/2016 24.8 36.1 79 44 42

12/05/2016 25.7 34.8 81 42 47

13/05/2016 25.8 34.7 69 43 47

14/05/2016 24.3 32.4 75 54 45

15/05/2016 26.1 34.6 68 46 78

16/05/2016 23.6 32.7 87 56 71

17/05/2016 24.4 36.1 80 42 67

18/05/2016 24.0 36.6 87 53 73

19/05/2016 24.9 36.2 81 42 71

20/05/2016 24.8 38.9 81 40 66

21/05/2016 26.1 38.2 80 40 72

22/05/2016 25.5 38.5 80 43 67

23/05/2016 26.0 37.8 78 41 56

24/05/2016 24.7 37.8 81 36 64

25/05/2016 25.5 37.1 79 41 59

26/05/2016 25.3 37.4 78 40 47

27/05/2016 24.9 38.2 81 38 78

28/05/2016 24.4 35.1 74 47 56

29/05/2016 21.7 37.5 82 49 96

Minimum 21.7 32.4 50 34 29

Maximum 26.6 38.9 87 56 96



Page 49 of 262

Summary:

It has been observed that the temperature varied between a minimum of

19.2°C to a maximum of 38.9°C indicating signif icant temperature

changes. Relative humidity was in the range of 20 to 96 %. The

observed value of Relative humidity indicates moist weather condition.

The minimum and maximum values observed for the monitoring period

for Temperature and Humidity are presented in figure-3.2 and 3.3.

Figure-3.2: Temperature variations during study period

Figure-3.3: Relative humidity variations during study period

Rain fall

There was no rain Observed during monitoring period.

3.1.2 Air Environment

To assess the baseline ambient air quality, nine air quality monitoring

locations were selected on the basis of wind direction, topography,

human settlement and other meteorological parameters in core and

buffer zone area. Two air sampling station was identif ied in core zone

and the remaining seven in the buffer zone. The study area represents



Page 50 of 262

totally rural environment. Descriptive l isting of the ambient air quality

monitoring stations is given in Table-3.5 and shown in Figure-3.4.

Table-3.5: Description of Ambient Air Monitoring Stations

Sr. No.

Description of monitored stations

Sample code

Distance from proposed plant expansion

Direction Zone Remark

1. Proposed Steel Plant Site

A-1 Within - Core Core zone

2. Adjacent to Pel let Plant

A-2 Within - Core Core zone

3. Al langara Vi llage A-3 2.5km E Buffer Downwind

4. Hire Baglani vi l lage A-4 3.5km SE Buffer Upwind

5. Kunikeri Tanda Village

A-5 2.0km S Buffer Downwind

6. Huvinahalu Vi l lage A-6 4.0km W Buffer Downwind

7. Koppal Vi l lage A-7 6.0km NW Buffer Upwind

8. Belanalu Vi l lage A-8 1.5km N Buffer Upwind

9. Basapur Vi l lage A-9 3.5km NE Buffer Downwind

Figure-3.4: Locations of Ambient Air Quality Monitoring Stations

A-1 A-3

A-4A-5

A-6

A-7

A-8

AIR MONITORING STATION

A-9

76°15'

15°20'

15°15'

76°15'

76°10'

76°10'

15°25'15°25'

15°20'

15°15'

PREPARED BY-POLLUTION AND ECOLOGY CONTROL SERVICES

Village - Halavarthi, Tahsil - Koppal, District -Koppal State - Karnataka

AIR MONITORING STATION

Halavarti

Kunikeri Tanda

Allanagara

Kidadhala

KanakapuraLingadahalli

Hire Bagnali

Hire Kasinkandi

LachankeriChikka Bagnala

TUNGABHADRATUNGABHADRA

Karkihalli

MundrigiMellekeriHyati

Kunikeri

Hosahalli

ChukkanakalliBahadurabanda

Huvinahalu

Hosa kanakpuraBevinal

GingeraBasapur

BelanaluKOPPAL

BhagyanagarYattinahatti

Mangalpur

Haratattanahalu

GbburGuddanahali

Halhalli

Tavargera

Lebigeri

TenakaaakalluChilavadgi

Naregallu

Daddegallu

Sangapura

Hanumanahalli

Katakkanahalli

Muddaballi

HIRE H

ALLA

ICH

HALA

HALLA

ADDA HALLA

HIRE H

ALLA RS

STREAMS

RIVER / NALA

POND

ROAD

HABITATION

GRID

PROJECT SITE

INDEX

RAILWAY LINE

RESERVOIR RESERVOIR

A-2



Page 51 of 262

3.1.2.1Frequency of Monitoring

Ambient air quality (AAQ) samples were collected on basis of 24 -hour

sampling and twice a week at each site. The ambient air quality samples

were collected for continuous 13-weeks beginning from 01 s t March-2016

to 29 th May, 2016.

The samples were preserved and analysed as per the standard methods

recommended by Standard Operating Procedure (SOPs) of Central

Pollution Control Board (CPCB 2011).Ozone (O 3) and Carbon Monoxide

(CO) were monitored by randomly collecting the gas through one hour

sampling procedure. Samples for Ammonia (NH 3) were randomly

monitored for its presence.

3.1.2.2Method of Analysis

Ambient air samples were analysed with Gravimetric, Co lorimetric or

Atomic Absorption Spectrophotometric (AAS) method as per standard

methods specif ied by Central Pollution Control Board (CPCB 2011).

The Techniques used for ambient air quality monitoring and minimum

detectable levels are presented in Table-3.6.

Table-3.6: Techniques & Instruments used for Monitoring of Ambient Air

Quality(AAQ)

Sr.

No. Parameter Technique

Technical

Protocol

Minimum

Detectable

Limit (μg)

1. PM10

APM 550 – Dust

Sampler (Gravimetric

Method)

IS-5182

(part-IV) 5.0 μg/m3

2. PM2.5

APM 550 – Dust

Sampler (Gravimetric

Method)

IS-5182

(part-IV) 5.0 μg/m3

3. Sulphur dioxide

APM 433 – Gaseous

Sampler (Chemical

Absorption)

IS-5182

(Part-II) 3.0 μg/m3

4. Oxides of

Nitrogen

APM 433 – Gaseous

Sampler (Chemical

Absorption)

IS-5182

(Part-VI) 3.0 μg/m3

5. Carbon

Monoxide

Carbon Monoxide

Detector Tubes

DGMS

procedure 12.5 ppm

6. Ozone

APM 433 – Gaseous

Sampler (Chemical

Absorption)

IS-5182 2.0 ppb

7.

Other Gaseous

samples [NH3,

Benzene &

Low volume sampling

pump connected to

Adsorption Tube /

USEPA

method

TO-1 or

0.1 ppb



Page 52 of 262

B(α)P] Tedlar bags TO-2

8.

Heavy Metals

[Lead, Arsenic

& Nickel]

APM 550 – Dust

Sampler

(AAS Method)

IS-5182 0.1 ppb

3.1.2.3Observations

The results of Ambient Air Quality monitoring with regard to the

parameters are given below in tables from Table–3.7 to Table–3.15. A

summarized report of Ambient Air Quality is given in Table-3.16 and

summarized report of 98 th percentile in table 3.17. The National Ambient

Air Quality Standards are given in Table–3.18.

Table–3.7: AAQ Observations A -1: Project Site One At Proposed Steel Plant

Week Date PM10 PM2.5 SO2 NOx

μg/m3 μg/m3 μg/m3 μg/m3

W-1 01/03/2016 56.5 25.7 12.8 27.7

02/03/2016 55.3 25.1 16.3 21.8

W-2 08/03/2016 54.0 24.5 10.3 17.5

09/03/2016 54.5 24.8 12.2 18.2

W-3 15/03/2016 52.6 23.9 11.7 24.3

16/03/2016 55.7 25.3 14.3 19.9

W-4 22/03/2016 54.0 24.5 10.5 18.2

23/03/2016 49.0 22.3 9.8 15.3

W-5 29/03/2016 55.3 25.1 12.7 22.6

30/03/2016 50.2 22.8 14.2 20.1

W-6 05/04/2016 56.0 25.5 11.9 22.5

06/04/2016 53.7 24.4 16.2 27.5

W-7 12/04/2016 46.9 21.3 13.2 22.4

13/04/2016 55.8 25.4 11.3 19.2

W-8 19/04/2016 53.0 24.1 10.2 17.3

20/04/2016 51.2 23.3 11.2 19.0

W-9 26/04/2016 53.7 24.4 12.8 23.8

27/04/2016 55.2 25.1 13.9 21.2

W-10 03/05/2016 49.2 22.4 13.5 23.0

04/05/2016 51.4 23.3 11.2 19.0

W-11 10/05/2016 53.9 24.5 13.8 23.5

11/05/2016 54.6 24.8 12.4 21.1

W-12 17/05/2016 54.0 24.5 11.1 20.3

18/05/2016 52.3 23.8 10.9 18.9

W-13 24/05/2016 53.9 24.5 12.7 21.6

25/05/2016 50.1 22.8 13.6 23.1

Minimum 46.9 21.3 9.8 15.3

Maximum 56.5 25.7 16.3 27.7

Average 53.2 24.2 12.5 21.1

98th Percentile 56.3 25.6 16.3 27.6



Page 53 of 262

Table–3.8 : AAQ Observations

A -2: Adjacent From One Pellet Plant



W-1 01/03/2016 46.6 24.5 9.5 17.1

02/03/2016 48.4 25.5 10.4 15.9

W-2 08/03/2016 41.2 21.7 13.2 21.3

09/03/2016 44.3 23.3 10.9 16.7

W-3 15/03/2016 49.5 26.1 12.5 17.9

16/03/2016 47.6 25.0 10.5 20.4

W-4 22/03/2016 45.2 23.8 12.2 18.7

23/03/2016 41.0 21.6 11.5 17.4

W-5 29/03/2016 39.8 20.9 9.9 17.1

30/03/2016 44.3 23.3 10.0 18.2

W-6 05/04/2016 48.4 25.5 12.5 20.2

06/04/2016 46.9 24.7 11.5 21.4

W-7 12/04/2016 43.7 23.0 10.2 21.9

13/04/2016 47.9 25.2 13.5 19.7

W-8 19/04/2016 44.3 23.3 13.9 21.1

20/04/2016 42.5 22.4 12.5 19.3

W-9 26/04/2016 42.1 22.2 12.6 19.8

27/04/2016 47.8 25.1 11.6 21.7

W-10 03/05/2016 41.8 22.0 10.5 16.9

04/05/2016 41.0 21.6 11.7 16.2

W-11 10/05/2016 43.0 22.6 11.4 20.2

11/05/2016 48.7 25.6 12.5 19.6

W-12 17/05/2016 43.4 22.9 13.7 23.3

18/05/2016 40.3 21.2 12.2 20.7

W-13 24/05/2016 49.2 25.9 13.5 23.0

25/05/2016 41.8 22.0 12.4 21.0

Minimum 39.8 20.9 9.5 15.9

Maximum 49.5 26.1 13.9 23.3

Average 44.6 23.5 11.8 19.5

98th percentile 49.3 26.0 13.8 23.2



Page 54 of 262

Table–3.9: AAQ Observations A -3: Allangara Village



W-1 01/03/2016 44.2 23.3 11.2 20.1

02/03/2016 46.2 24.3 13.2 23.8

W-2 08/03/2016 45.4 23.9 12.5 22.4

09/03/2016 43.3 22.8 10.9 19.7

W-3 15/03/2016 45.4 23.9 9.9 17.9

16/03/2016 46.5 24.5 11.2 20.1

W-4 22/03/2016 46.1 24.3 9.7 17.4

23/03/2016 48.0 25.2 8.4 15.1

W-5 29/03/2016 43.9 23.1 9.7 17.4

30/03/2016 44.9 23.6 11.4 20.5

W-6 05/04/2016 47.1 24.8 12.8 23.1

06/04/2016 47.9 25.2 12.0 21.6

W-7 12/04/2016 45.8 24.1 9.8 22.3

13/04/2016 48.1 25.3 13.3 24.0

W-8 19/04/2016 51.9 27.3 14.8 17.8

20/04/2016 50.8 26.7 15.5 27.8

W-9 26/04/2016 47.4 25.0 14.6 26.3

27/04/2016 53.0 27.9 14.2 25.5

W-10 03/05/2016 46.9 24.7 14.8 26.6

04/05/2016 50.7 26.7 14.0 25.2

W-11 10/05/2016 45.0 23.7 15.9 28.7

11/05/2016 46.5 24.5 18.0 28.9

W-12 17/05/2016 48.6 25.6 14.4 25.9

18/05/2016 45.0 23.7 16.1 28.9

W-13 24/05/2016 51.9 27.3 16.4 29.5

25/05/2016 49.6 26.1 15.3 27.6

Minimum 43.3 22.8 8.4 15.1

Maximum 53.0 27.9 18.0 29.5

Average 47.3 24.9 13.1 23.2

98th percentile

52.5 27.6 17.2 29.2



Page 55 of 262

Table–3.10: AAQ Observations A-4: Hira Baglani Village



W-1 03/03/2016 46.3 25.7 11.7 28.7

04/03/2016 43.7 24.3 13.1 22.4

W-2 10/03/2016 48.6 27.0 10.2 22.1

11/03/2016 42.6 23.7 14.0 28.7

W-3 17/03/2016 44.6 24.8 11.5 27.2

18/03/2016 46.1 25.6 12.3 25.4

W-4 24/03/2016 43.9 24.4 10.9 29.4

25/03/2016 40.7 22.6 13.7 24.3

W-5 31/03/2016 42.5 23.6 11.7 25.7

01/04/2016 46.3 25.7 12.1 26.7

W-6 07/04/2016 47.4 26.3 10.4 22.9

08/04/2016 45.0 25.0 10.9 23.9

W-7 14/04/2016 43.7 24.3 11.5 21.5

15/04/2016 42.0 23.3 9.9 24.3

W-8 21/04/2016 45.1 25.1 10.6 23.3

22/04/2016 45.4 25.2 12.2 26.8

W-9 28/04/2016 48.1 26.7 14.0 28.4

29/04/2016 41.3 22.9 13.8 27.1

W-10 05/05/2016 48.6 27.0 12.5 27.4

06/05/2016 45.1 25.1 11.6 25.5

W-11 12/05/2016 42.2 23.5 15.3 25.4

13/05/2016 44.2 24.6 14.3 31.4

W-12 19/05/2016 46.1 25.6 17.8 29.8

20/05/2016 42.8 23.8 14.7 26.7

W-13 26/05/2016 46.2 25.7 12.9 28.5

27/05/2016 46.1 25.6 11.7 25.7

Minimum 40.7 22.6 9.9 21.5

Maximum 48.6 27.0 17.8 31.4

Average 44.8 24.9 12.5 26.1

98th Percentile

48.6 27.0 16.6 30.6



Page 56 of 262

Table–3.11: AAQ Observations A -5: Kunikeri Tanda Village



W-1 03/03/2016 40.2 25.1 16.0 27.2

04/03/2016 42.1 26.3 14.7 24.9

W-2 10/03/2016 41.0 25.6 13.4 22.8

11/03/2016 39.8 24.9 18.7 31.7

W-3 17/03/2016 43.2 27.0 16.2 27.5

18/03/2016 39.5 24.7 14.7 24.9

W-4 24/03/2016 38.7 24.2 15.1 25.6

25/03/2016 41.4 25.9 17.8 30.3

W-5 31/03/2016 39.1 24.4 13.6 23.1

01/04/2016 41.2 25.8 16.3 27.6

W-6 07/04/2016 43.6 27.3 13.6 23.1

08/04/2016 44.8 28.0 14.7 24.9

W-7 14/04/2016 45.3 28.3 12.8 21.8

15/04/2016 41.3 25.8 15.8 26.8

W-8 21/04/2016 42.7 26.7 18.6 31.6

22/04/2016 43.1 26.9 18.3 31.2

W-9 28/04/2016 40.2 25.1 16.4 27.9

29/04/2016 42.0 26.3 15.3 26.1

W-10 05/05/2016 39.5 24.7 16.8 28.5

06/05/2016 37.4 23.4 13.7 23.2

W-11 12/05/2016 40.2 25.1 17.8 30.2

13/05/2016 43.7 27.3 16.4 27.9

W-12 19/05/2016 41.6 26.0 20.7 31.2

20/05/2016 39.6 24.8 17.2 29.2

W-13 26/05/2016 40.3 25.2 17.3 29.3

27/05/2016 42.7 26.7 16.3 27.8

Minimum 37.4 23.4 12.8 21.8

Maximum 45.3 28.3 20.7 31.7

Average 41.3 25.8 16.1 27.2

98th Percentile 45.1 28.2 19.7 31.7



Page 57 of 262

Table–3.12: AAQ Observations A -6: Huvinahalu Village



W-1 03/03/2016 45.7 25.4 15.7 28.7

04/03/2016 47.0 26.1 19.8 25.2

W-2 10/03/2016 44.1 24.5 17.5 27.9

11/03/2016 49.0 27.2 18.5 26.7

W-3 17/03/2016 45.7 25.4 22.5 29.7

18/03/2016 46.2 25.7 17.9 29.5

W-4 24/03/2016 48.1 26.7 17.0 26.4

25/03/2016 45.4 25.2 20.4 29.2

W-5 31/03/2016 50.5 28.1 24.4 28.5

01/04/2016 46.3 25.7 21.3 31.1

W-6 07/04/2016 45.1 25.1 24.0 29.2

08/04/2016 48.0 26.6 19.4 28.1

W-7 14/04/2016 49.7 27.6 17.8 27.3

15/04/2016 45.8 25.4 20.5 28.6

W-8 21/04/2016 44.7 24.8 22.8 30.2

22/04/2016 49.9 27.7 19.6 29.4

W-9 28/04/2016 48.6 27.0 20.2 31.1

29/04/2016 45.9 25.5 18.8 29.4

W-10 05/05/2016 48.7 27.1 20.1 28.7

06/05/2016 49.7 27.6 19.9 27.6

W-11 12/05/2016 47.4 26.3 18.8 29.1

13/05/2016 45.3 25.2 19.4 26.4

W-12 19/05/2016 49.2 27.3 18.1 28.9

20/05/2016 46.9 26.0 21.5 26.3

W-13 26/05/2016 48.5 27.0 18.9 23.1

27/05/2016 45.9 25.5 19.4 30.1

Minimum 44.1 24.5 15.7 23.1

Maximum 50.5 28.1 24.4 31.1

Average 47.2 26.2 19.8 28.3

98th Percentile 50.2 27.9 24.2 31.1



Page 58 of 262

Table–3.13: AAQ Observations A -7: Koppal Village



W-1 05/03/2016 41.5 19.7 12.4 22.4

06/03/2016 42.4 20.2 13.4 24.1

W-2 12/03/2016 39.6 18.9 11.4 20.6

13/03/2016 41.1 19.6 14.5 26.1

W-3 19/03/2016 38.7 18.4 12.8 23.1

20/03/2016 39.8 18.9 15.8 28.4

W-4 26/03/2016 45.5 21.7 13.7 24.6

27/03/2016 42.2 20.1 12.1 21.8

W-5 02/04/2016 40.2 19.2 14.1 25.3

03/04/2016 37.7 17.9 13.8 24.9

W-6 09/04/2016 39.4 18.8 13.1 23.6

10/04/2016 38.5 18.4 14.8 26.7

W-7 16/04/2016 42.8 20.4 11.9 21.5

17/04/2016 44.7 21.3 12.7 22.8

W-8 23/04/2016 41.1 19.6 13.8 24.9

24/04/2016 39.8 19.0 14.7 26.4

W-9 30/04/2016 45.1 21.5 12.7 22.8

01/05/2016 40.5 19.3 11.3 20.4

W-10 07/05/2016 43.2 20.6 13.1 23.6

08/05/2016 42.2 20.1 14.7 26.4

W-11 14/05/2016 40.6 19.3 11.9 21.5

15/05/2016 41.8 19.9 14.1 25.4

W-12 21/05/2016 38.8 18.5 15.9 28.7

22/05/2016 45.8 21.8 14.5 26.1

W-13 28/05/2016 46.5 22.1 12.8 23.1

29/05/2016 42.2 20.1 21.6 23.2

Minimum 37.7 17.9 11.3 20.4

Maximum 46.5 22.1 21.6 28.7

Average 41.6 19.8 13.8 24.2

98th Percentile

46.1 22.0 18.8 28.6



Page 59 of 262

Table–3.14: AAQ Observations A -8: Belanalu Village



W-1 05/03/2016 39.2 23.0 13.8 24.8

06/03/2016 39.5 23.2 14.4 25.9

W-2 12/03/2016 41.0 24.1 12.7 22.9

13/03/2016 37.2 21.9 14.4 25.9

W-3 19/03/2016 38.2 22.5 17.6 31.6

20/03/2016 37.8 22.2 14.9 26.8

W-4 26/03/2016 42.0 24.7 18.5 33.4

27/03/2016 39.7 23.4 15.1 27.3

W-5 02/04/2016 38.4 22.6 17.2 30.9

03/04/2016 37.9 22.3 12.8 23.1

W-6 09/04/2016 36.9 21.7 16.3 29.3

10/04/2016 42.3 24.9 15.0 27.0

W-7 16/04/2016 39.0 22.9 15.9 28.6

17/04/2016 43.9 25.8 13.8 24.9

W-8 23/04/2016 39.7 23.4 15.1 27.1

24/04/2016 42.4 24.9 16.3 29.4

W-9 30/04/2016 39.8 23.4 14.4 26.0

01/05/2016 43.2 25.4 13.8 24.9

W-10 07/05/2016 38.7 22.8 17.8 32.1

08/05/2016 41.4 24.3 16.9 30.4

W-11 14/05/2016 39.7 23.4 14.9 26.9

15/05/2016 44.5 26.1 15.3 27.6

W-12 21/05/2016 38.2 22.5 18.1 32.5

22/05/2016 43.0 25.3 15.1 27.3

W-13 28/05/2016 42.5 25.0 15.3 27.6

29/05/2016 39.9 23.5 16.7 30.1

Minimum 36.9 21.7 12.7 22.9

Maximum 44.5 26.1 18.5 33.4

Average 40.2 23.7 15.5 27.8

98th Percentile

44.2 26.0 18.3 32.9



Page 60 of 262

Table–3.15: AAQ Observations A -9: Basapur Village



W-1 05/03/2016 44.3 24.6 10.8 18.3

06/03/2016 45.4 25.2 12.4 21.1

W-2 12/03/2016 46.2 25.7 9.7 16.5

13/03/2016 47.7 26.5 12.4 21.1

W-3 19/03/2016 45.4 25.2 11.5 19.6

20/03/2016 46.3 25.7 11.9 20.2

W-4 26/03/2016 46.2 25.7 13.1 22.2

27/03/2016 45.1 25.1 13.8 23.5

W-5 02/04/2016 47.9 26.6 11.6 19.7

03/04/2016 44.5 24.7 12.7 21.6

W-6 09/04/2016 48.2 26.8 15.0 25.6

10/04/2016 47.9 26.6 12.4 21.1

W-7 16/04/2016 44.9 24.9 12.4 21.1

17/04/2016 46.0 25.5 14.0 23.7

W-8 23/04/2016 47.4 26.3 11.7 19.8

24/04/2016 48.5 27.0 12.4 21.0

W-9 30/04/2016 43.4 24.1 13.7 23.2

01/05/2016 49.6 27.6 12.9 21.9

W-10 07/05/2016 47.7 26.5 11.7 19.8

08/05/2016 47.4 26.3 13.6 23.1

W-11 14/05/2016 44.5 24.7 15.4 26.3

15/05/2016 46.2 25.7 13.3 22.5

W-12 21/05/2016 47.7 26.5 15.0 25.4

22/05/2016 45.8 25.4 15.4 26.3

W-13 28/05/2016 49.6 27.6 12.5 21.3

29/05/2016 47.4 26.3 13.8 23.5

Minimum 43.4 24.1 9.7 16.5

Maximum 49.6 27.6 15.4 26.3

Average 46.6 25.9 12.9 21.9

98th Percentile 49.6 27.6 15.4 26.3



Page 61 of 262

Table 3.16:Summarized Report of Ambient Air Quality

Details

A-1 At pellet Plant

A-2 Proposed Steel Plant Site

A-3 Allangara Village

PM10

(µg/m3)

PM2.5

(µg/m3)

SO2

(µg/m3) NOx

(µg/m3) PM10

(µg/m3)

PM2.5

(µg/m3)

SO2

(µg/m3) NOx

(µg/m3) PM10

(µg/m3)

PM2.5

(µg/m3)

SO2

(µg/m3) NOx

(µg/m3)

Minimum 46.9 21.3 9.8 15.3 39.8 20.9 9.5 15.9 43.3 22.8 8.4 15.1

Maximum 56.5 25.7 16.3 27.7 49.5 26.1 13.9 23.3 53.0 27.9 18.0 29.5

Average 53.2 24.2 12.5 21.1 44.6 23.5 11.8 19.5 47.3 24.9 13.1 23.2

Details

A-4 Hira Baglani Village

A-5 Kunikeri Tanda Village

A-6 Huvinahalu Village

PM10

(µg/m3)

PM2.5

(µg/m3)

SO2

(µg/m3) NOx

(µg/m3) PM10

(µg/m3)

PM2.5

(µg/m3)

SO2

(µg/m3) NOx

(µg/m3) PM10

(µg/m3)

PM2.5

(µg/m3)

SO2

(µg/m3) NOx

(µg/m3)

Minimum 40.7 22.6 9.9 21.5 37.4 23.4 12.8 21.8 44.1 24.5 15.7 23.1

Maximum 48.6 27.0 17.8 31.4 45.3 28.3 20.7 31.7 50.5 28.1 24.4 31.1

Average 44.8 24.9 12.5 26.1 41.3 25.8 16.1 27.2 47.2 26.2 19.8 28.3

Details

A-7 Koppal Town

A-8 Belanalu Village

A-9 Basapur Village

PM10

(µg/m3)

PM2.5

(µg/m3)

SO2

(µg/m3) NOx

(µg/m3) PM10

(µg/m3)

PM2.5

(µg/m3)

SO2

(µg/m3) NOx

(µg/m3) PM10

(µg/m3)

PM2.5

(µg/m3)

SO2

(µg/m3) NOx

(µg/m3)

Minimum 37.7 17.9 11.3 20.4 36.9 21.7 12.7 22.9 43.4 24.1 9.7 16.5

Maximum 46.5 22.1 21.6 28.7 44.5 26.1 18.5 33.4 49.6 27.6 15.4 26.3

Average 41.6 19.8 13.8 24.2 40.2 23.7 15.5 27.8 46.6 25.9 12.9 21.9



Page 62 of 262

Table 3.17: Percentile Distributions of Various Parameters in Ambient Air Quality

Details

A-1:Project Site One at Proposed Steel Plant Site

A-2:Adjacent From One Pellet Plant A-3:Allangara Village

PM10 (µg/m3)

PM2.5 (µg/m3)

SO2 (µg/m3)

NOx (µg/m3)

PM10 (µg/m3)

PM2.5 (µg/m3)

SO2 (µg/m3)

NOx (µg/m3)

PM10 (µg/m3)

PM2.5 (µg/m3)

SO2 (µg/m3)

NOx (µg/m3)

98th percentile 56.3 25.6 16.3 27.6 49.3 26.0 13.8 23.2 52.5 27.6 17.2 29.2

Details

A-4:Hira Baglani Village A-5:Kunikeri Tanda Village A-6:Huvinahalu Village

PM10 (µg/m3)

PM2.5 (µg/m3)

SO2 (µg/m3)

NOx (µg/m3)

PM10 (µg/m3)

PM2.5 (µg/m3)

SO2 (µg/m3)

NOx (µg/m3)

PM10 (µg/m3)

PM2.5 (µg/m3)

SO2 (µg/m3)

NOx (µg/m3)

98th percentile 48.6 27.0 16.6 30.6 45.1 28.2 19.7 31.7 50.2 27.9 24.2 31.1

Details

A-7:Koppal Village A-8:Belanalu Village A-9:Basapur Village

PM10 (µg/m3)

PM2.5 (µg/m3)

SO2 (µg/m3)

NOx (µg/m3)

PM10 (µg/m3)

PM2.5 (µg/m3)

SO2 (µg/m3)

NOx (µg/m3)

PM10 (µg/m3)

PM2.5 (µg/m3)

SO2 (µg/m3)

NOx (µg/m3)

98th percentile 46.1 22.0 18.8 28.6 44.2 26.0 18.3 32.9 49.6 27.6 15.4 26.3



Page 63 of 262

Table 3.18: National Ambient Air Quality Standards

POLLUTANT UNIT TIME

WEIGHTED AVERAGE

CONCENTRATION IN AIR

INDUSTRIAL AREAS,

RESIDENTIAL RURAL & OTHER

AREAS

SENSITIVE AREAS

PM10 µg/m3 Annual

Average 24 hours

60.0 100.0

60.0 100.0

PM2.5 µg/m3 Annual

Average 24 hours

40.0 60.0

40.0 60.0

Nitrogen Dioxide (NOx)

µg/m3 Annual

Average 24 hours

40.0 80.0

30.0 80.0

Sulphur dioxide (SO2)

µg/m3 Annual

Average 24 hours

50.0 80.0

20.0 80.0

Ozone (O3) µg/m3 8 hours 1 hour

100.0 180.0

100.0 180.0

Lead (Pb) µg/m3 Annual

Average 24 hours

0.50 1.00

0.50 1.00

Carbon monoxide (CO)

mg/m3 8 hours

24 hours 2.0 4.0

2.0 4.0

Ammonia (NH3) µg/m3 Annual

24 hours 100.0 400.0

100.0 400.0

Benzene (C6H6) µg/m3 Annual 5.0 5.0

Benzo(α)Pyrene (BαP) –

Particulate Phase only

ng/m3 Annual 1.0 1.0

Aresnic (As) ng/m3 Annual 6.0 6.0

Nickel (Ni) ng/m3 Annual 20.0 20.0

Refer: GSR 826(E) dated 16th Nov. 2009



Page 64 of 262

Results

On the basis of observations the parameter wise result of monitored parameters are

discussed below.

PM10 Particulate Matter (<10 μm)

The average PM10 concentration at all air quality monitoring stations A-1, A-2, A-3, A-

4, A-5, A-6, A-7, A-8 and A-9 are 53.2, 44.6, 47.3, 44.8, 41.3, 47.2, 41.6, 40.2 and

46.6 µg/m3 respectively. All monitoring station have PM10 concentrations well within

stipulated 24 hours average limit, 100 µg/m3 as prescribed for industrial, residential,

rural and other areas as in revised NAAQ Standards from MoEF&CC. These values

represent quite satisfactory condition regarding PM10 concentration in ambient air.

PM2.5 Particulate Matter (<2.5 μm)

The average PM2.5 concentration at all air quality monitoring stations A-1, A-2, A-3, A-

4, A-5, A-6, A-7, A-8 and A-9 are 24.2, 23.5, 24.9, 24.9, 25.8, 26.2, 19.8, 23.7 and 25.9

µg/m3 respectively. All monitored stations have PM2.5 concentrations well within

stipulated annual 24 hours limit, 60µg/m3 as prescribed for industrial, residential, rural

and other areas as in revised NAAQ Standards from MoEF&CC. These values

represent quite satisfactory condition regarding PM2.5 concentration in ambient air.

Sulphur dioxide (SO2)

The average SO2 concentrations at all sampling stations A-1, A-2, A-3, A-4, A-5, A-6,

A-7, A-8 and A-9 are 12.5, 11.8, 13.1, 12.5, 16.1, 19.8, 13.8, 15.5 and 12.9µg/m3

respectively. All monitored stations have SO2 concentrations well within stipulated

annual 24 hours limit, 80µg/m3 as prescribed for industrial, residential, rural and other

areas as in revised NAAQ Standards from MoEF&CC.

Oxides of Nitrogen (NOx)

The average NOx concentrations at all sampling stations A-1, A-2, A-3, A-4, A-5, A-6,

A-7, A-8 and A-9 are 21.1, 19.5, 23.2, 26.1, 27.2, 28.3, 24.2, 27.8 and 21.9µg/m3

respectively. All monitored stations have NOX concentrations well within stipulated

annual 24 hours limit, 80µg/m3 as prescribed for industrial, residential, rural and other

areas as in revised NAAQ Standards from MoEF&CC.

Carbon Monoxide (CO)

Samples of air were collected and analysed for CO content. All sampling stations have

very less CO content (< 0.2 mg/m3) in comparison of stipulated annual average 2

mg/m3 limit recommended for sensitive area as in revised NAAQ Standards from

MoEF&CC.



Page 65 of 262

Ozone, Ammonia, benzene &b(α)p


gases and compounds i.e. Ozone, Ammonia, Benzene &Benzo (α) Pyrene. The

concentrations of these gases & compounds were either absent or well within as per

NAAQ Standards from MoEF&CC.

Toxic metals (Lead, Nickel & Arsenic)


Toxic Metals i.e. Lead, Arsenic & Nickel. The concentrations of Toxic Metals were either

below detectable limit or well within as per NAAQ Standards from MoEF&CC.

Overall Ambient Air Quality of the plant area and its buffer zone is good and there are

no any abnormal values recorded. Concentrations of all monitored parameters are

within stipulated standards from MoEF&CC AAQ Standards. Some higher values of

particulate matters are result of heavy traffic movement over highways.

3.1.3 Water Environment

The water quality monitoring stations were selected to represent the surface and

ground water quality of water bodies in and around 10 kilometre Buffer Zone of

proposed plant. Sampling stations for water were selected taking all water sources into

account, as per MoEF&CC norms.

The list of ground and surface water sampling stations selected in 10 km buffer zone of

plant expansion is presented in Table-3.19a & 3.19b and in Figure-3.5

Table-3.19a: Descriptive Listing Of Ground Water Sampling Stations

Sr.

No.

Description of the

sampling station

Sample

code

Distance from

proposed plant

Direction Zone

1. Project Site (Bore well) GW-1 Within - Core

2. Allangara Village

(Open Dug Well ) GW-2 2.5km E Buffer

3. Huvinahalu Vil lage (Hand

Pump) GW-3 4.0km W Buffer

4. Kunikeri Tanda (Bore

Well) GW-4 2.0km S Buffer

5. Koppal Village (Bore Well) GW-5 6.0km NW Buffer



Page 66 of 262

Table-3.19b: Descriptive Listing of Surface Water Sampling Stations

Sr.

No.

Description of the

sampling station

Sample

code

Distance

from

proposed

plant

Directio

n

Zone

1. Daddegallu (Hira Nalla) SW-1 8.0km W Buffer

2. Daddegallu (Hira Nalla) SW-2 9.0km W Buffer

3. Hayati Tungbhadra

Reservoir SW-3 8.0km SW Buffer

4. Hira Kasinkandi

Tungabhadra Reservoir SW-4 7.5km SE Buffer

5. Bhimanur (dam Between

Bhimanur & Halhali) SW-5 7.0km NE Buffer

Figure-3.5: Figure Showing Of Ground & Surface Water Sampling Locations

GW 1

GW 2

GW 4

GW 3

GW 5

SW 4

SW 3

SW 1

SW 2

SW 5

SURFACE WATER MONITORING STATION

GROUND WATER MONITORING STATION

76°15'

15°20'

15°15'

76°15'

76°10'

76°10'

15°25'15°25'

15°20'

15°15'



STREAMS

RIVER / NALA

POND

ROAD

HABITATION

GRID

PROJECT SITE

INDEX

RAILWAY LINE

Halavarti

Kunikeri Tanda

Allanagara

Kidadhala


Hire Bagnali

Hire Kasinkandi



Karkihalli


Kunikeri

Hosahalli


Huvinahalu


GingeraBasapur

BelanaluKOPPAL


Mangalpur

Haratattanahalu

GbburGuddanahali

Halhalli

Tavargera

Lebigeri


Naregallu

Daddegallu

Sangapura

Hanumanahalli

Katakkanahalli

Muddaballi

HIRE H

ALLA

ICH

HALA

HALLA

ADDA HALLA

HIRE H

ALLA RS

RESERVOIR RESERVOIR

WATER MONITORING STATION

Samples were collected in March-2016 from all available water sources in

the study area. Grab samples of surface and ground water were collected.

On spot analysis was carried out for the parameters like pH, Temperature,

Odour, Taste, DO etc.



Page 67 of 262

Samples for chemical analysis were collected in polyethylene carboys.

Samples collected for metal content were acidif ied with 1.0 ml HNO 3.

Bacteriological Samples were collected in sterilized glass bottles. Selected

physico-chemical and bacter iological parameters have been analysed for

evaluating the existing base line water quality status in the study area.

Analytical Techniques

The analytical techniques followed for evaluation of water quality were as

per the Standard Methods for the Examina tion of water and wastewater,

22nd Edition, 2012, APHA and the methods for a few parameters is given in

the Table-3.20.

Table-3.20: Methodology for sampling and analysis of water & wastewater

Sr.

No. Parameters

Methods

(Indian Standard) Methods (APHA)

1. pH IS 3025 (part 11) : 1983 APHA-4500-H+

2. Colour IS 3025 (part 4) : 1983 APHA-2120 C

3. Odour IS 3025 (part 5) : 1983 IS:3025, part-4

4. Temperature IS 3025 (part 9) : 1984 APHA-2550 B

5. Dissolved Oxygen IS 3025 (part 38) : 1989 APHA-4500 O

6. BOD IS 3025 (part 44) : 1993 APHA-5210 B

7. COD IS 3025 (part 58) : 2006 --

8. Electrical Conductivity IS 3025 (part 14) : 1984 APHA-2510 B

9. Turbidity IS 3025 (part 10) : 1984 APHA-2130 B

10. Chlorides IS 3025 (part 32) : 1988 APHA-4500 Cl -

11. Fluorides -- APHA-4500 F

12. Total Dissolved Solids IS 3025 (part 16) : 1984 APHA-2540 C

13. Total Suspended

Solids IS 3025 (part 17) : 1984 APHA-2540 D

14. Total Hardness IS 3025 (part 21) : 1983 APHA-2340 C

15. Alkalinity IS 3025 (part 23) : 1986 APHA-2320 B

16. Sulphates IS 3025 (part 24) : 1986 APHA-4500 SO4-2

17. Calcium IS 3025 (part 40) : 1991 APHA-3120 B/ APHA-

3500 Ca

18. Magnesium IS 3025 (part 46) : 1994 APHA-3120 B/ APHA-

3500 Mg

19. Boron IS 3025 (part 57) : 2005 APHA-4500 B

20. Coliforms IS 5401 (part 1) : 2002 APHA-9215 D



Page 68 of 262

Observations

The characteristics of ground and surface water samples are presented in

Table-3.21. Desirable as well as permissible limits for each parameter

prescribed by of Indian Standard: BIS 10500:2012 are also incl uded in the

below tables.



Page 69 of 262

Table – 3.21(A): Analysis Report of Ground Water Samples

Sr. No.

Parameters Units GW1 GW2 GW3 GW4 GW5 As Per IS 10500 of 2012

Acceptable Permissible

Physical Parameters

1 Ambient Temperature 0C 26.1 26.3 25.6 25.3 26.1 - -

2 Colour Hazen CL CL CL CL CL 5 15

3 Odour - AG AG AG AG AG AG AG

4 Taste - - - - - - AG AG

5 Turbidity NTU <5 <5 <5 <5 <5 1 5

6 pH at 25 0C - 7.7 7.4 7.1 7.2 7.4 6.5-8.5 NR

Inorganic Parameters

7 Electrical Conductivity μS/cm 898 890 816 1010 1120 - -

8 Total Dissolved Solids mg/l 550 534.8 486.2 612 663.2 500 2000

9 Total Suspended Solids mg/l <5 <5 <5 <5 <5 - -

10 Total Alkalinity as CaCO3

mg/l 346 492 394 460 342 200 600

11 Total Hardness as CaCO3

mg/l 370 272 428 789 371 200 600

12 Calcium Hardness as CaCO3

mg/l 164 208 220 525 291 - -

13 Calcium as Ca++ mg/l 64.4 81.2 88.0 212.0 116.4 75 200

14 Magnesium as Mg++ mg/l 50.4 17.4 44.4 66.2 22.6 30 100

15 Sodium as Na mg/l 17.0 25.2 20.9 22.2 25.1 - -

16 Potassium as K mg/l 4.2 7.1 7.7 9.5 8.1 - -

17 Chlorides as Cl mg/l 118.7 70.3 73.4 256.7 153.4 250 1000

18 Sulphates as SO4 mg/l 66.8 21.2 41.8 143.4 95.9 200 400

19 Nitrates as NO3 mg/l 14.2 0.3 1.2 21.7 13.4 45 NR

20 Fluoride as F mg/l 0.2 0.2 0.1 0.3 0.2 1 1.5

21 Dissolved Oxygen mg/l - - - - - - -

Pollutants

22 Amonical Nitrogen as NH3-N

mg/l BDL BDL BDL BDL BDL 0.5 NR

23 Nitri te Nitrogen as NO2- mg/l BDL BDL BDL BDL BDL - -



Page 70 of 262

N

24 Total Phosphate as PO4-P

mg/l BDL BDL BDL BDL BDL - -

25 Cyanide as CN mg/l BDL BDL BDL BDL BDL 0.05 NR

26 Phenolic Compounds mg/l BDL BDL BDL BDL BDL 0.001 0.002

29 Total Oil & Grease mg/l BDL BDL BDL BDL BDL - -

27 B O D 3 days 27 0C mg/l - - - - - - -

28 C O D mg/l - - - - - - -

30 Pesticides mg/l Absent Absent Absent Absent Absent Absent NR

31 Poly Nuclear Hydrocarbon (PAH)


Trace Metals

32 Aluminium as Al mg/l BDL BDL BDL BDL BDL 0.03 0.2

33 Arsenic as As mg/l BDL BDL BDL BDL BDL 0.01 0.05

34 Boron as B mg/l BDL BDL BDL BDL BDL 0.5 1.0

35 Cadmium as Cd mg/l BDL BDL BDL BDL BDL 0.003 NR

36 Chromium as Cr6+ mg/l BDL BDL BDL BDL BDL 0.05 NR

37 Copper as Cu mg/l 0.03 0.02 0.03 0.03 0.02 0.05 1.50

38 Iron as Fe mg/l 0.21 0.14 0.28 0.09 0.12 0.3 NR

39 Lead as Pb mg/l BDL BDL BDL BDL BDL 0.01 NR

40 Manganese as Mn mg/l BDL BDL BDL BDL BDL 0.1 0.3

41 Mercury as Hg mg/l BDL BDL BDL BDL BDL 0.001 NR

42 Selenium as Se mg/l BDL BDL BDL BDL BDL 0.01 NR

43 Zinc as Zn mg/l BDL BDL BDL BDL BDL 5 15

Microbiology

44 Coliform MPN/100

ml <3 <3 <3 <3 <3 - -

Note:- BDL is Below Detectable Limit ; Minimum Detectable Limit For parameters tested are as Under (NO2-0.1,PO4-0.05,Oil & Grease-5,BOD-1,COD-5,Al-0.02,AS-0.02,B-0.01,Cd-0.01,Cr+6-0.05,Cu-0.03,Fe-0.05,Pb-0.05, Mn-0.02,Hg-0.001,Zn-0.01, Se =0.005 ) (Unit mg/l). NTU - nephalometery turbitity unit;; NR - no relaxation; MPN - most probable number UO - unobjectionable: AG - agreeable; NA- not applicable



Page 71 of 262

Table – 3.21(B): Analysis Report of Surface Water Samples

Sr. No.

Parameters Units SW1 SW2 SW3 SW4 SW5

As Per IS 10500 of 2012

Acceptable Permissible

Physical Parameters

1 Ambient Temperature 0C 26.4 27.1 26.9 26.6 26.3 - -

2 Colour Hazen CL CL CL CL CL 5 15

3 Odour - AG AG AG AG AG AG AG

4 Taste - - - - - - AG AG

5 Turbidity NTU <5 <5 <5 <5 <5 1 5

6 pH at 25 0C - 7.6 7.5 7.9 7.5 7.8 6.5-8.5 NR

Inorganic Parameters

7 Electrical Conductivity μS/cm 1200 1208 355 328 521 - -

8 Total Dissolved Solids mg/l 727.2 711 215 196 320 500 2000

9 Total Suspended Solids mg/l <5 <5 <5 <5 <5 - -

10 Total Alkalinity as CaCO 3 mg/l 321 328 118 303 203 200 600

11 Total Hardness as CaCO 3 mg/l 267 254 164 190 154 200 600

12 Calcium Hardness as CaCO 3 mg/l 148 141 58 49 46 - -

13 Calcium as Ca++ mg/l 49.2 56.4 21.2 25.6 17.2 75 200

14 Magnesium as Mg++ mg/l 34.6 33.1 21.4 32.9 24.2 30 100

15 Sodium as Na mg/l 40.4 44.8 42.7 56.7 42.1 - -

16 Potassium as K mg/l 12.9 14.1 12.1 16.2 12.1 - -

17 Chlorides as Cl mg/l 220.2 209.3 41.2 49.6 73.7 250 1000

18 Sulphates as SO4 mg/l 122.3 128.6 17.2 14.3 26.1 200 400

19 Nitrates as NO3 mg/l 1.3 1.0 0.2 0.4 BDL 45 NR

20 Fluoride as F mg/l 0.1 0.2 0.1 0.2 0.1 1 1.5

21 Dissolved Oxygen mg/l 6.1 6.8 5.6 5.8 6.1 - -

Pollutants

22 Amonical Nitrogen as NH3-N mg/l BDL BDL BDL BDL BDL 0.5 NR

23 Nitrite Nitrogen as NO 2-N mg/l BDL BDL BDL BDL BDL - -



Page 72 of 262

24 Total Phosphate as PO4-P mg/l 0.1 0.1 0.1 0.1 BDL - -

25 Cyanide as CN mg/l BDL BDL BDL BDL BDL 0.05 NR

26 Phenolic Compounds mg/l BDL BDL BDL BDL BDL 0.001 0.002

29 Total Oil & Grease mg/l BDL BDL BDL BDL BDL - -

27 B O D 3 days 27 0C mg/l 28.0 29.0 23.0 26.0 15.0 - -

28 C O D mg/l 65.0 62.0 90.0 104.0 27.0 - -

30 Pesticides mg/l Absent Absent Absent Absent Absent Absent NR

31 Poly Nuclear Hydrocarbon (PAH)


Trace Metals

32 Aluminium as Al mg/l BDL BDL BDL BDL BDL 0.03 0.2

33 Arsenic as As mg/l BDL BDL BDL BDL BDL 0.01 0.05

34 Boron as B mg/l BDL BDL BDL BDL BDL 0.5 1.0

35 Cadmium as Cd mg/l BDL BDL BDL BDL BDL 0.003 NR

36 Chromium as Cr6+ mg/l BDL BDL BDL BDL BDL 0.05 NR

37 Copper as Cu mg/l 0.01 0.02 BDL BDL BDL 0.05 1.50

38 Iron as Fe mg/l 0.22 0.32 0.56 0.12 0.13 0.3 NR

39 Lead as Pb mg/l BDL BDL BDL BDL BDL 0.01 NR

40 Manganese as Mn mg/l BDL BDL BDL BDL BDL 0.1 0.3

41 Mercury as Hg mg/l BDL BDL BDL BDL BDL 0.001 NR

42 Selenium as Se mg/l BDL BDL BDL BDL BDL 0.01 NR

43 Zinc as Zn mg/l BDL BDL BDL BDL BDL 5 15

Microbiology

BDL BDL BDL BDL BDL BDL

44 Coliform MPN/100

ml >1100 >1100 480 240 >1100 - -

Note:- BDL is Below Detectable Limit ; Minimum Detectable Limit For parameters tested are as Under (NO2-0.1,PO4-0.05,Oil & Grease-5,BOD-1,COD-5,Al-0.02,AS-0.02,B-0.01,Cd-0.01,Cr+6-0.05,Cu-0.03,Fe-0.05,Pb-0.05, Mn-0.02,Hg-0.001,Zn-0.01, Se =0.005 ) (Unit mg/l). NTU - nephalometery turbitity unit;; NR - no relaxation; MPN - most probable number UO - unobjectionable: AG - agreeable; NA- not applicable



Page 73 of 262

Results

The results of analysis are discussed under three headings namely Organoleptic,

Chemical and Health related parameters as per findings and its significance over

environment and human being. Water quality & certain common characteristics have

been described in following paragraphs.

3.3.1 Organoleptic Parameter

A. Ambient Temperature

The ambient temperature of all ground water samples varied from 25.3 to 26.3 ºC:

while for all surface water samples varied from 26.3 to 27.1. All values of ambient

temperature for all ground and surface water samples are representing a scenario,

free of any thermal discharge.

B. Colour, Odour and Taste

Presence of these parameters gives some hints regarding source of water sample.

These parameters are checked at site with help of relevant sense-organs.

Surface water samples and ground water samples are colorless in appearance.

All surface water samples and ground water samples collected for Odour test did not

have any objectionable odour.

Any salty or metallic taste in water samples comes only if salts or metals are present

in high concentration. Here, all surface water samples and ground water samples

have agreeable taste.

C. Turbidity

Turbidity occurs due to presence of suspended matter or colour pigment in water

sample. High values of turbidity indicate abnormal activity in related area.

Turbidity values for all of samples are less than permissible limit (5 NTU) as

prescribed in IS 10500:2012.

3.3.2 Chemical Parameters

pH value

The pH values for all ground water samples are ranging between 7.1 to 7.7, whereas

pH values for all surface water samples are ranging between 7.5 to 7.9. These values

are within desirable range as per IS 10500:2012 standards for drinking water.

A. Dissolved Oxygen

All surface water samples have Dissolved Oxygen levels ranging from 5.6 to 6.8 mg/l.

B. Biochemical Oxygen Demand (BOD)

The Surface water samples have BOD values ranging from 15.0 to 29.0 mg/l. These

results indicate very low organic pollution load. All BOD values are within the

prescribed limit (< 30.0 mg/l) as in IS 2490:1982.



Page 74 of 262

C. Chemical Oxygen Demand (COD)

All surface water samples have COD values in range between 62.0 to 104.0 mg/l. All

water samples are indicating very low organic pollution load in terms of COD. All COD

values are well below the prescribed limit (< 250.0 mg/l) as in IS 2490:1982).

D. Total Dissolved Solids (DS)

The total solids in ground water are in the range of 486.2 to 663.2. All surface water

samples have dissolved solids ranges from 196 to 727 mg/l which are well below

Permissible limit of 2000 mg/l as per IS 10500:2012.

E. Chlorides

The chloride concentrations in all ground water samples have ranged between 70.3 to

256.7 mg/l and all surface water ranges from 41.2 to 220.2 mg/l these values are

below permissible limit of 1000 mg/l as prescribed in IS 10500:2012.

F. Sulphates

The Sulphate concentrations for all ground water samples are ranging between 21.2

to 143.4 mg/l, and all surface water samples ranges from 14.3 to 128.6 mg/l these

values are below acceptable limit of 200 mg/l as prescribed in IS 10500:2012.

G. Total Hardness

All ground water samples have hardness in the range of 272 to 789 mg/l and all

surface water samples ranges from 154 to 267 mg/l which are below the permissible

limit of 600 mg/l

3.3.3 Health Related Parameters

H. Fluorides

All the ground water and surface water samples have fluoride content within the range

of 0.1 to 0.3 mg/l which are much lower than acceptable limit of 1.0 mg/l as per in IS

10500:2012.

I. Nitrate

All ground and surface water samples have low nitrate concentrations ranged between

0.2 to 21.7 mg/l, and much below the acceptable limit of 45 mg/l as per in IS

10500:2012.

J. Heavy Metals

Heavy metals, Boron and other trace elements in all water samples are either absent

or wherever present were below their respective permissible limits.



Page 75 of 262

K. Coliforms

Three surface water samples have Coliforms 240 and >1100 MPN/100 ml. Thus, the

surface water samples are contaminated. This is due to surface runoff entering these

sources.

Overall quality of water samples are showing that the water sources of the area are

not polluted except the surface water samples getting contamination from surface run-

off. The coliforms values are exception otherwise all the water samples are indicating

its characteristics within limit as given in relevant Indian Standards.

3.1.4 Noise Environment

Noise is most often and mostly defined as unwanted sound. In an

environment noise affects the health or interferes with the work zone

activit ies of the people if the noise levels are more than the permissible

levels. Considerable noise gets generated in any industrial situation due to

operation of equipment.

At present, noise at area is produced due to multiple sources of commercial

activit ies, industrial activit ies and due to heavy movement of vehicles on

the road. Noise levels have measured at hourly intervals at Nine Stations

N–1 to N-9 are described at Table-3.22 and noise levels measured at all 8

sites are detailed in Table–3.23. Noise level measurement stations have

shown in Figure–3.6

Table-3.22: Details of Sampling Stations of Noise Level Measurement

Sr. No.

Description of monitored stations

Sample

code

Distance from

proposed plant

Direction

Zone Remark

1. Project Site One at Proposed Steel Plant Site

N-1 Within - Core Core zone

2. Adjacent From One Pellet Plant

N-2 Within - Core Core zone

3. Allanagar Village N-3 2.5km E Buffer Downwind

4. Hire Baganal vil lage N-4 3.5km SE Buffer Upwind

5. Kunikere Village N-5 2.0km S Buffer Downwind

6. Huvinahalu Vil lage N-6 4.0km W Buffer Downwind

7. Koppal Village N-7 6.0km NW Buffer Upwind

8. Belavinal Vil lage N-8 1.5km N Buffer Upwind

9. Basapura Village N-9 3.5km NE Buffer Downwind



Page 76 of 262

Figure-3.6: Figure Showing Locations of Noise Level Monitoring

N-2N-3

N-4N-5

N-6

N-7

N-8

NOISE MONITORING STATION

N-9

76°15'

15°20'

15°15'

76°15'

76°10'

76°10'

15°25'15°25'

15°20'

15°15'



NOISE MONITORING STATION

Halavarti

Kunikeri Tanda

Allanagara

Kidadhala


Hire Bagnali

Hire Kasinkandi



Karkihalli


Kunikeri

Hosahalli


Huvinahalu


GingeraBasapur

BelanaluKOPPAL


Mangalpur

Haratattanahalu

GbburGuddanahali

Halhalli

Tavargera

Lebigeri


Naregallu

Daddegallu

Sangapura

Hanumanahalli

Katakkanahalli

Muddaballi

HIRE H

ALLA

ICH

HALA

HALLA

ADDA HALLA

HIRE H

ALLA RS

STREAMS

RIVER / NALA

POND

ROAD

HABITATION

GRID

PROJECT SITE

INDEX

RAILWAY LINE

RESERVOIR RESERVOIR

N-1

Parameters Measured During Monitoring

For noise levels measured over a given period of t ime interval, it is

possible to describe features of noise using statistical quantit ies. This is

calculated using the percent of the time certain levels exceeds the time

interval. The notation for the statistical quantit ies of noise lev els is

described below.

i. Hourly Leq values have been computed by integrating sound level meter.

i i. Lday: As per the CPCB guidelines the day time limit is between 0600 to

2200 hours as outlined in the Ministry of Environment and Forest

Notif ication S.O. 123 (E) dated 14/02/2000.

i i i. Lnight: As per the CPCB guidelines the night t ime limit is between 2200 to

0600 hours as outlined in the Ministry of Environment and Forest

Notif ication S.O. 123 (E) dated 14/02/2000.

A noise rating developed by E P A for specif icat ion of community noise

from all the sources, is the Day-Night Sound Level (Ldn).



Page 77 of 262

Method of Monitoring

Noise level monitoring was performed April -2016. Noise level monitoring

was carried out continuously for 24-hours with one hour interval starting at

0030 hrs to 0030 hrs next day. The noise levels were monitored on working

days only and Sundays and Public holidays were not monitored. During

each hour Leq were directly computed by the instrument based on the

sound pressure levels. L day (Ld), Ldn values were computed using

corresponding hourly Leq of day and night respectively. Monitoring was

carried out at ‘A’ response (slow mode) and at fast mode.

Observations

The observations for noise level measurement had collected for continuous

24-hours. Measured noise levels are given below in Table-3.23

Table-3.23: Measured Noise Levels At Monitored Stations Noise Level in dB(A)

Time (Hrs) Stations Code

N1 N2 N3 N4 N5 N6 N7 N8 N9

Day Time

600 38.0 38.3 38.5 38.7 39.3 39.1 39 39.3 38.9

700 38.4 38.7 38.9 39.1 38.7 38.5 40.8 41.1 40.7

800 39.4 39.7 39.9 40.1 40.8 40.6 39.7 40 39.6

900 41.5 41.8 42.0 42.2 41.1 40.9 40.4 40.7 40.3

1000 39.7 40.0 40.2 40.4 39.9 39.7 39.9 40.2 39.8

1100 41.2 41.5 41.7 41.9 41.0 40.8 41.9 42.2 41.8

1200 41.5 41.8 42.0 42.2 44.0 43.8 43.4 43.7 43.3

1300 45.9 46.2 46.4 46.6 41.9 41.7 42.4 42.7 42.3

1400 48.5 48.8 49.0 49.2 40.5 40.3 43 43.3 42.9

1500 50.4 50.7 50.9 51.1 43.8 43.6 41.2 41.5 41.1

1600 51.8 52.1 52.3 52.5 45.9 45.7 44.6 44.9 44.5

1700 53.4 53.7 53.9 54.1 48.0 47.8 43.2 43.5 43.1

1800 54.8 55.1 55.3 55.5 46.0 45.8 42 42.3 41.9

1900 52.4 52.7 52.9 53.1 41.9 41.7 50 50.3 49.9

2000 48.9 49.2 49.4 49.6 41.1 40.9 50.4 50.7 50.3

2100 49.5 49.8 50.0 50.2 40.4 40.2 44 44.3 43.9

2200 51.1 51.4 51.6 51.8 42.9 42.7 47 47.3 46.9

Night Time

2300 45.9 46.2 46.4 46.6 44.4 46.2 42.9 43.2 42.8

2400 48.5 48.8 49 49.2 43.8 45.6 41.1 41.4 41.0



Page 78 of 262

100 48.2 48.5 48.7 48.9 39.9 41.7 44.4 44.7 44.3

200 46.5 46.8 47 47.2 40.9 42.7 46.4 46.7 46.3

300 45.2 45.5 45.7 45.9 38.7 40.5 42.4 42.7 42.3

400 41.9 42.2 42.4 42.6 39.7 39.5 40.1 40.4 40.0

500 39.6 39.9 40.1 40.3 38.9 40 40.8 41.1 40.7

Range 38.0 - 54.8

38.3 - 55.1

38.5 - 55.3

38.7 - 55.5

38.7 - 48.0

38.5 - 47.8

39.0 - 50.4

39.4 - 50.7

38.9 - 50.3

Results

It has found that in the proposed plant buffer zone, noise levels are in the range of 38.0

– 55.5 dB(A) at all nine stations. Maximum levels of noise have recorded in day hours

which are natural as our most of activities have done in day hours.

3.1.5 Soil Environment Soil samples were collected at selected locations in the study area to

assess the existing soil conditions around the proposed plant expansion

area. This will establish the baseline cha racteristics and will facilitate

identifying the incremental concentrations due to the proposed project at a

later stage. The baseline characteristics, which are analysed now, include

the impact on soil due to all the miscellaneous activit ies and natural s oil

quality. The soil quality data have generated for April -2016.

Overall, f ive sampling locations have been selected at proposed study

area. The locations of sampling station are given at Table-3.24 and the

locations of soil sampling points have shown in Figure-3.7

Table-3.24: Details of Soil Sampling Locations

Sr. No.

Sampling Sites Station Code

Distance from proposed plant

Area

Direction Zone

1. Project site (Barren Land) S – 1 Within - Core

2. Hire Baganal (Agri. Land) S – 2 4.0km SE Buffer

3. Kunikeri (agri. Land) S – 3 1.5km NW Buffer

4. Huvinahalu (Barren Land) S – 4 Within - Core

5. Belanalu (Agri. Land) S – 5 1.6km SE Buffer



Page 79 of 262

Figure3.7: Figure Showing Locations of Soil Sampling Locations

15°25'15°25'

15°20'

15°15'



S-1

S-5

S-2S-3

S-4

SOIL MONITORING STATION

SOIL MONITORING STATION

Halavarti

Kunikeri Tanda

Allanagara

Kidadhala


Hire Bagnali

Hire Kasinkandi



Karkihalli


Kunikeri

Hosahalli


Huvinahalu


GingeraBasapur

BelanaluKOPPAL


Mangalpur

Haratattanahalu

GbburGuddanahali

Halhalli

Tavargera

Lebigeri


Naregallu

Daddegallu

Sangapura

Hanumanahalli

Katakkanahalli

Muddaballi

HIRE H

ALLA

ICH

HALA

HALLA

ADDA HALLA

HIRE H

ALLA RS

STREAMS

RIVER / NALA

POND

ROAD

HABITATION

GRID

PROJECT SITE

INDEX

RAILWAY LINE

RESERVOIR RESERVOIR

76°15'

15°20'

15°15'

76°15'

76°10'

76°10'

Methodology of Sampling & Analysis

Samples were col lected of April-2016 from all the sources. Total f ive

samples from f ive different locations of three different depths viz. 0 -30, 30-

60 and 60-90 cm below the surface and homogenized from each. This

method is in line with IS: 2720 & Methods of Soil Analysis , Part-1, 2nd

edition, 1986 (American Society for Agronomy and Soil Science of

America). Samples were collected from two types i.e. agriculture land and

Barren land. The soil samples were collected and analyses once during

study period.

The homogenized samples were analysed for physical and chemical

characteristics. The samples have been analysed as per the established

scientif ic methods for physico-chemical parameters. The parameters and

relevant standard methods have described in Table-3.25.



Page 80 of 262

Table-3.25: Analytical Techniques for Soil Analysis

Parameters Method (Indian Standard)

Method (ASTM number)

Particle size distribution

IS 2720 Sieve analysis (D 422 – 63)

Natural Moisture IS 2720 -

Texture Classif ication

IS 2720 Chart developed by Public Roads Administration

Inf iltration rate IS 2720 Inf iltrometer

Liquid Limit IS 2720 -

Plastic Limit IS 2720 -

Bulk density IS 2720 Sand replacement, core cutter

Porosity IS 2720 Void ratio

pH IS 2720 pH meter (D 1293 – 84)

Electrical conductivity

IS 2720 Conductivity meter (D 1125 – 82)

Nitrogen IS 2720 Kjeldahl distil lation (D 3590 – 84)

Phosphorous IS 2720 Molybdenum blue, colorimetric (D 515 – 82)

Potassium IS 2720 Flame Photometer (D 1428 – 82)

Observations:

The physico-chemical characteristics of soil samples have reported in

Table-3.26 to Table-3.30.



Page 81 of 262

Table-3.26: Barren Land Project Site (S-1)

Sr. No.

Parameters Unit S-1

00.0 - 30.0 cm

30.0 - 60.0 cm

60.0 - 90.0 cm

A. PHYSICAL PROPERTIES

1 Colour -- Red Red Red

2 Soil Texture -- Loam Silt loam Silt loam

3 Grain Size Distribution %

Gravel 2 2 2

Sand 38 34 32

Silt 47 50 52

Clay 13 14 14

4 Natural Moisture Content

% 6 6 8

5 Bulk Density gm/cc 1.71 1.73 1.70

6 Liquid Limit % 40 41 43

7 Plastic Limit % 19 20 20

8 Porosity % 54.42 54.31 55.08

9 Water Retention Capacity

% 35.09 33.46 37.44

B. CHEMICAL PROPERTIES

1 pH - 6.68 7.12 6.89

2 Electrical Conductivity

mmhos/cm 0.028 0.034 0.032

3 Organic Matter % 0.34 0.54 0.41

4 Calcium as Ca++ mg/kg 1.8 2.1 3.2

5 Magnesium as Mg++ mg/kg 2.1 1.2 1.8

6 Chlorides as Cl mg/kg 12.9 15.4 18.1

7 Sulphates as SO4 mg/kg 111.0 123.0 132.0

8 Total Nitrogen as N kg/ha 145.0 233.1 188.2

9 Total Phosphorous as P

kg/ha 23.4 31.0 34.7

10 Total Potassium as K kg/ha 256.6 307.1 317.2



Page 82 of 262

Table-3.27: Agriculture Land In Hira Baglani Village (S-2)

Sr. No.

Parameters Unit

S-2

00.0 - 30.0 cm

30.0 - 60.0 cm

60.0 - 90.0 cm



2 Soil Texture -- Sandy loam

Loamy sand

Loamy sand


Gravel 2 Nil 2

Sand 62 83 76

Silt 30 14 18

Clay 6 3 4


% 14 11 13


6 Liquid Limit % Nil Nil Nil

7 Plastic Limit % Nil Nil Nil

8 Porosity % 57.17 59.94 38.25


% 30.78 22.49 27.48


1 pH - 8.01 7.88 7.87


mmhos/cm 0.067 0.075 0.068

3 Organic Matter % 0.39 0.12 0.32







kg/ha 29.8 41.8 16.2

10 Total Potassium as K

kg/ha 280.1 177.7 219.1



Page 83 of 262

Table-3.28: Waste Land In Kunikeri Tanda Village (S-3)

Sr. No.

Parameters Unit

S-3

00.0 - 30.0 cm

30.0 - 60.0 cm

60.0 - 90.0 cm



2 Soil Texture -- Silt loam Silt loam Loam


Gravel 2 2 2

Sand 32 33 36

Silt 50 50 48

Clay 16 15 14


% 4 7 7




8 Porosity % 43.44 38.69 36.44


% 31.34 31.20 31.55


1 pH - 8.81 7.98 7.67


mmhos/cm 0.032 0.036 0.038

3 Organic Matter % 0.28 0.43 0.68







kg/ha 32.9 34.1 43.9




Page 84 of 262

Table-3.29: Barren Land In Huvinahalu Village (S-4)

Sr. No.

Parameters Unit

S-4

00.0 - 30.0 cm

30.0 - 60.0 cm

60.0 - 90.0 cm



2 Soil Texture -- Sandy loam

Sandy loam

Sandy loam


Gravel 7 12 22

Sand 61 63 48

Silt 28 22 24

Clay 4 3 6


% 5 4 6


6 Liquid Limit % Nil Nil Nil

7 Plastic Limit % Nil Nil Nil

8 Porosity % 46.64 45.28 54.97


% 21.53 22.15 20.32


1 pH - 6.05 5.98 6.03


mmhos/cm 0.026 0.027 0.022

3 Organic Matter % 0.32 0.51 0.29







kg/ha 42.1 89.0 88.0




Page 85 of 262

Table-3.30: Agriculture Land In Belanalu Village (S-5)

Sr. No.

Parameters Unit

S-5

00.0 - 30.0 cm

30.0 - 60.0 cm

60.0 - 90.0 cm



2 Soil Texture -- Loam Loam Loam


Gravel 4 6 4

Sand 40 32 43

Silt 44 41 42

Clay 12 11 11


% 12 13 13




8 Porosity % 51.39 53.14 52.28


% 22.00 20.73 22.97


1 pH - 7.80 7.91 7.64


mmhos/cm 0.084 0.061 0.068

3 Organic Matter % 0.43 0.38 0.44







kg/ha 91.0 76.3 65.1




Page 86 of 262

Standard Soil Classification

Standard soil classif ication regarding agriculture, in view of its test

parameters, is detailed below in Table-3.31. The use of soil for agriculture

or for other use may be decided on basis of soil characteristics.

Table-3.31: Standard Soil Classification

SR. NO.

TEST PARAMETERS

CLASSIFICATION

1. pH

< 4.50 extremely acidic 4.51-5.00 very strongly acidic 5.01-5.50 strongly acidic 5.51-6.00 moderately acidic 6.01-6.50 slightly acidic 6.51-7.30 neutral

7.31-7.80 slightly alkaline 7.81-8.50 moderately alkaline 8.51-9.0 strongly alkaline > 9.0 very strongly alkaline (* tolerable to crops)

2.

Salinity or Electrical Conductivity (mmhos/cm) (1mmhos/cm = 640 ppm)

upto 1.00 average 1.01-2.00 harmful to germination 2.01-3.00 harmful to crops > 3.00 sensitive to salts

3. Organic Carbon (%)

upto 0.30 very less 0.31-0.40 less 0.41-0.50 medium 0.51-0.80 on an average suff icient

0.81-1.00 sufficient > 1.0 more than suff icient

4. Nitrogen (kg/ha) upto 50 very less 51-100 less 101-150 good

151-300 better > 300 sufficient

5. Phosphorous (kg/ha)

upto 15 very less 16-30 less 31-50 medium

51-65 on an average suff icient 65-80 suff icient > 80 more than sufficient

6. Potassium (kg/ha)

0 very less 120-180 less 181-240 medium

241-300 average 301-360 better > 360 more than suff icient

Source: Hand book of Agr iculture ICAR (Indian Council of Agr iculture Research



Page 87 of 262

Results and Discussion

The observations of soil characteristics are discussed parameter wise

below.

a. Texture of soil samples from agriculture lands are sandy loam, silt loam

and loam. Samples from barren lands are loam and silt - loam in Texture

Classif ication.

b. Colour of soil samples from agriculture and barren land are red in colou r.

c. The bulk density of soil samples from agriculture land are in the range of

1.66 to 1.93 g/cc and sample from Barren land are in the range of 1.70 to

1.84 g/cc.

d. Soil samples from agriculture land have pH values 7.64 to 8.81 and sample

from barren land have 5.98 to 7.12 ranges of pH values. The pH values are

indicating nature of soil samples is neutral to alkaline.

e. Soil samples from agriculture land have conductivities 0.032 to 0.084

mmhos/cm however; conductivity of soil sample from barren land ran ges

between 0.022 to 0.034 mmhos/cm.

f. Soil samples from agriculture land have Organic Matter 0.12 to 0.68 % and

sample from barren land have between 0.29 to 0.54 % Organic Matter.

These values represent good fertility of soils.

g. Soil samples from agriculture land have concentration of Available

Nitrogen values ranged 112.2 to 188.2 kg/ha and samples from barren land

range between 132.0 to 233.1 kg/ha Available Nitrogen value.

h. Soil sample from agriculture land have concentration of Available

Phosphorous values ranged 16.2 to 91.0 kg/ha and soil samples from

barren land have concentration values ranges from 23.4 to 89.0 kg/ha.

i. Soil sample from agriculture land have concentration of Available

Potassium values range between 177.7 to 352.1 kg/ha, whereas sample

from barren lands concentration of Available Potassium as its values range

234.7 to 317.2 kg/ha.

Characteristic of barren and on agriculture land soil is a litt le deficient in

nutrients concentration. Whereas, two agricultural land soils are moderately

suitable for cultivation of climatic crops and have good fertility.



Page 88 of 262

3.1.6 Land Environment

General topography of the area is gradually undulating to flat, known as northern

"Maidan" region where the area is sloping towards south and south-east. Low

isolated hill ranges or hillocks marked by this area. These hills are of granites and

Dharwad schists. Most of them are bare or with very sparse vegetation cover. At

many places, heaps of bare rock boulders can be observed. Their direction is

mainly from the north-west to the south or the south-east and their height varies

between 530 m and 570 m above MSL while the average height of the terrain is

around 500 m above the MSL.

The undulating terrain and valley portions are marked prominently by black cotton

soil in the western and northern part of the study area and the remaining part are

dominated by red loamy soil. These soils are dissected by most of small non-

perennial streams.

Few streams are there which the tributaries of Tungabhadra River are. Few water

ponds namely Ginigera tank, Pond near Kunikeri village, Pond near Kerehalli

village exists in the study area. Part of the Tungabhadra River and the part of

reservoir of Tungabhadra dam falls in the general study area.

Due to the scanty rainfall from south-west monsoon and poor soil condition in the

area, the vegetative growth is limited near the watercourses and that too is

observed on the banks of the Tungabhadra River and canals.

Land use pattern of the study area has been assessed through Remote Sensing

methodology using IRS-P6, LISS-III geocoded images. Figure-3.8 shows

the satellite imagery around the Project.



Page 89 of 262

Figure-3.8: Figure showing satellite imagery

Land use / land cover categories identified in the area are Agriculture, Built -up,

Forest, Industry, Mining, Open Land, Reservoir, River, Wasteland and Waterbody.

The land use pattern of the study area is given below and in detail presented in

Figure-3.9 and Table–3.32.



Page 90 of 262

Figure-3.9: Figure Land Use / Land Cover Map of 10Km Radius.

Table-3.32: Land Use / Land Cover in 10 Km Radius

Land use / Land

cover Area Ha. % To Total

Agriculture 17699.25 56.0186176

Built-up 1870.46 5.92005324

Forest 648.99 2.05407101

Industry 556.41 1.76104171

Mining Area 1340.07 4.24135136

Open Land 2625.47 8.30968081

Reservoir 2751.14 8.70744782

River 197.66 0.62560244

Wasteland 3739.05 11.8341801

Waterbody 166.81 0.52795395

Total Area 31595.31 100



Page 91 of 262

List of Major Industries in Study Area

Table-3.33: List of Major Industries in 10 Km Radius

Sr. No Name of Industries Distance

1 Scan Ispat Pvt Ltd. 05 kms by road

2 Xindia Steels Limited. 12 kms by road

3 Hospet Steels Limited. 8 kms by road

4 Kirloskar Ferrous Industries Ltd. 15 kms by road

5 Tungabhadra Fertilizers & Chemicals

ltd 20 kms by road

6 Coca Cola Limited 8 kms by road

3.1.7 Geology

Regional Geology

The geological history of Karnataka is largely confined to the two oldest

areas -

The Archean

The Proterozoic

The rest of the great periods from Cambrian to Recent hardly represented

but for minor sediments of recent age along the coastal margin to the west.

Thus the bulk of the rocks of Karnataka, therefore are Archean in age going

back to the very dawn of geological history. The study area largely falls in

the basin of Tungabhadra River. It lays between two major river systems of

South India namely the Krishna and the Tungabhadra. The area is marked

with undulating topography with granite hil ls and a few chains of hills

composed of Dharwad schists.

The Geological Time-Scale in Karnataka is as given below:

Laterite, alluvium, black soils

Coastal Tertiary

Deccan Volcanic

Bhima

Badami

Hospet Granite

Dharwar Schist Belt

Kolar type Auriferous Schist Belt



Page 92 of 262

Older Gneissic Complex

Ancient Supracrustals (Sargar Group)

Basement not seen

Local Geology

The main rock types found in the Study Area are:

Table-3.34: The Rock Types Found in the Study Area

Sr

.

No

Rock Series Description

1. Pleistocene and Recent Reddish, light green, reddish brown and black

soils

2. Precambrian: Kaladgi

series Sandstone and conglomerate basic dyke

3. Archaean

i. Peninsular Complex Granite porphyrit ic, Red Seynite Pink genesis

Grey genesis

i i. Dharwars

Chlorite schist, Talc chlorite schist,

Ferruginous quartzite, Hornblende schist,

Granodiorite rocks, Quartzite, Amphibolite

Stratigraphy around Ginigera and Koppal is as follows:

Table-3.35: Stratigraphic sequence observed around Koppal & Ginigera

Pleistocene & Recent Reddish brown and black Soil

Peninsular Complex

Granite porphyry

Pink and Grey Gneiss's

Dharwar Super Group

Ferruginous Quartzite

Granodiorite rock

Quartzite

Amphibolite



Page 93 of 262

Dharwar:

The Dharwar series of rocks occur in the form

of three prominent bands viz., the Kustagi

band, the Maski band, and the Raichur band.

The Kustagi band and Maski band and minor

patches of Dharwar are made of a

metamorphic series comprising chlorite

schist, banded ferruginous Quartzite’s,

hornblende schist, trappoid schist, diabotic

schist and Amphibolite.

3.1.8 Flora & Fauna

Ecosystems play a key role in balancing the human-environment relations. Their

plant species consumes solar radiation along with water and minerals and

produces food and oxygen rich air for other components of ecosystem. They also

accumulate the toxic air pollutants whereas animal population consumes organic

waste. They are particularly valuable as repositories of many unique varieties of

flora and fauna.

Large-scale development projects alter the natural surrounding and hence impact

on ecosystem and its components i.e. flora and fauna, is obvious. Before

implementing such projects, it is vital to understand the baseline status of floral

and faunal diversity. The baseline data helps to design project in such a way that

any harmful impacts on the vegetation and fauna can be avoided. It also provides

an insight to mitigate plans to reorganize adverse impact on the natural

surroundings.

An ecological survey of the study area was conducted particularly with reference to

listing of species and assessment of the existing baseline ecological (Terrestrial

and Aquatic ecosystem) conditions.

The core study area is 10 km radius around the proposed site. The general

topography of the area is gradually undulating to flat. It is sloping towards

southeast. It is marked with isolated hill ranges or hillocks. These hills are of

granites and Dharwar schists. The rocks exposed in the area are Pre-Cambrians.

The hills are made up of granites and meta-sediments such as Quartzite, BHQ.

The oldest rocks exposed in the area are peninsular gneiss and it is exposed in

the riverbed. Hills formed due to BHQ and meta-sediments have flat tops and

gentle slopes, whereas granitic hills are dome shaped as they are made up of

massive granite boulders on top of each other. Most of them were bare or with

very scanty vegetation. Heap of bare rock boulders was a common feature of this

area. The average elevation of land surface is 500 m above the MSL.



Page 94 of 262

Flora

Natural flora and fauna are important features of environment. They are organized

into communities with mutual dependencies among their members and show

various responses and sensitivities to outside influences. Therefore, nature of

development and baseline characteristics of terrestrial flora and fauna around the

site of existing activities is required to be assessed. Assessment of study area was

carried out by collecting field data and collating available information.

The topography and relief of the area is southward. The study area best

represents as arid or semi-arid region. The vegetation is very sparse consisting

mainly stunted, thorny or prickly shrubs and herbs capable of drought resistance.

Trees are very few and scattered. The vegetation can be described as scrubland

and almost xerophytic in nature. The floristic survey was carried out in the

proposed area. Overall 346 plant species have been recorded.

The total genera of plants are 247 and species 346 belonging to 80 families;

indicating the floristic richness of the area. However, these species are very

sparse in their distribution. The most dominant genera were Acacia and Cassia (8

species each) followed by Euphorbia and Ficus (7 species each) and Cyperus (5

species). The most dominant family was Asteraceae(25 species) followed by

family Fabaceae and Poaceae (22 species each). These are followed by,

Mimosaceae (19 species), Caesalpinaceae and Euphorbiaceae (16 species each),

Asclepiadaceae (11 species) and Cucurbitaceae (10 species).

There was predominance of herbs (114) and shrubs (86) followed by trees (74),

climbers (30) and grasses (19), sedges (06), palms (03). The common climbers

are Sarcostemma brevistigma (Photo-2), Wattakaka volubilis, Pergularia daemia,

Cocculus villosus, and Rivea ornate.

Herbaceous Flora of the Area

The most frequent and abundant herbaceous flora includes the species like

Parthenium, Evolvulus, Spermacoce, Hedyotis, Alysicarpus, Leucas, Mollugo,

Euphorbia, Pulicaria, Polygala, Cassia, along with the grasses like Aristida,

Heteropogon, Melanocenchrus, Tripogon, Chloris, Chrysopogon, Sporobolus,

Dactyloctenium etc.

The herbaceous vegetation was surveyed by random walk through the forest,

agriculture, and pasturelands. The abundant herb species includes Celosia

argentea, Aca/ypha indica, Lepidagathis sp, Ageratum sp., Euphorbia sp.,

Tephrosia sp., Cassia sp., Alysicarpus sp., Leucas sp., Sida sp., Boerrhavia sp.,

Polygala sp., Amaranthus sp., Evolvulus sp., Parthenium sp., Tridax sp., etc.



Page 95 of 262

Grasses and Sedges

The ecological surveys also include the documentation of grasses and sedges.

The grasses and sedges occupy important status in the herbaceous flora. The

grasses usually manage to grow on outskirts of the forests, in degraded forests,

and wastelands, whereas the sedges are adapted to grow along the watercourse.

The grasses are useful as fodder and subsequent grazing and to check the

exposure of soil. The important grass species comprising the region are Digitaria,

Dimeria, Dactyloctenium, Aristida, Chloris, Setaria, Cenchrus, and Cyperus sp.

Weed Flora

The area represents agriculture as major land use pattern. Majority of land is canal

or well irrigated. As a result large number of weeds grow in the agricultural fields.

Especially the irrigated fields are having high number of weeds. The weed density

may vary depending on the season. The typical weeds of the area recorded are

Bidens sp., Blumea sp., Cassia sp., Desmodium sp., Alternanthera sp., Acalypha

sp., Ageratum sp., Alysicarpus sp., Argemone mexicana, Euphorbia sp. Etc.

The Exotic flora

The local people cultivate many ornamentals. horticultural plants. important

vegetables, trees, shrubs and climbers for aesthetic purpose These represent

fairly high number of exotic species. It has further enriched the flora. The forest

department has introduced some species for plantation, which involves Eucalyptus

sp. and Casuarina equisetifolia. Among the exotic flora most common species are

Delonix regia, Eucalyptus sp., Pithecolobium dulce, Polyalthia longifolia, Plumeria

alba, Nerium odorum, Bougainvillea spectabilis, Canna indica, etc. Some of the

species are now naturalized in the area though they are exotic in nature. These

include Casuarina, Prosopis juliflora, and Leucaena etc.

Agriculture Pattern

The main and use in around the proposed area is farming, mainly cultivated

with crops like Sugarcane (Saccharum off icinarum), Rice (Oryza sativa),

Wheat (Trit icum aetivum), Red gram (Cajanus cajan) and Groundnut

(Arachis hypogea).

The other crops taken are Sunflower (Helianthus annuus), Bajara

(Pennisettum sp.) and Jwari (Sorghum vulgare). The leafy vegetable crops

are Brassica oleracea var capitata, Spinac ia oleracea, Coriandrum sativum,

and Amaranthus sp. The Peucedanum graveolens (Shepu) is found

cultivated occasionally. The fruit vegetables are Tomato (Lycopersicon

esculenta), Brinjal (Solanum melongea) and Capsicum annum.

The important fruit plants are Musa paradisica (Banana), Mangifera indica

(Mango), Carica papaya (Papita), Psidium guyava and Syzigium cumini

(Jamun). Occasionally, Achrus sapota was found grown nearby the houses.



Page 96 of 262

The wild fruit species are Ziziphus maurit iana, Carissa spinarum and

Cordia dichotoma. The farms are interspersed with human habitation,

villages and townships.

The most common grasses Cenchrus barbatus, Lasiurus hirsutus,

cymbopogon jwarancusa and Aristida sp. are found to grow in this region.

Table-3.36: List of Plant Species Recorded From the Study Area

Botanical Name Habit Family

Trees

Acacia chundra (Roxb. ex Rottler) Willd. Tree Mimosaceae

Acacia farnesiana Willd. Tree Mimosaceae

Acacia ferruginea DC. Tree Mimosaceae

Acacia leucophloea Willd. Tree Mimosaceae

Acacia nilotica (L.) Wild. Tree Mimosaceae

Aegle marmelos Corr. Tree Rutaceae

Ailanthus excelsa Roxb. Tree Simaroubaceae

Albizzia lebbek Benth. Tree Mimosaceae

Albizzia procera Benth. Tree Mimosaceae

Anogeissus pendula Edgew. Tree Combretaceae

Areca catechu L. Tree Arecaceae

Azadirachta indica Juss. Tree Meliaceae

Balanites aegyptiaca (L.) Del. Tree Balanitaceae

Bauhinia purpurea Linn. Tree Caesalpinaceae

Bauhinia racemosa Lamk. Tree Caesalpinaceae

Bauhinia variegata Linn. Tree Caesalpinaceae

Borassus f labellifer Linn. Tree Arecaceae

Butea monosperma (Lam.) Taub. Tree Fabaceae



Page 97 of 262


Carica papaya Linn. Tree Caricaceae

Cassia f istula Linn Tree Caesalpinaceae

Cassia siamea Lamk. Tree Caesalpinaceae

Casuarina equisetifolia Forst. Tree Casuarinaceae

Ceiba pentandra Gaertn. Tree Bombacaceae

Cocos nucifera Linn. Tree Arecaceae

Cordia dichotoma Forst.f. Tree Boraginaceae

Dalbergia latifolia Roxb. Tree Fabaceae

Delonix regia (Bojer) Raf. Tree Caesalpinaceae

Dolichandrone sp. Tree Bignoniaceae

Etythrina indica Lam. Tree Fabaceae

Eucalyptus sp. Tree Myrtaceae Euphorbiaceae Euphorbia pulchen-ima Wilid. Tree

Euphorbia tirucalli Linn. Tree Euphorbiaceae

Ficus bengalensis Linn Tree Moraceae

Ficus benjamina Linn. Tree Moraceae

Ficus racemosa L. Tree Moraceae

Ficus religiosa Linn. Tree Moraceae

Holoptelia integrifolia Planch Tree Ulmaceae

Jacaranda mimosaefolia D. Don Tree Bignoniaceae

Kigelia pinnata DC. Tree Bignoniaceae

Leucaena leucocephala (Lam.) de Wit. Tree Mimosaceae

Mangifera indica L. Tree Anacardiaceae Meliaceae

Melia azedarach L. Tree Meliaceae

Millingtonia hortensis Linn. Tree Bignoniaceae

Moringa oleifera Lam. Tree Moringaceae

Peltophorum pterocarpum (DC.) Baker ex K. Heyne Tree Caesalsinaceae

Phoenix sylvestris Roxb. Tree Arecaceae

Pithecolobium dulce Benth. Tree Mimosaceae

Pithecolobium samara Benth. Tree Mimosaceae

Plumeria acutifolia Poir. Tree lApocynaceae



Page 98 of 262


Plumeria alba Linn. Tree Apocynaceae

Polyalthea longifolia (Sonnerat) Thw. Tree Annonaceae

Pongamia pinnata (L.) Pierre Tree Fabaceae

Prosopis spicigera Linn. Tree Mimosaceae

Santalum album Linn. Tree Santalaceae

Spathodea campanulata Beauv. Tree Bignoniaceae

Syzygium cumini (L.) Skeels Tree Myrtaceae

Tectona grandis Linn. Tree Verbenaceae

Terminalia catappa Linn. Tree Combretaceae

Thespesia populnea Soland Tree Malvaceae

Thevetia neriifolia Juss. Tree Apocynaceae

Wrightia tinctoria R.Br. Tree Apocynaceae

Ziziphus maurit iana Lam. Tree Rhamnaceae

Ziziphus nummularia (Burm.f.) Wight & Arn. Tree Rhamnaceae

Ziziphus xylopyrus (Retz.) Wiild. Tree Rhamnaceae

Shrubs

Abutilon indicum Sweet. Shrub Malvaceae

Adhatoda vasica Nees. Shrub Acanthaceae

Aerua lanata Juss. Shrub Amaranthaceae

(Agave americana Linn. Shrub Agavaceae

Agave cantala Roxb. Shrub Agavaceae

Alangium salvifolium (L.f.) Wangerin Shrub Alangiaceae

Aloe vera Linn. Shrub Liliaceae

Annona squamosa L. Shrub Annonaceae

Asclepias curasavica Linn. Shrub Asclepiadaceae

Asparagus officinalis Linn. Shrub Asparagaceae

Barleria prionitis Linn. Shrub Acanthaceae

Caesalpinia bonducella Fleming Shrub Caesalpinaceae

Calotropis gigantea R.Br. Shrub Asclepiadaceae

Calotropis procera R. Br. Shrub Asclepiadaceae

Canna indica Linn. Shrub Cannaceae



Page 99 of 262


Canthium dicoccum (Gaertn.) Teys. & Binn. Shrub Rubiaceae

Capparis decidua Pax. Shrub Capparaceae

Carissa spinarum Linn. Shrub Apocynaceae

Cassia auriculata L. Shrub Caesalpinaceae

Cassia occidentalis Linn. Shrub Caesalpinaceae

Cassia sophera Linn. Shrub Caesalpinaceae

Catunaregam spinarum (Thunb) Tirveng Shrub Rubiaceae

Chromolaena odorata (L.) King Robinson Shrub Asteraceae

Clerodendrum indicum (L.) Kuntze Shrub Verbenaceae

Clerodendrum phlomidis Linn. Shrub Verbenaceae

Commiphora sp. Shrub Burserac.:eae

Crossandra undulaefolia Salisb. Shrub Acanthaceae

Croton gibsoni Grah. Shrub Euphorbiaceae

Dendrophthoe falcata (L.f.) Etting. Shrub Loranthaceae

Dichrostachys cinerea Wight & Arn. Shrub Mimosaceae

Dodonaea viscosa L. Shrub Sapindaceae

Duranta plumieri Jacq. Shrub iVerbenaceae

Euphorbia antiquorum Linn Shrub Euphorbiaceae

Euphorbia ligularia Roxb. Shrub Euphorbiaceae

Euphorbia trigona Shrub Euphorbiaceae

Ficus asperrima Roxb. Shrub Moraceae

Flacourtia indica Merr. Shrub Flacourtiaceae

Helianthus annuus Linn. Shrub Asteraceae

Holarrhena antidysenterica Wall. Shrub Apocynaceae

Ipomoea cairica (L.) Sweet Shrub Convolvulaceae

Ipomoea carnea Jacq. Shrub Convolvulaceae

lxora nigricans Br. Shrub Rubiaceae

Jasminum auriculatum Vahl. Shrub Oleaceae

Jasminum grandif lorum Linn. Shrub Oleaceae

Jasminum sambac Ait Shrub Oleaceae

Jatropha gossypifolia Linn. Shrub Euphorbiaceae



Page 100 of 262


Lantana camara Linn. Shrub Verbenaceae

Maerua arenaria (DC.) Hook. Shrub Capparaceae

Maytenus rothiana (Walp.) Lobreau. Shrub Celastraceae

Mimosa hamata Willd Shrub Mimosaceae

Morus a/ba Linn. Shrub Moraceae

Murraya koenigii Spreng. Shrub Rutaceae

Musa bulbisianacoll ia Shrub Musaceae

Musa paradisiaca Linn. Shrub Musaceae

Nerium odorum Soland. Shrub Apocynaceae

Ocimum cannum Sims. Shrub Lamiaceae

Ocimum sanctum Linn. Shrub Lamiaceae

.Opuntia dillenii Haw. Shrub Cactaceae

Opuntia nigricans Haw. Shrub Cactaceae

Phyllanthus reticulatus Poir. Shrub Euphorbiaceae

Prosopis julif lora (Swartz) DC. Shrub Mimosaceae

Psidium guyava Linn. Shrub Myrtaceae

Punica granatum Linn. Shrub Punicaceae

Pupalia lappacea Moq. Shrub Amaranthaceae

Ravenala madagascarensis Sonnerat Shrub Musaceae

Ricinus communis Linn. Shrub Euphorbiaceae

Sansevieria zeylanica Willd. Shrub Haemadoraceae

Securinega leucopyrus (Willd.) Muell. Shrub Euphorbiaceae

Solanum melongena Linn. Shrub Solanaceae

Tecoma stans Juss. Shrub Bignoniaceae

Triumfetta rhomboidea Jacq. Shrub Tiliaceae

Typha angustifolia Sibth. & Sm. Shrub Typhaceae

Vernonia divergens Edgew. Shrub Asteraceae

Viscum angulatum Heyne ex DC Shrub Loranthaceae

Vitex negundo Linn. Shrub Verbenaceae

Herbs Aceiypna ,i,clica Linn. Herb Euphorbiaceae



Page 101 of 262


Achyranthes aspera Linn. Herb Amaranthaceae

Ageratum conyzoides Linn. Herb Asteraceae

Alternanthera triandra Lam. Herb Amaranthaceae 1

Polygonum glabrum Willd. Herb Polygonaceae

Polygonum plebejum R.Br. var. indica Hook. Herb Polygonaceae

Portulaca oleracea Linn. Herb Portulacaceae

Pulicaria wightiana C.B. Clarke Herb Asteraceae

Rhynchosia minima DC. Herb Fabaceae

Russelia juncea Zuec. Herb Scrophulariaceae

Senecio sp. Herb Asteraceae

Sida acuta Burm. Herb Malvaceae

Sida cordifolia Linn. Herb Malvaceae

Sida rhombifolia Linn. Herb Malvaceae

Solanum nigrum Linn. Herb Solanaceae

Solanum surattense Burm. f . Herb Solanaceae

Sonchus oleraceus Linn. Herb Asteraceae

Striga lutea Lour. Herb Scrophulariaceae

Tagetes erecta Linn. Herb Asteraceae

Tephrosia purpurea (L.) Pers. Herb Fabaceae

Tribulus terrestris Linn. Herb Zygophyllaceae

Tricholepis radicans DC. Herb Asteraceae

Tridax procumbens Linn. Herb Asteraceae

Urena tobata L. Herb Malvaceae

Vernonia cinerea Less. Herb Asteraceae

Wedelia chinensis (Osbeck) Merr. Herb Asteraceae

Wolffia sp. Herb Lemnaceae

Xanthium strumarium Linn. Herb Asteraceae

Climbers Acacia concinna DC. Climber Mimosaceae

Argyreia pilosa Wight & Am. Climber Convolvulaceae

Asparagus racemosus Willd. Climber Asparagaceae



Page 102 of 262


Bougainvillaea spectabilis Willd. Climber Nyctaginaceae

Capparis zeylanica Linn. Climber Capparaceae

Clitoria ternatea Linn. Climber Fabaceae

Coccinia indica Wight & Am. Climber Cucurbitaceae

Cocculus vil/osus DC. Climber Menispermaceae

Combretum ovalifolium Roxb. Climber Combretaceae

Ctyptolepis buchanani Roem & Schult. Climber Periplocaceae

Cryptostegia grandiflora R.Br. Climber Periplocaceae

Cucurbita maxima Duch. Climber Cucurbitaceae

Cuscuta reflexa Roxb. Climber Cuscutaceae

Hemidesmus indicus R.Br. Climber Asclepiadaceae

Luffa acutangula Roxb. Climber Cucurbitaceae

Luffa aegyptiaca Mill. Climber Cucurbitaceae

Momordica charantia Linn. Climber Cucurbitaceae

Passiflora foetida Linn. Climber Passif loraceae

Pergularia daemia Chiov. Climber Asclepiadaceae

Quisqualis indica Linn. Climber Combretaceae

Rivea ornata Choisy Climber Convolvulaceae

Saroostemmo brevistigmaWight. Climber Asclepiadaceae

Tylophora sp. Climber Asclepiadaceae

Wattakaka volubilis (L.f .) Stapf Climber Asclepiadaceae

Grasses

Aristida depressa Retz. Grass Poaceae

Aristida setacea Retz. Grass Poaceae

Brachiaria distachya (Linn.) Stapf Grass Poaceae

Chloris barbata Sw. Grass Poaceae

Cynodon dactylon (Linn.) Pers. Grass Poaceae

Cyperus compressus Linn. Grass Cyperaceae

Cyperus distans Linn.f. Grass Cyperaceae

Cyperus halpan Linn. Grass Cyperaceae

Cyperus rotundus Linn. Grass Cyperaceae



Page 103 of 262


Dactyloctenium aegyptium (Linn.) P.Beauv. Grass Poaceae

Digitaria cil iaris (Retz.) Koel. Grass Poaceae

Dimeria ornithopoda Trin. Grass Poaceae

Eleocharis geniculata (Linn.) Roem. et Schult. Grass Cyperaceae

Heteropogon contortus (Linn.) P. Beauv. ex Roem. et Schult.

Grass Poaceae

lsachne miliacea Roth ex Roem. et Schult. Grass Poaceae

Oryza sativa L. Grass Poaceae

Pennisetum typhoideum Rich. Grass Poaceae

Saccharum officinarum Linn. Grass Poaceae

Sorghum vulgare Pers. Grass Poaceae

Sporobolus indicus (Linn.) R.Br. Grass Poaceae

Themeda ciliata Hack. Grass Poaceae

Triticum aestivum Linn. Grass Poaceae

Zea mays Linn. Grass Poaceae

Fauna

Fauna of a particular region indicates environmental conditions and the well -

being of the population residing in the region. Faunal studies help to understand

the well-being of a nature and functioning of ecosystems. It helps to monitor

pollution levels, biological richness or heritage quality, habitat change and

quantifying threatening species. The Faunal components such as Arthropods,

Molluscs, Pisces, Birds and Mammals are very sensitive to the change in the

ecosystem, therefore are best used as indicators of the ecosystem function and

considered crucial in the ecology and management of the Aquatic and Terrestrial

Ecosystems.

Animals and birds in the study area were documented using following means:

Secondary sources and published literature

By interviewing local people

Actual sighting

Indirect evidence (pellets, dung, droppings, scat, mould, marking on the stems

etc.)

Calls (birds as well as animals)

Nesting (birds, burrows for small mammals)

The records for the birds, mammals and other faunal groups were made at the

same site where vegetation sampling was carried out. Most of the records of the



Page 104 of 262

mammalian and herpeto fauna are opportunistic, nonetheless very useful to

understand habitat specificity and interrelationship between certain floral and

faunal elements and also between certain geological and faunal features.

The list of species located and identified from various localities in the study area

is given below.

Mammals

The study area is a place of poor mammalian diversity. 19 species of mammals

have been recorded during visit from the study area. According to local people

wild boars are of common occurrence in this area. The area represent good

habitat for this animal. At places, the damage caused by them to agriculture and

plantations make them vulnerable to control.

Reptiles

The reptiles have a prominent role in the ecological b alance and

conservation of nature. Due to thoughtless destruction of biotypes by man

for his own uses, a large number of reptiles have become endangered

today. The reptiles of arid zones exhibit remarkable diversity. The reptiles

include turtles, lizards, amphibians, and snakes. Some of the reptiles

recorded during f ield visit

Avian Fauna

All the study sites have fairly good avifaunal diversity despite anthropogenic

activities. Birds are important to human welfare in various ways including seed

dispersal agents. The field survey resulted in documentation of about 82 bird

species.

Table-3.37: List of Fauna in the Study Area

Common Name Scientific Name

Mammals

Striped squirrel Funambulus spp.

Bandicoot Bandicoota indica

Common mongoose Herpestes edwardl i

Musk shrew Suncus caeruleus

Field mouse Rattus norvegicus

House rat Rattus rattus

Bat Rhinolopus spp.

Bat Hipposiderus spp.

Bat Pipistrefius spp.

Jun le cat Fells chous

Common hare Lepus dayanus

Bonnet monkey Macaca radiata



Page 105 of 262


Common langur Presbytis entelius

Rhesus macaque Macaca mutate

Stri.ed Hyena Hyaena hyaena

Indian Wolf Canis lupas

Jackal Canis aureus

Chousingha Tetracerus quadricornis

Common frog Rana tigrina

Toad Bufo melanostictus

Garden lizard Calotes versicolor

Wall lizard Hemidactylus brooki

Giant Gecko Hemidactylus giganticus

Monitor lizard Varanus benghalensis

Rat snake Ptyas mucosus

Wolf snake Oligodon venustus

Checkered Keel Back Xernochrophis piscator

Cobra Naja naja

Krait Bungarus coeruleus

Russell's viper Vipera russeli

Avian

Domestic sparrow Passer domesticus

Ring dove Streptopelia decaocto

Pariah kite Milvus migrans

Crested hawk eagle Spizaetus cirrhatus

Common gray quail Coturnix coturnix

Blue rock pigeon Columba Livia

Shikra Accipitar badius

Large Indian .arakeet Psiltacula eupatria

Hoopoe Upupa epops

Gre necked Bunting Emberiza melanocephala

Koel Eudynamys scolopacea

Crow pheasant Centropus cinensis

Cromson breasted barbet Megalaima hemacephala

Green bee eater Merops orientalis

Bule throated barbet Megalaima asiatica

Red headed bunting Emberiza melanocephala

Screech owl Tyto alba

Brown f ish owl Bubo zeylonesis



Page 106 of 262


Brahminy kite Haliastur Indus

Spotted dove Streptopela chinensis

Indian great horned Bubo bubo owl

Indian pipits Anthus novaeseelan-diae

Common night jar Caprimulgus asiaticus

Plam swift Cypsiurus parvus

Alpine swift Apus melba

Rose ringed parakeet Psiltacula krameri

Red munia Estrilda amandave

Blue jay Caracias benghalensis

Golden headed woodpecker Dinopium benghalense

Collored bushchat Saxicola torquata

White throat lesser Sylvia curuca

Blackwinged stilt Himantopus himantopus

Avocet Recurvirostra avaselta

Blackwinged kite Elanus caeru/eus

Brahmani Duck Tadoma ferruginea

Palm swift Cypsiarus parvus

Pheasant tailed Jacana Hydrophasianus chirugus

Black drongo Dicrus adsimilis

Litt le egret Egretta garzetta

Demoiselle crane Anthropoides virgo

Yellow wattled lapwing Vanellus ma/abaricus

Litt le cormorant Phalacrocorax niger

Brahminy kite Haliastar indus

Common hawk Cuculus va, ,us

Pond heron Ardeola grayii

Sarus crane Grus antigone

King vultt. ire

White eyed Buzzard Buloster teesa

Purple moor hen Porphyrio porphyrio

Tawny Eagle Aquila rapax

Rain quail Cotumix coromandelica

Common quail Cotumix suscitator

White breasted water hen Amauromis phoenicurus

Spotted sand piper Tringa glareola

Coots Fulica atra



Page 107 of 262


Common sand piper Tringa hypoleucos

Common snipe Gallinago gallinago

Red wattled lapwing Vanellus indicus

River tern Sterna aurentia

Black winged stilt Himantopus himantopus

Yellow wagtail Motacilla f lava

Indian myna Acrodontherus tristis

Jungle crow Corvus macrorhynchus

House crow Corvus spledens

Blossom headed parakeet Psiltacula cynoncephala

Indian small sky lark Alanda gulgula

Yellow wagtail Motacilla f lava

Common swallow Hirando rustica

Grey wagtail Motacilla caspica

Small minivet Pericrocotus cinnanomus

Common babbler Turdoides candatus

Paradise f lycatcher Terpsiphone paradisi

Purple sunbird Nectarinia asiatica

Tailor bird Orthotonus sutor ias

Indian robin Saxicoloides fulicata

Magpie robin Copsychus saularis

Pied king f isher Ceryle rudius

Red start Phoeniourus ochrurus

Weaver bird Ploceus phil lippinus

Small blue king f isher Alcedo atthis

White throated munia Lonchuro malabarica

Red vented bulbul Picnonotus cater

The plant life in an area seems to be fairly disturbed and do not show any

integrity except at few places.

1. There were no National Park, Wildlife Sanctuary/Reserve within the 10

km radius.

2. The survey also i llustrates that there are no rare plant species on the

proposed site.

3. Major factors responsible for disturbance are anthropogenic activit ies.



Page 108 of 262

4. Among trees Albizia amara, Acacia chundra, Prosopis julif lora, Capparis

deciduas and Albizzia procera are the abundant and dominan t species of

plants.

5. The Carissa spinarum, Maytenus rothiana, Opuntia sp., Securinega

leucopyrus, Calotropis procera and Dodonea viscosa are most common

among the shrubs.

6. Total numbers of plant species recorded are 346 including 114 herbs, 83

shrubs, 77 trees, 31 climbers, 28 grasses and 13 sedges.

7. Birds represent dominant group among the faunal composition.

8. Among birds majority of species are carnivorous, omnivorous or insect

eater.



Page 109 of 262

CHAPTER-4.0: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 INTRODUCTION

In this chapter, the anticipated environmental impacts and the proposed mitigation

measures for the integrated steel plant have been described.

Impact prediction is a way of mapping the environmental consequences of the significant

aspects of the proposed steel plant. The impact assessment will focus on the proposed

steel plant and will broadly cover the following information and components:

- Assessment of physical effects for all phases including location, design,

construction, operation and possible accidents.

- Estimation by type and quantity of expected contaminants, residues, and emissions

(air, water, noise, solid wastes) resulting from the operation of the proposed steel

plant.

The anticipated environmental impacts of the proposed steel plant are discussed below

under the following categories:

Impacts and mitigation measures due to project location.

Impacts and mitigation measures due to project design.

Impacts and mitigation measures during construction.

Impacts and mitigation measures during operation.

Impacts and mitigation measures because of possible accidents.

4.1.1 IMPACTS AND MITIGATION MEASURES DUE TO PROJECT LOCATION

4.1.1.1 Impacts

The proposed integrated steel plant will be located in the land already in possession of

AISL at Village Halavarthi, district Koppal in Karnataka. The land is barren and has no

agriculture value. Therefore, from location point of view, the proposed steel plant does

not have any adverse impact.

4.1.1.2 Mitigation Measures

No impact envisaged.



Page 110 of 262

4.1.2 IMPACTS AND MITIGATION MEASURES DUE TO PROJECT DESIGN

Impacts

The proposed steel plant is being envisaged based on techno-economic feasibility of the

state of art technology at presently available in the country and based on demand supply

of steel products. Thus, no anticipated impacts are envisaged due to project design.

4.1.2.1 Mitigation Measures

A number of environmental friendly features have been envisaged in the proposed steel

plant due to which the anticipated adverse environmental impacts are either avoided or

minimized. These features are briefly described here under.

i) Use of Continuous Casting Technology:

Hundred percent of the steel production through continuous casting facilities saves

considerable energy and protects environment. The major environmental

advantages are:

- Elimination of Soaking pits resulting in reduction in consumption of fuels and

Electricity.

- Considerable energy is saved vis-à-vis less energy generation and reduces

pollutant emissions.

- Less scrap production resulting in improved yield and less solid waste

generation / handling.

ii) Incorporation of Coal Dust Injection System in Blast Furnaces to save coke in

charge.

iii) Top Pressure Recovery Turbine (TRT) in Blast Furnace and CDQ in Coke Oven,

thereby reducing power requirement.

iv) Coke Ovens provided with HPLA, Coal charging cars fitted with screw feeders and

hydraulically pressed sleeves, Hydro Jet Door Cleaners, Leak Proof Oven Door,

and Land Based Pushing Emission Control (PEC) resulting in pollutant emission

reduction in atmosphere.

v) Dry-fog Dust Suppression System in Coke Cutter / Coke Conveyor.

vi) BF: Stock House and Cast House De-dusting System to reduce fugitive emission.

vii) State of Art Pollution Control system for Gaseous Emission Control, Process Dust

Emission Control, Fugitive Dust Emission Control in different units of the proposed

Integrated Steel Plant.



Page 111 of 262

4.1.3 IMPACT AND MITIGATION MEASURES DURING CONSTRUCTION PHASE

Construction phase impact may be on land use, ground water, surface water quality and

air quality etc. These aspects are discussed here under:

4.1.3.1 Land Use

Impacts

The proposed steel plant will be accommodated in 922.19 acres of industrial land

already in company possession and additional 995.50 acres of land under process by

Karnataka Government. Large-scale excavation is expected. The land is rocky in nature

and has no soil cover to recon with. Koppal is nearest town and already a fairly well-

developed area with all sorts of infrastructure available for construction labour. 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.

Mitigation Measures


Air Quality

Impacts

The construction and other associated activities will lead to emission of different

pollutants. During the construction phase, particulate matter will be the main pollutant.

As plant will be constructed in phases, construction activity covering a large area is not

expected. Therefore, the particulate matter emission will not be much and will be

localized only. Gaseous pollutants like SO2, NO x, CO will also be added to the ambient

air due to vehicular traffic movement associated with this construction phase. Gaseous

emissions from construction machineries and vehicles will be contaminating AAQ. The

impact will be confined within the specific plant area where the construction is taking

place. Further, the impact of such activities will be temporary and will be restricted to the

construction phase only.

During the construction period the impacts that are associated with the air quality are:



Page 112 of 262

Deterioration of air quality due to fugitive dust emissions from construction activities

(especially during dry season) like excavation, back filling and concreting, hauling

and dumping of earth materials and from construction spoils.

Generation of pollutants due to operation of heavy vehicles and movement of

machineries and equipment for material handling, earth moving, laying of sands,

metal, stones, asphalt, etc.

Mitigation Measures

The following mitigation measures will be employed during construction period to reduce

the pollution level to acceptable limits.

Proper and prior planning, appropriate sequencing and scheduling of all major

construction activities will be done, and timely availability of infrastructure supports

needed for construction will be ensured to shorten the construction period vis-à-vis

to reduce pollution.

Construction materials will be stored in covered shed or enclosed spaces to prevent

the windblown fugitive emissions.

Truck carrying soil, sand, stone dust, and stone will be duly covered to avoid spilling

and fugitive emissions.

Adequate dust suppression measures such as regular water sprinkling at vulnerable

areas of construction sites will be undertaken to control fugitive dust during material

handling and hauling activities in dry seasons.

The construction material delivering vehicles will be covered in order to reduce

spills.

It will be ensured that all construction equipment and vehicles are in good working

condition, properly tuned and maintained to keep emission within the permissible

limits and engines turned off when not in use to reduce emission.

Vehicles and machineries would be regularly maintained so that emissions confirm

to standards of Central Pollution Control Board (CPCB) norms.

Monitoring of air quality at regular intervals will be conducted during construction

phase.

Water Quality

A: Surface Water

Impacts

The impacts on water quality during construction phase mainly arise due to site cleaning,

leveling, excavation, storage of construction material etc. A leveling and excavation



Page 113 of 262

activity normally increases the level of suspended solids in the surface water runoff.

However, for the proposed steel plant, no large scale leveling is required. Excavation will

also be limited.

Mitigation Measures

Quality of construction wastewater emanating from the construction site will be

controlled through sediment traps (silting basin as water intercepting ditch) for

arresting the silt / sediment load before its disposal.

All the washable construction material will be stored under sheds or enclosed space

by fencing it with brick or earth in order to prevent spillage into the drainage network,

so that the same does not find its way into the surface water runoff.

The sediment traps and storm water drainage network will be periodically cleaned

and especially before monsoon season.

B: Ground water

Impacts

The water requirement during the construction phase will be low and will be met through

the already existing water supply facilities to group company MSPL. Thus, no ground

water extraction is envisaged. 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 steel plant will have insignificant impact on the

ground water.

Mitigation Measures

No impact on ground water regime envisaged.

4.1.4 IMPACTS AND MITIGATION MEASURES DURING OPERATION PHASE

4.1.4.1 General

During the operation phase, depending upon operating condition environmental releases

may occur from raw material and product handling, processing, fuel burning etc.

Environmental releases may be in the form of

a) Emission to atmosphere

b) Waste water discharges to water regime

c) Solid waste disposal

d) Noise etc.



Page 114 of 262

These emissions, discharges and disposal may release different pollutants, which may

affect air quality, water quality, land and ecological environment directly. However, all

these are mainly primary impact. In addition to these primary impacts, any industrial

project has some overall impact on its surrounding socio-economic environment through

the existence of social and economic linkages between the project and society, which

are actually secondary impact. Under this clause, all the primary impacts due to this

proposed steel plant are being discussed and wherever required, impacts have also

been quantified. Accordingly, under subsequent clauses impacts on air environment,

water environment, soil and noise due to the proposed steel plant are being elaborated.

4.1.4.2 Air Environment

In Steel plant, air pollutants are generated at different stages of production. Air pollutants

may be particulate matter, Sulphur dioxide, oxides of nitrogen and carbon di oxides etc.

The pollutants may be released as point source emission or fugitive emission.

Accordingly, it is most expected that there will be some variation in the emitted pollution

load. It is therefore most justified to first assess the anticipated variation in the emitted

pollution load. Once these variations vis-à-vis increase or decreases in emitted pollution

load are estimated, its impact on air environment will be assessed and predicted.

Major unit wise emission potentials are discussed below.

Sintering Plant

During the process of agglomeration by sintering, waste gases are generated which

carries along with-it particulate matter, oxides of sulphur and nitrogen as major pollutant.

The waste gases generated during the process stage and cooling of sinter after passing

through an electrostatic precipitator are released to the atmosphere. Further

transportation and handling of different material in the sinter plant area will also generate

dust, for which dust extraction systems will be provided and the clean air will be

discharged through stacks in atmosphere.

Coke Oven

The operation of a Coke Oven battery comprises of the following activities:

- Coal charging

- Heating / Firing of the chambers

- Coking

- Coke pushing and

- Coke quenching

During coke making, heating of the Coke Oven chambers is carried out by burning Coke



Page 115 of 262

Oven / BF gas as fuel and the resultant flue gas is led to the stacks. Excess Coke Oven /

BF gas is transported via pipeline to large gas holders to utilize these gases for Power

generation and rolling mill heating needs.

During operation of Coke Ovens fugitive emissions are also generated during charging,

pushing, and quenching activity. However, MOEF prescribed emission standard for coke

oven emission shall be met.

c) Blast Furnace

Flue gas from hot stoves is the main emission source from the operation of blast

furnace. Hot stoves are fired with blast furnace and CO gas for heating air fed to blast

furnace. Flue gas generated in the hot stoves is discharged to the atmosphere through

stacks. This flue gas contains particulate matter (in very small quantity) and oxides of

Sulphur and Nitrogen. Oxides of nitrogen are formed due to the high temperature of the

stoves.

In addition to the above emissions fugitive emissions also occurs during charging and in

cast house. During charging normally, a sealed charging system is provided but since

the furnace pressure is higher than atmospheric pressure, the components present in BF

Gas along with particulate matter may be emitted.

Pig Casting

The pig casting facilities will cast surplus hot metal when during poor off take of hot

metal from SMS. The casting of pig iron generates fugitive emissions, mainly arising

from contact between hot metal and slag and ambient oxygen. The main pollutants in

the fugitive emissions are particulate matter with some amount of sulphur dioxide.

Slag Granulation Plant (SGP)

The process of treating blast furnace slag involves pouring the molten slag through a

high-pressure water spray in a granulated head. Due to high-pressure water spray no

particulate matter is expected to be emitted.

De-sulphurisation

A de-sulphurisation unit for hot metal pre-treatment to ensure consistent supply of

homogenous and low sulphur hot metal to the BOF has been envisaged. The process of

de-sulphurization generates fugitive emissions. The exhaust air generated in the process

is contaminated with particulate matter.



Page 116 of 262

d) EOF/BOF Shop

The objective of EOF/BOF in steel making is to burn (oxidize) the undesirable impurities

contained in the metallic feedstock. The main elements are thus converted into oxides

are carbon, silicon, manganese, phosphorus, and sulphur. The purpose of this oxidation

process is:

To reduce the carbon content to a specified level

To adjust the contents of desirable foreign elements

To remove undesirable impurities to the greatest possible extent

The production of steel by the EOF/BOF process is a discontinuous process, which

involves the following steps:

Transfer and storage of hot metal

Pre-treatment of hot metal (de-sulphurization)

Oxidation in the EOF/BOF (de-carburization and oxidation of impurities)

Secondary metallurgical treatment

Casting (continuous)

The following emissions of off gases are generally recognized in EOF/BOF area:

Oxygen blowing and BOF gas

Secondary off gases are generated during:

Removal of undesirable impurities (to the maximum possible extent)

EOF/BOF charging

Tapping of liquid steel and slag from EOF/BOF and ladles

Continuous Casting

Air pollution control system comprising of suction hood, duct and bag filters are

envisaged in SMS area, mixer and de-slagging systems. The fumes generated during

charging and tapping of converters are also not controlled at times. The fugitive

emissions in the area will be limited within the limits given below:

i) Respirable Particulate Matter : 2000 microgram / m3

ii) Suspended Particulate Matter : 5000 microgram / m3

iii) SO2 : 250 microgram / m3

iv) NOx : 150 microgram / m3

v) CO (8 hr.) : 55000 microgram / m3



Page 117 of 262

e) Secondary Refining Facilities:

The secondary refining is not an emission intensive process except for some fugitive

dust emissions during the process. Necessary fume extraction system has been

envisaged for the process.

f) Raw Material Handling Complex (RMHC)

Necessary pollution control facilities in the form of dust extraction / dust suppression

system will be provided to restrict the emitted pollutant within statutory norms. Dust

extraction system provided will discharge air after cleaning to limit the dust content in the

emitted air within statutory norms.

The sources of emissions from the proposed steel plant and the control measures

suggested are given below. In addition to the measures taken to control pollution, it is

also proposed to limit the design emission norms to a maximum of 50 mg/Nm3 of

particulates.

Sl.

No

Area of operations Air pollution control measures

proposed to be adopted

Design limits

1 Raw material handling

Fugitive emissions in

material handling

Dust suppression systems

(chemical and dry fog type)

Water sprinklers

DE systems with bag filters in

case of conveyors, lime

handling

Work area 5.0

mg/Nm3

Stack: 50

mg/Nm3

2 Coke ovens

Coal & Coke handling DE systems Stack: 50

mg/Nm3

Coal charging On main charging with HPLA

aspiration

CGT car for aspirating gas into

adjacent ovens

As per MOEF

norms applicable

for coke ovens

Carbonization Leaking of doors, lids etc

Use of lean gas for under firing

Low NOx burners

As above

Coke pushing Land based pushing emission

control

As above

Coke quenching Dry quenching with stand by As above



Page 118 of 262

Sl.

No

Area of operations Air pollution control measures

proposed to be adopted

Design limits

wet quenching facility

3 Sinter Plant

Sintering process ESP for collected waste gases 50 mg/Nm3

Raw material

preparation and

handling

Centralized De-dusting system

with ESP common for both

areas

50 mg/Nm3

Sinter screening and

transport

4. Blast Furnaces

Sinter, coke and flux

handling in stock

house

ESP/Bag filters 50 mg/Nm3

BF processes Gas cleaning in Venturi

scrubbers

5 mg/Nm3

Cast house FE systems with ESP/Bag filter 50 mg/Nm3

Stoves heating Use of lean gas 50 mg/Nm3

5. EOF/BOF

Material handling

operations

Bag filters 50mg/Nm3

Converters Secondary fume extraction

system

50 mg/Nm3

Desulphurization,

RHFs, LHFs etc.

Spark arresters followed by

Bag filters

6. Billet/bloom/slab

casters

Use of low sulphur gases for

SO2 control

7. Rolling mills Use of low sulphur gases for

SO2 control

Low NOx burner

50 mg/Nm3

8. Power Plant ESP

Low NOx burners

50 g/Nm3

4.1.4.3 Methodology: Impact Assessment on Air Environment

For prediction of impacts for any proposed projects, in order to study the impacts due to

pollution load, in general, contributions from the units will be added to the existing back

ground concentrations and predictions will be done accordingly.

Once the pollutants are emitted into the atmosphere, the dilution and dispersion of the

pollutants are controlled by various meteorological parameters like wind speed and



Page 119 of 262

direction, ambient temperature, mixing height, etc. In most dispersion models the

relevant atmospheric layer is that nearest to the ground, varying in thickness from

several hundred to a few thousand meters. Variations in both thermal and mechanical

turbulence and in wind velocity are greatest in the layer in contact with the surface. The

atmospheric dispersion modeling and the prediction of ground level pollutant

concentrations has great relevance in the following activities:

- Estimation of impact of setting up of new industry on surrounding environment.

- Estimation of maximum ground level concentration and its location in the study area.

The prediction of Ground level concentrations (GLC) of pollutants emitted from the

stacks have been carried out using ISCST-3 / AERMOD Air Quality Simulation model

released by USEPA which is also accepted by Indian statutory bodies. 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 term averages up to 24 hours.

The impact has been predicted over a 10 km X 10 km area with the proposed location of

the stack as the centre. GLC have been calculated at every 500 m grid point.

AISL shall be implementing steel plant in two phases. Phase 1 with 1 MTPA facilities

and phase-2 with additional 2.5 MTPA facilities. The details of the stacks and emissions

from them are given in Table 4.1a.

vi) Table 4.1a: Stack emission details for AISL 3.5 MTPA Steel Plant phase-1

Stack Code Height

in (m)

Dia

in m

Flue

volume

Nm3/h

Temp 0 C

Actual

volume

m3/h

exist

velocity

m/s

PM

g/s

SO2

g/s

NOx

g/s

COB#1-

cumbustion

120.00 3.5 88000 200 139678 4.03 0.5 4.9 6.11

COB#2-

cumbustion

120.00 3.5 88000 200 139678 4.03 0.5 4.9 6.11

coke guide

car ehaust-1

50.00 2.2 200000 100 250336 18.29 2.2 0.0 0.00

SP#1-

cumbustion

80.00 4.5 864000 100 1081450 18.89 9.6 18.00 18.00

SP#1-DE 50.00 4.5 900000 40 945302 16.51 10.0 0.00 0.00

BF#1CH-DE 35.00 3.5 561000 100 702191 20.27 3.1 0.0 0.0

BF#1Stove-

C

60.00 3.5 170000 150 241309 6.97 0.9 0.7 2.36



Page 120 of 262

BF#1SH-DE 35.00 3 400000 40 420134 16.51 2.2 0.00 0.00

PCM de-

dusting

stack

35.00 2.5 200000 100 250336 14.16 1.1 0.00 0.00

EOF-1

exhaust

stack

50.00 1.5 100000 60 111745 17.56 0.6 0.83 2.08

EOF-2

exhaust

stack

50.00 1.5 100000 60 111745 17.56 0.6 0.83 2.08

EOF1-2-

common-DE

35.00 3 400000 40 420134 16.51 4.4 0.00 0.00

EOF-DE-

bulk

material

conveyor

35.00 3 400000 40 420134 16.51 4.4 0.00 0.00

Rolling Mill-

1 RHF stack

50.00 2 30000 300 57685 5.10 0.1 0.0 0.00

Rolling Mill-

1 DE stack

35.00 2 200000 40 210067 18.57 2.2 0.0 0.00

Rolling Mill-

2 RHF stack

50.00 2.5 75000 300 144211 8.16 0.3 0.0 0.00

Rolling Mill-

2 DE stack

35.00 2.5 300000 40 315101 17.83 3.3 0.0 0.00

CPP 1 stack

70 MW

180.00 5 850000 200 1349161 19.08 7.1 23.6 23.61

Coal mill DE

stack

35.00 3 400000 40 420134 16.51 4.4 0.0 0.00

Boiler stack

for TB

steam

50.00 2 120000 200 190470 16.84 1.3 0.0 0.00

Table – 4.1B: Stack emission details for AISL 3.5 MTPA Steel Plant Phase-2

Stack Code Height

in m

Dia

in

m

Flue

volume

Nm3/h

actual

volume

m3/h

exist

velocity

m/s

Temp

0C

PM g/s SO2

g/s

NOx

g/s

COB#3-

cumbustion

120.00 3.5 88000 139678 4.03 200 0.5 4.9 6.11

COB#4-

cumbustion

120.00 3.5 88000 139678 4.03 200 0.5 4.9 6.11

coke guide 50.00 2.2 200000 250336 18.29 100 2.2 0.0 0.00



Page 121 of 262

car ehaust-2

SP#2-

cumbustion

80.00 6.5 1800000 2253020 18.86 100 20.0 37.50 37.50

SP#2-DE 50.00 6 2000000 2100671 20.64 40 22.2 0.00 0.00

BF#2CH-DE 35.00 5.5 1600000 2002685 23.41 100 17.8 0.0 0.0

BF#2Stove-

C

60.00 5.5 452000 641597 7.50 150 0.6 3.8 6.28

BF#2SH-DE 35.00 4.5 1000000 1050336 18.34 40 11.1 0.00 0.00

PCM de-

dusting

stack

35.00 2.5 200000 250336 14.16 100 2.2 0.00 0.00

BOF-1flare

stack

80.00 2.5 270000 301711 17.07 60 1.9 3.75 5.63

BOF-2 flare

stack

80.00 2.5 270000 301711 17.07 60 1.9 3.75 5.63

BOF-1DE-1 45.00 5.5 1440000 1512483 17.68 40 16.0 0.00 0.00

BOF-1 DE-2 45.00 5.5 1440000 1512483 17.68 40 16.0 0.00 0.00

BOF-2 DE-1 45.00 5.5 1440000 1512483 17.68 40 16.0 0.00 0.00

BOF-2 DE-2 45.00 5.5 1440000 1512483 17.68 40 16.0 0.00 0.00

HSM RHF-1 60.00 3.5 150300 289000 8.34 300 0.6 0.0 0.00

HSM RHF-2 60.00 3.5 150300 289000 8.34 300 0.6 0.0 0.00

HSM DE-1 45.00 4.5 1000000 1050336 18.34 40 11.1 0.0 0.00

HSM DE-2 45.00 4.5 1000000 1050336 18.34 40 11.1 0.0 0.00

CRM-ARP

duct-DE

30.00 0.8 30000 31510 17.41 40 0.3 0.0 1.25

CRM-Batch

Annealing

furnace

45.00 1.2 32000 33611 8.25 40 0.1 0.0 0.67

Galv. Line

fur stack

45.00 1.5 20000 21678 3.41 50 0.1 0.0 0.00

CPP 2 stack

100 MW

180.00 5.5 1200000 1904698 22.27 200 10.0 33.3 33.33

CPP 2 stack

100 MW

180.00 5.5 1200000 1904698 22.27 200 10.0 33.3 33.33

Coal mill DE

stack

35.00 3 400000 420134 16.51 40 4.4 0.0 0.00

Boiler stack

for TB

steam

50.00 2 120000 190470 16.84 200 1.0 3.3 3.33



Page 122 of 262

Stack emission details are based on the estimated emission and actual monitored data

elsewhere, fuel balance, prevailing emission factors as available in literature for steel

plants, and different statutory regulations prevailing in the country.

Meteorological data plays an important role in computation of Ground Level

Concentration using ISCST-3 / AERMOD model. Meteorological data of the project site

is another input taken for computation of the contribution by the proposed steel plant.

Data related to wind velocity and direction were generated during the monitoring period.

Part of this site-specific monitored data have been used as input data of the model

during computation.

The input meteorological data used in the computation are presented in Table 4.2 and

uniform Cartesian grid system was used to locate/fix sources and receptors in the study

area. The predicted GLC values are given in Table 4.3.

Table 4.2: Meteorological data used as input for Air quality modeling

Hour

Wind

direction

(degrees)

Wind speed

(m/s)

Ambient air

temp. (K)

Wind

stability

class

Inversion

layer

01 135.0 0.9 302.7 6 0.0

02 247.0 3.5 301.6 6 0.0

03 270.0 4.3 300.7 6 0.0

04 202.5 1.7 299.8 6 0.0

05 202.5 4.3 298.9 5 0.0

06 202.5 0.9 297.9 4 125.0

07 202.5 0.9 297.4 4 145.0

08 202.5 1.7 297.0 3 287.0

09 202.5 2.6 297.1 3 542.0

10 202.5 3.5 298.3 3 841.0

11 202.5 0.9 300.4 2 1110.0

12 225.0 2.6 302.2 2 1347.0

13 225.0 2.6 304.3 2 1602.0

14 270.0 1.7 306.2 1 1740.0

15 292.5 1.7 307.8 2 1808.0

16 202.5 0.9 308.8 3 1717.0

17 067.5 2.6 308.9 4 1690.0

18 112.5 3.5 309.4 4 1466.0



Page 123 of 262

Hour

Wind

direction

(degrees)

Wind speed

(m/s)

Ambient air

temp. (K)

Wind

stability

class

Inversion

layer

19 112.5 3.5 309.0 5 1150.0

20 135.0 1.7 308.3 5 1025.0

21 157.5 0.9 307.7 5 0.0

22 270.0 7.8 304.3 6 0.0

23 270.0 1.7 303.4 6 0.0

24 180.0 0.9 302.4 6 0.0

Results: Impact on Air Environment

The resultant ambient air concentrations after the setting up integrated steel plant has

been presented in Table 4.3 for PM10, SO2 & NOx. This includes phase wise

computation of GLC i.e. Phase-1 and Phase-2 and combined Phase 1+2. In the

combined phase the maximum GLC for PM10, SO2 & NOx is 20.3, 10.7 & 19.43 ug/m3 .

when these values are added to monitored maximum background values for PM10, SO2

& NOx is 56.5, 24.4 & 33.4 ug/m3 , the resultant values are for PM10, SO2 & NOx is 76.8,

35.1 & 52.83 ug/m3 . this indicate that if all the pollution control systems are placed with

processes well-functioning, still the ambient air quality shall remain within acceptable

ambient air quality norms. Thus, it is anticipated that there will not be any adverse

changes in AAQ in the study area. The isopleths of the computed results for combined

phase RPM, SO2 and NOx are presented in Fig. 4.1, 4.2 & 4.3 respectively showing

GLC and direction from Plant.

Table 4.3 Prediction of GLC's at 3.5 MTPA (Phase-1) Proposed steel

Location

Code

AAQM location RPM (PM10) All Values in ug / m3

Back Ground

value

From stack

prediction

Total

A1 Project Site 56.5 3.0 59.5









Norm

100



Page 124 of 262

Stn. Code

AAQM location SO2 NOX

BG* Phase-1 Total BG* Phase-1 Total

A1 Project Site 16.3 0.00 16.3 27.7 0.00 27.7

A2 Adjacent to Pellet Plant 13.9 0.00 13.9 23.3 0.00 23.3

A3 Allangara Village 18.0 1.57 19.57 29.5 2.22 31.72

A4 Hirabaglani Village 17.8 1.57 19.37 31.4 2.22 33.62

A5 Kunikeri Tanda Village 20.7 0.00 20.7 31.7 0.00 31.7

A6 Huvinahalu Village 24.4 1.57 25.97 31.1 2.22 33.32

A7 Koppal village 21.6 0.00 21.6 28.7 0.00 28.7

A8 Belanalu Village 18.5 3.15 21.65 33.4 2.22 35.62

A9 Basapur Village 15.4 4.72 20.12 26.3 8.88 35.18

Norm 80 80

Table 4.3 Prediction of GLC's at 3.5 MTPA (Phase-2) Proposed steel

All Values in ug / m3

Location

Code


Back Ground

value

From stack

prediction

Total

A1 Project Site 56.5 3.18 59.68









Norm 100

Location

Code


BG* Phase-2 Total BG* Phase-2 Total

A1 Project Site 16.3 0.00 16.3 27.7 0.00 27.7

A2 Adjacent to

Pellet Plant 13.9 0.00 13.9 23.3 0.00 23.3

A3 Allangara Village 18.0 1.60 19.6 29.5 1.60 31.1

A4 Hirabaglani

Village 17.8 0.00 17.8 31.4 0.00 31.4

A5 Kunikeri Tanda 20.7 0.00 20.7 31.7 0.00 31.4



Page 125 of 262

Village

A6 Huvinahalu

Village 24.4 1.60 26.0 31.1 3.19 34.29

A7 Koppal village 21.6 1.60 23.2 28.7 1.60 30.3



Norm 80 80

Table 4.3 Prediction of GLC's at 3.5 MTPA (Phase 1+2) Proposed steel

All Values in ug / m3

Location

Code


Back Ground

value

From stack

prediction

Total

A1 Project Site 56.5 4.06 60.56









Norm 100

Location

Code


BG* Phase-1+2 Total BG* Phase-1+2 Total

A1 Project Site 16.3 0.00 16.3 27.7 0.00 27.7

A2 Adjacent to

Pellet Plant 13.9 0.00 13.9 23.3 0.00 23.3

A3 Allangara

Village 18.0 2.16 20.16 29.5 3.95 33.45

A4 Hirabaglani

Village 17.8 2.16 19.96 31.4 3.95 35.35

A5 Kunikeri Tanda

Village 20.7 2.16 22.86 31.7 0.00 31.7

A6 Huvinahalu

Village 24.4 2.16 26.56 31.1 3.95 35.05

A7 Koppal village 21.6 4.33 25.93 28.7 3.95 32.65



Norm 80 80



Page 126 of 262

Maximum GLC: 20.3 µg/m3 at ()

Fig. 4.1: Isopleths for PM10 Concentration Due to proposed steel project (phase-1+2 combined)



Page 127 of 262


Fig. 4.2: Isopleths for SO2 Concentration Due to proposed steel project (Phase-1+2 Combined)



Page 128 of 262


Fig. 4.3: Isopleths for NOx Concentration Due to proposed steel project (Phase-1+2 combined)



Page 129 of 262

Mitigation Measures

During the design phase all efforts have been made to select latest state of art

technology and adequate pollution control measures adopted for different processes and

de-dusting stacks for different fugitive emission sources. During the construction phase

of the proposed project appropriate mitigation measures will be implemented to

ameliorate the anticipated air quality problems. The following mitigation measures will be

employed during operation period to reduce the pollution level to acceptable limits:

Bag filter based DE system in BF with gas cleaning plant.

Bag filter based DE system for ground-based pushing emission control in Coke Oven

battery

Dry fog type DS system for material handling junction points

Fume Extraction system for EOF/BOF & LF along with gas cleaning plant.

Dust extraction system in Sinter Plant.

Dedusting System in lime & dolo plant

Stack monitoring to ensure proper functioning of different major stacks.

Air monitoring in the Work-zone to ensure proper functioning of fugitive emission

control facilities.

Adequate plantation in and around different units.

Vehicles and machineries would be regularly maintained so that emissions confirm to

the applicable standards.

Monitoring of ambient air quality through online AAQ monitoring system at four

locations.

Workers will be provided with adequate protective measures to protect them from

inhaling dust.

Impact of Transportation of Raw Materials and Finished Products by Road

Impact

The total annual external freight for both phases will be approximately 18.514 MTPA

including 13.8 MTPA of incoming materials and 2.34.755 MTPA of outgoing finished

products. The quantity of raw materials to be received and the finished products to be

dispatched annually is shown in Table below:

Table below shows the transportation of raw materials and finished product to and from

the plant. From the table it can be seen that the majority of bulk quantity of raw material /

finished product is being transported from Rail and only small quantity of material is

being transported from road.



Page 130 of 262

Transportation of Raw Materials and Finished Product

Gross weight including 5% moisture and 5% handling losses Unit: ‘000t

Sl.NO Material From To Phase-1 Phase-2 Phase 1+2

A Receipt

1 Iron ore Lump Hospet Plant 505.65 1147.92 1653.57

2 Iron Ore fines Hospet Plant 1425.27 3252.10 4677.37

3 Raw Lime stone Bagalkot/imported Plant 198.19 448.95 647.14

4 Raw Dolomite Bagalkot/imported Plant 231.52 526.87 758.40

5 Manganese ore Chitradurg, Sandur Plant 7.78 17.66 25.44

6 Quartzite Local Plant 31.1 7.06 38.16

6 Coking coal Imported through

Mangalore/Goa

Plant 1516.05 1614.06 3228.12 *

7 Coal for injection Imported through

Mangalore/Goa

Plant 194.48 441.52 636

8 Steam coal Singareni/Imported Plant 397.85 1135.77 1533.62

9 Misc. Outside Plant 110.25 330.75 441.00

Total receipt 4618.13 8922.67 13540.80

B Dispatch

1 Rolled Products Plant Outside 850.00 2419.00 3269.00

2 Pig Iron Plant Outside 302.20 302.02

3 Granulated Slag Plant Out

side

362.2 822.30 1184.50

Total dispatch 1514.40 3241.30 4755.70

Total external rail

freight turnover

6132.53 12163.97 18296.50

* The coal throughput of battery 1 & 2 in phase 1&2 will be more than in Phase-1 due to

increased requirement of coke in the blast furnaces.

External Road movement

Several materials both incoming and outgoing coming from near sources/destination will

be moved through roads. The road movement is complementary to many material

movements. The projection is given below:



Page 131 of 262

External road movements Unit: ‘000 t

Sl.

NO.

Material From To Phase-1 Phase-2 Phase

1+2

A. Receipt

1 DRI/Sponge iron Outside SMS yards 185 243 428

2 Burnt Lime BOO Plant

outside

Plant /SMS 111.9 150 261.9

3 Burnt dolomite BOO Plant

outside

Plant /SMS 25 66 91

4 Ferro alloys Local plant Plant/SMS 10 27 37

5 Refractory Local plants Plant 6 15 21

6 Bentonite Local plants Plant

7 Fuel oil Hospet Plant 1.07 15.097 16.2

8 By – Products /CRM

acids and chemicals

Many suppliers By-products

/CRM

11.97 11.97 24

9 Maintenance spares

including rolls

Many sources Plant 2 5 7

10 Misc. Many sources Plant 1 2.5 3.5

Total receipt by road 353.94 535.67 890.61

B. Dispatch

1 SMS slag Slag recovery

Plant

Outside 135 291.6 426.6

2 Coke Oven by

products

Coke oven by-

product Plant

outside 110.7 116.96 292.4

3 Muck/waste/rubbish Plant waste

dump

Outside 10 25 35

Total dispatch by

road

255.7 433.56 689.26

Total external road

transport

609.64 969.120 1578.760

Mitigation Measures

To reduce the traffic on NH-63, AISL is planning to transport maximum through rail

network. This will reduce the traffic substantially.

AISL is also planning to have dedicated railway siding within complex for their

operations for which in principal approval from SE railway has already been taken.



Page 132 of 262

4.1.4.3 Water Environment

Water environment may be affected by industries in different ways depending upon the

type of industries. The water environment may be surface or ground water or both.

Water environment may be affected by the industry due to drawl of water, discharge of

polluted water / waste water, and by contaminated leachate from land disposal /

dumping of solid waste. The activities are scrutinized in light of the above factors and its

impact is predicted accordingly.

Effect of Water Drawl (Surface water)

Impacts

The water supply for the proposed steel plant shall be basically for cooling of various

intermediate products and also for machinery cooling. Water shall also be required to

make up boiler water requirement in the DM plants for steam raising. There shall also be

requirement of water for drinking and other washing/cleaning purposes. To minimize the

fresh water drawn from the source, cooling water re-circulation systems have been

envisaged.

The source of water has been identified as the back water of Tungabhadra Reservoir

located at a distance of about 9.5 Km from the plant site, from where raw water will be

pumped to the plant storage reservoir located on the northern side of the site near the

national highway.

No impact on ground water is envisaged since no ground water will be drawn by the


Mitigation Measures


Many water conservation schemes envisaged are:

o The blow downs water from cooling towers and the neutralized effluent discharged

from the processes shall be utilized for coke quenching, slag granulation, steel slag

cooling, de-dusting/defogging and other direct contact water treatments aiming at zero

discharge.

o Blow down water from power plant will be reused for Pig Casting Machines and Coke

Quenching in Coke ovens.



Page 133 of 262

o Blow down water from BOF re-circulation system will be reused in SMS slag yards for

spraying on hot slag.

o Blown down water from Blast Furnace re-circulation system will be reused in Slag

Granulation Plant as make-up water to SGP re-circulation Water System.

In addition, rain water harvesting schemes are also envisaged for the proposed

project.

Water Usage

Background

In an integrated steel plant, wastewater may be generated from different units / shops.

The maximum quantity of which are reused in the plant itself after treatment and only

bleed off quantity are being further treated and reused. All attempts will be made to

achieve Zero discharge from plant.

Impacts

In an integrated steel plant, water is generally used for purposes like:

Material conditioning i.e. for slurrying, quenching, mill scale removal, rinsing etc.

Air pollution control i.e. for wet scrubbing of air pollutants

Heat transfer i.e. water used for protecting the equipment by cooling refractory and

shell of equipment.

Overall, approximately 75 % of water use is for heat transfer. Accordingly, a

considerable portion of water supplied is lost by evaporation. Evaporation losses include

slag quenching at blast furnaces and basic oxygen furnaces, Coke quenching, spray

chamber cooling at casters and evaporation in cooling towers. However, wastewater

discharges from any plant mainly depend upon the water usage and type of use.

Wastewater discharges from an integrated steel plant can be broadly divided into two

parts. Non-contact water discharges and contact water discharges. Water is used in a

series of heat exchangers in coke oven gas treatment, blast furnaces, basic oxygen

furnaces, and rolling operations and boilers. This non-contact water is generally

contaminated with high dissolved solids comprising of salts of calcium and magnesium

which were originally present in the raw / feed water. Due to repeated re-circulation and

high temperature concentration of these salts starts to build up necessitating bleeding off

of some part of circulating water. Water is also used for contact cooling e.g. quenching,



Page 134 of 262

Coke oven gas treatment, slag handling etc. This contact water discharges may be

contaminated with different pollutants and needs to be treated prior to discharges.

a) Sinter Plant

Wastewater may generate in Sinter plant if wet scrubbers are used for pollution control

facilities. However, in this project dry ESPs are used in the sinter plant for pollution

control, which does not generate any effluent. Further the water requirement /

consumption in sinter plant is very less and no water is required for process purposes

and as such no wastewater is generated from the process.

b) Blast Furnace

Blast furnace requires a considerable quantity of water. Water required is mainly for

direct contact water used in the gas coolers / wet scrubbers which cleans the blast

furnace gas. This water is treated in settling tank / clarifier for removal of suspended

solids and the overflows are recycled to the gas scrubbers.

Only the final blow down from the re circulated systems are being discharged. The blow

down will conform to the following quality:

pH 6.5 - 8.5

Suspended Solids (mg/l) 100

Oil & Grease (mg/l) 10

Cyanide as CN - (mg/l) 0.2

Ammonical Nitrogen as NH 3 – N (mg/l) 50

Therefore, there is no possibility of any adverse impact of water pollution.

c) Steel Making and Primary Refining: EOF/BOF

The water requirement for EOF/BOF is not significant. The wastewater generated from

Gas Cleaning Plant will be contaminated only with particulate matter and will be pumped

to a sludge pond. Further any bleed off water from cooling circuit will be used for slag

cooling and as such no wastewater is anticipated to be generated from cooling water

circuit. Thus, no adverse impact on water environment is anticipated.

d) Secondary Refining Facilities: Ladle Furnace

The other water usages indicated are mainly for refining and casting operations. The

refining operation except vacuum degassing does not generates any effluent.



Page 135 of 262

e) Continuous Casting Facilities and Rolling Mills

Continuous Caster usually requires water for cooling of different mechanical equipment,

and for flushing of mill scale (generated during cutting) down the flume beneath the

runout table. The principal pollutants are suspended solids, oil and greases. This will be

treated in scale pits for mill scale recovery and oil removal and the treated effluent will be

discharged.

f) Coke Oven & By Product Plant

Waste waters are generated from the coke oven & bye product plant as waste ammonia

liquor from moisture contaminated in the charged coal, steam used in distilling ammonia

from the waste liquor, light oil recovery and other processes. Wastewaters are

contaminated with oil & grease, ammonia, cyanides, thiocyanates, and phenols.

Further whatever wastewater is generated from the Coke Oven & By Product Plant area

is collected and transported through pipeline to a wastewater treatment plant (BOD

Plant). The wastewater after treatment is meeting the statutory norms for discharge of

treated effluent but instead of discharging it outside, the wastewater is used for

plantation and as such no water pollution is anticipated.

Treated effluent will conform to the following:

i) pH of the treated effluent - Between 6.0 to 8.0

ii) Suspended solids - Not more than 100mg/l

iii) Phenol - Not more than 1.0 mg/l

iv) Cyanide - Not more than 0.2 mg/l

v) Ammonical Nitrogen - Not more than 50mg/l

vi) Free ammonia - Not more than 5.0 mg/l

vii) Oil & grease - Not more than 10 mg / l

viii) Nitrate Nitrogen - Not more than 10mg/l

ix) BOD (3 days, 27 o C) - Not more than 30 mg/l

x) COD - Not more than 250 mg/l

g) Wastewater from Other Sources

In addition to the above some additional wastewater may be generated due to floor

washings and also from the toilet blocks of the units envisaged during the proposed steel

plant. The sewage generated from the toilet blocks will be very less in quantity and will

be taken to the Sewage Treatment Plant (STP).



Page 136 of 262

Mitigation Measures

During the design phase all efforts shall be made to adopt latest state of art technology

and propose to install adequate effluent treatment facilities for different units expected to

generate water pollutants. During the construction phase of the proposed project

appropriate mitigation measures will be implemented to ameliorate the anticipated water

/effluent quality problems. The following mitigation measures will be employed during

operation period to reduce the pollution level to acceptable limits.

Re-circulating water in the process whereby discharged volume shall be minimum.

Clarifier and sludge pond shall be used for removal of suspended solids.

Neutralization of acidic water by lime.

Removal of oil and grease from the contaminated water by means if oil traps,

skimming devices, etc.

Effluent quality monitoring will be at inlet and outlets of different effluent treatment

plants to ensure proper functioning of different effluent treatment facilities.

Use of treated wastewater in different shops and for plantation development as far

as practicable.

The list of water pollution control systems envisaged is summarized below:

List of Water Pollution Control Systems

Source Pollutants Control System

Raw material handling

yard

Suspended Solids Catch Pits

Raw Water Treatment

Plant

Suspended Solids Clarifier, Thickener,

BF& BOF Gas Cleaning

Plant

Suspended Solids Clarifier, Thickener,

Coke Oven and by

product plant

Oils, Suspended Solids,

ammonia, phenols etc

Oil, organics and ammonia

removal, in BOD Plant

Bloom Caster, Billet

caster, slab caster &

Rolling mills

Suspended Solids, Oil &

Grease

Settling Tanks fitted with Oil &

Grease Trap

Soft and DM Water Plant pH and dissolved solids Neutralizing Pit

Cooling Tower and Boiler

Blow-down

Temperature, Dissolved

Solids

For re use

Canteens, Toilets BOD, Suspended Solids Sewage treatment plant

The proposed steel plant aims at zero discharge philosophy.



Page 137 of 262

Ground Water

Impacts

The proposed steel plant does not envisage any ground water drawl and hence no

impact on ground water availability around the plant is anticipated.

The waste disposal area around any industry is one of the major factors deteriorating

ground water quality, if the water leached from the waste dumps contains toxic

substances. At the proposed steel plant, some wastes are dumped in secured land fill

sites and some inert wastes are dumped in low lying area. All other solid wastes are re-

used / recycled or sold out.

Mitigation Measures

Periodical monitoring of ground water quality at up-gradient and down gradient of

slag dump area.

Disposal of waste generated from the proposed project will be done in a systematic

/scientific manner as per guidelines to prevent any ground water pollution.

4.1.4.4 Solid Waste Generation and Disposal

General

Integrated Iron & steel plant generates solid wastes, some of which are hazardous while

others are non-hazardous. Some of these wastes are reused / re-utilized and some are

not. AISL is also not exception to that. Solid wastes are mainly generated from:

- Sinter Plant

- Blast Furnace

- EOF/BOF

- Coke Oven & By-product Plant

- Different Rolling Mills

- Lime & Dolomite Plant

In addition to above, wastes are also generated during operation / maintenance / annual

maintenance of other units / shops etc, which are

- Flue dust from BF

- Blast Furnace Gas Cleaning Plant sludge

- SMS Gas Cleaning Plant sludge



Page 138 of 262

- Waste Refractory materials

- Waste lubricant / oil etc. and Waste Lead – Acid Batteries

-

The characteristics of the generated solid wastes are presented in Table 4.4a. From the

table it can be noticed that except some sludge generated from Coke Oven and By

Product area none are hazardous. The generation quantity along with the reuse / recycle

and disposal methodology for the solid waste is presented in Table 4.4b.

Table 4.4a: Source of Generation / Characterization of Solid Wastes

Shop Type of waste Source of Generation Typical

Chemistry (%) Waste

Characterization

BF Plant BF Flue Dust Flue dust of coarser

particle is collected in dust

catcher located before wet

scrubbing

Fe(t) : 37.00

C : 23.69

SiO2 : 9.01

Al2O3 : 7.26,

TiO2 : 0.87,

CaO : 6.37,

MgO : 5.46,

P2O5 : 0.25,

S : 0.27

Not Applicable

BF Sludge Flue dust of fine particles

trapped by wet scrubbing

and finally settled at

sludge pond

Fe(t) : 20-30

FeO : 7-12

Fe2O3 : 25-35

C : 30-40

S : 0.5-0.8

ZnO : 0.2-0.4

CaO : 8-10

SiO2 : 5.0-7.0

Al2O3 : 0.8-1.3

Not Applicable

BF Slag BF operation CaO : 30-31

SiO2 : 32-33

Al2O3 : 18-22

MgO : 8-10

FeO :0.2-0.6

S :1.5-1.7,

Not Applicable

Spent

Refractories

Bricks from BF,

dismantled ladles /

torpedo ladles, cast house

runners, etc.

- Not Applicable



Page 139 of 262


Chemistry (%) Waste

Characterization

Hot metal

Pretreatm

ent Unit

Hot Metal

Pretreatment

Dust

Dust collected in bag

house filter of dust

extraction system

Not Applicable

Hot Metal

Pretreatment

Slag

Slag skimmed after

pretreatment of hot metal

Not Applicable

BOF

Shop

BOF Dust /

Sludge

BOF flue dust collected in

gas cleaning system either

in dry form or as sludge

BOF dust :

Fe(t) : 52.25

SiO2 : 5.92,

Al2O3 : 1.1

CaO : 18.26

MgO : 5.98

S : 0.18

BOF sludge :

Fe(t) : 50.84

CaO : 15.39

SiO2 : 2.19

P : 0.17,

S : 0.29

Not Applicable

BOF Slag BOF CaO : 40-50

FeO : 20,

SiO2 : 15-17

P2O5 : 2.45

MgO :3.9 - 4.5

Al2O3 : 5.2-6.3

Not Applicable

Spent

Refractories

Bricks from dismantled

converter

Not Applicable

Refractory

Materials

Plant

Limestone /

Dolomite Fines

Screening of raw

limestones / dolomite in

raw materials handling

yard / lime plant / dolomite

calcination plant

Not Applicable

Lime / Calcined

Dolomite Fines

Screening of calcined lime

/ dolomite in lime /dolomite

calcination plant

Not Applicable

Spent

Refractories


kilns of refractory

materials plant

Not Applicable



Page 140 of 262


Chemistry (%) Waste

Characterization

RMP Sludge Collected after scrubbing

of kiln flue

Not Applicable

Continuou

s Casting

Plant

Caster Scale Caster Area Fe(t) : 62-68

FeO : 60-70

Fe2O3 : 15-25

C : 0.3-0.5,

S : 0.12-0.25

P : 0.15-0.25

CaO : 0.3-0.5

SiO2 : 0.8-1.5,

Al2O3 : 0.1-0.2

Not Applicable

Caster Sludge Sludge pit of continuous

casting plant

Not Applicable

Spent

Refractories

Repair of tundish and

ladles

Not Applicable

Hot

Rolling

Mill

Mill Scales Relatively coarse mill

scale is collected from

reheating furnaces and dry

processing areas like

cooling beds,

straighteners, shears and

saws

Fe(t) : 62-68

FeO : 60-70

Fe2O3 : 15-25

C : 0.3-0.5,

S : 0.12-0.25

P : 0.15-0.25

CaO : 0.3-0.5

SiO2 : 0.8-1.5,

Not Applicable

Mill Sludge Fine mill scale

contaminated with oil is

collected in sludge pit

Fe(t) : 64.4

CaO : 0.6,

SiO2 : 4.0

P : 0.085

Al2O3 : 1.85

LOI : 0.4

Oil : 10-11

Not Applicable

Spent

Refractories


reheating furnaces

Not Applicable

Coke

Oven

Plant

Spent

Refractories

Rebuilding of coke ovens

and miscellaneous repairs

in coke ovens

Not Applicable

By-

Products

Plant

Decanter Tar

Sludge

Decanter for separation of

tarry sludge from

Ammonical liquor and tar

As per Category

13.3 of Schedule

– I



Page 141 of 262


Chemistry (%) Waste

Characterization

Tar Storage

Tank Residues

Cleaning of Tar storage

tank & Gas Traps & Seals

As per Category

1.2 & 13.4 of

Schedule – I

Tarry & Acidic

wastes

Coal Chemical Plant:

Reactor / Electrostatic Tar

Precipitator (ETP)

Cleaning & Annual

Maintenance

As per Category

1.2 & 17.1 of

Schedule – I

BOD Plant

Sludge

Sludge from BOD Plant As per Category

34.3 of Schedule

– I

Mineral

Oil/synthe

tic oil

used as

lubricants

Spent / Wash /

Lubricant

As per Category

5.1 & 20.2 of

Schedule – I

Batteries Lead Acid

Batteries

From various operations Category B4 & E3

of Schedule – II

Impacts

Solid waste generated from different units and its re-utilization and disposal is given in

Table 4.4b.

Table 4.4b: Solid Waste Generation and Disposal

Solid Waste Total generation at

full capacity (tons)

Utilization and mode Disposal as

wastes

Phase-1

units

Phase-2

units

Coal/coke dust 11,854 12,653 100% utilized in coal blend charge

in the coke oven complex

Nil

Undersize coke 26,000 59,200 100% utilized in sintering plants as

a bed material for heat energy

Nil

Tar sludge 240 256 To be used along with coal charge

in the coke ovens

Nil

Acid sludge from

by-product units

100 100 - To be

neutralized

and disposed

as landfill.



Page 142 of 262

Lime sludge from

PCM

450 To be used as neutralizing agent Nil

Iron bearing dusts

from dust

catchers/ESPs/Ba

g filters

232,980 556,669 To be used along with the charge

mix in the sintering plants. The

design has provisions to use these.

Nil

Blast Furnace

granulated slag

362,208 822,298 To be sold to cement plants for

making blast furnace slag cement

Nil

Steel making slag 150,000 324,000 Only iron bearing portion of the

steel slag would be recovered and

iron to be used in steel making. A

small % of the steel slag can be

used in Blast furnace as source of

lime.

These would

be used as

landfills either

inside the

plant or in the

neighborhood

Iron oxide from

acid regeneration

plant of Cold

rolling mills

40,000 To be sold to users like Ferro

magnet industry, iron powder

industry etc.

Nil

Power plant fly ash 127,360 490,758 To be sold to fly ash brick makers

and cement plants making fly ash

cements

Nil

Power plant

Bottom ash

31,840 122,689 Cannot be used in the processes

adopted.

To be used as

land fill

Arising of

skull/scraps

94,197

(114,197)*

191,315 To be used in steel making for re-

melting.

Nil

Rejects after Two

stage WHIMS

treatment in the

fine ore

beneficiation plant.

4,44,188

(Dry)

To be temporarily stocked at the

designated site in the plant and

later transported to a nearby ore

mine pit for re-filling and green

development.

Phase-1:

Phase-2:

4,44,188 t

Refractory wastes 10,880 26,849 Un-contaminated (80%) bricks will

be sold (for construction) or crushed

to be used as mortar.

About 20% of

the waste

bricks which

are

contaminated

with slag/skull

etc. would

have to

discarded and

dumped in



Page 143 of 262

landfills.

Muck/sludge/waste

s

5,050 7,750 Cannot be re-used

Total arising 1,053,159 3,098,723 174,066 (16.53%) 870,968

(28.2%)

Mitigation Measures

All attempts shall be made to utilize solid waste as per the guidelines given in CREP.

4.1.4.4 Noise Levels

Impacts

During normal operations of the plant ambient noise levels may increase close to the

compressors and blowers but this will be confined only within plant boundary and that

too will be confined within shops. The level will be further minimised when the noise

reaches the plant boundary and the nearest residential areas beyond the plant

boundary.

Mitigation Measures

Various measures proposed to reduce noise pollution include reduction of noise at

source, provision of acoustic lagging for the equipment and suction side silencers,

vibration isolators, selection of low noise equipment, isolation of noisy equipment from

working personnel. In some areas, personnel working will be provided with noise

reduction aid such as ear muffs/ ear plugs and also the duration of exposure of the

personnel will be limited as per the norms. The following measures will be undertaken:

Technological Measures

Plugging leakages in high-pressure gas/air pipelines.

Reducing vibration of high-speed rotating machines by regular monitoring of vibration

and taking necessary steps.

Design of absorber system for the shift office and pulpit operator's cabin.

Noise absorber systems in pump houses.

Noise level at 1m from equipment will be limited to 85 dB (A).

The fans and ductwork will be designed for minimum vibration.

All the equipment in different units and in units where capacity proposed steel is

taking place will be designed/operated in such a way that the noise level shall not

exceed 85 dB (A).



Page 144 of 262

Periodical monitoring of work zone noise and outside plant premises.

Management Measures

In a steel plant, with a variety of noise producing equipment, it may not be practicable to

take technological control measures at all the places. In such cases the following

administrative measures shall also be taken:

Un-manned high noise zone will be marked as "High Noise Zone".

In shops where measures are not feasible, attempts shall be made to provide

operators with soundproof enclosure to operate the system.

Workers exposed to noise level will be provided with protection devices like earmuffs

as per present practice and will be advised to use them regularly, while at work.

Workers exposed to noisy work place shall be provided with rotational duties.

All workers will be regularly checked medically for any noise related health problem

and if detected, they will be provided with alternative duty.

Over and above all these adopted measures, trees and shrubs belts of substantial

depths within and surrounding plant premises will further attenuate the sound levels

reaching the receptors within and outside the plant premises.

4.1.4.5 Ecological Features

Impacts

Erection and commissioning of the project may change the land-use pattern of the

project area and may cause significant loss of habitat, which is unavoidable. However,

the proposed steel plant is coming up within the land allocated to AISL – thus such

changes are not of major concern.

During construction some existing vegetation which is bushes on the project site may be

cut / damaged.

The construction and operation of the project may cause direct impact to the wildlife

present in the area. However, there is not significant presence of wild life in the area as

per record and the proposed steel plant is coming up within the allocated land of AISL -

thus the impact on wild life is not envisaged.

Emissions from plant operation may affect the natural vegetation and agricultural crops

around the proposed steel plant.

The thresh-hold limit for continuous exposure of SO2 on plants is 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 operation

of the proposed steel plant will be much below the above said level. Moreover, the area



Page 145 of 262

is dry and the natural vegetation commonly found on hillocks and in plain areas are

scrub types. All the plants naturally occurring are xerophytic with sunken stomata, thick

and small leaves. All these adaptations are for water conservation. Side by side these

features are also helpful in protecting plants from air pollutants. Thus, it is expected that

the natural vegetation in the area will not be affected. 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.

The waste water from plant operation and domestic use may cause surface water

pollution in the area.

Mitigation Measures

All technological measures to limit air emissions, waste water discharge and noise

generation are envisaged in the proposed steel plant design and hence no further

mitigation measures envisaged.

An elaborate green belt / cover is proposed, which will ameliorate the fugitive emissions

and noise from the project operation.

The proposed project is designed for maximum re-circulation and no effluent will be

allowed to discharge out of plant premises. The project and domestic waste water will be

treated and after treatment the same will be re-used and recycled within the plant itself

and the excess water will be used for gardening purpose and dust suppression of plant

roads. Thus, there will be no impact on the ecological components of surface water

bodies in the area.

4.1.4.6 Occupational Safety and Health

Impact

Working operation of integrated steel plant is cumbersome and negligence in plant

operations may cause risk to safety and health problems.

Mitigation Measures

For ensuring better occupational health and safety the following measures will be

provided:

General Measures

Proper control of fugitive dust from sources inside plant including open stockyards

and to keep all de-dusting systems in prefect conditions. The de-dusting systems



Page 146 of 262

provided in shops will be regularly monitored and the level of dust in working zone

will be reported to the management for necessary control action.

Keeping plenum ventilation systems of premises in perfect working order to avoid

accumulation of dust on equipment inside the pressurized room. Regular cleaning of

air filters shall be practiced.

Keeping air conditioning plants in perfect running condition for control /

instrumentation rooms.

Proper functioning of pollution control systems to minimise dust fall on plant and

outside areas.

Based on the environmental monitoring for dust, gases, toxic chemical, noise &

vibration, the workers exposed to these will be regularly checked in medical unit and

results will be intimated to management.

Workers exposed to noise prone areas will be medically checked and proper noise

protective equipment will be supplied to them and will be encouraged to use the

same.

Spot cooling facilities will be provided for workers exposed to high heat generating

shops and will be checked periodically. If necessary, rotation of duties is advised.

Proper attention is given to township water quality so that water borne disease may

not affect residents.

More doctors in township hospital and plant medical unit will be additionally trained

in the field of occupational health as policy matter.

House Keeping Measures

Proper housekeeping is the key to proper environmental management. This creates

proper working environment for the work force and safe working conditions. However, for

the proposed capacity the following good housekeeping measures will be adopted:

Regular cleaning and watering of plant roads to avoid accumulation of dust/garbage.

Regular cleaning of shop floors.

Avoiding accumulation and dumping of wastes and damaged equipment and items

anywhere inside the plant affecting aesthetics.

Developing a positive outlook in the employees for keeping the work place, both in

factory, office or laboratory, clean and well maintained.

Maintaining hygienic conditions in areas like canteens, near drinking water sources

and toilets.



Page 147 of 262

4.1.4.7 Charter on Corporate Responsibilities for Environmental Protection (CREP)

The Charter on Corporate Responsibility (CREP) as laid down by Central Pollution

Control Board (CPCB) for Integrated Iron and Steel Industry will guides the production in

the proposed steel plant.

Table 4.5: Charter of Corporate Responsibility shall be as followed

SN Unit /

Item

Responsibilities Extent of fulfillment

1. Coke

Oven

Meeting parameters related to

PLD, PLL, PLO etc.

These criteria will be fulfilled

2. SMS To reduce fugitive emission by

installing a secondary dedusting

system

secondary dedusting facility

envisaged to reduce the fugitive

emission

3. BF Direct Injection of reducing agents Coal Dust Injection (CDI) system

for BF has been envisaged

4. SMS /

BF

Utilization of SMS and BF Slag 100 % utilization will be explored

through setting of cement

grinding unit

5. Coke

Oven

Charging of Tar sludge / ETP

sludge to coke oven

Possibility will be explored

6. Water

conserva

tion

Reduce specific water

consumption to 5m³/t for long

products and 8m³/t for flat

products.

Operation of COBP Effluent

Treatment Plant efficiently to

achieve notified discharge

standards

The statutory norms will be

complied.

4.1.5 IMPACTS AND MITIGATION MEASURES BECAUSE OF ACCIDENTS

Any accident / mishap resulting in Fire or consequent to fire will not have any serious

repercussions as that of a major hazard. Furthermore, the fire in such of these

installations will be contained and confined to the installation / facility only and there are

no chances of escalation.

Since many gases is used as fuel in the furnaces, any leakage of the same may lead to



Page 148 of 262

fire accidents which may cause damage to men, material and machinery in the nearby

areas and are controllable. Whereas, once the `BLEVE’ sets in, it is uncontrollable and it

is a major disaster situation. The physical damage caused by a `BLEVE’ cannot be

controlled.

Mitigation Measures

Proper on-site / off-site emergency plans & Disaster Management Plan will be made. In

addition, various fixed installations for Fire Detection, Alarm and Firefighting will be

available to effectively tackle the situation before the fire escalates into a conflagration.

Regular mock drills will be conducted to check the effectiveness of the system

4.2 Measures for Minimizing and / or Offsetting Adverse Impact

The potential adverse environmental impacts possible verses the mitigation measures

incorporated to minimize the possible impacts, in the proposed steel plant have been

summarized in brief in Table 4.6.

Table 4.6: Potential Impacts Verses Mitigation Measures Adopted

S

N.

Impact

Topics

Impact On Impact Due To Adopted Measures

1 Physical

Resources

Air

environment

Release of air

pollutants

Incorporation & installation of air

pollution control systems and ensuring

their effective functioning.

Water

environment

Drawl of water &

release of polluted

waste water

Sufficiency of water availability

assessed, maximum re-circulation of

water envisaged, and Incorporation &

installation of water pollution control

systems and ensuring their effective

functioning.

Soil Release of polluted

waste water,

Deposition of PM

released, &

Dumping of solid

waste

Incorporation & installation of water

and air pollution control systems,

Handling & disposal of solid waste

including hazardous waste in

accordance with statutory norms.

2 Biological

Resources

Vegetation Release of polluted

wastewater,

Deposition of

pollutants released.

Incorporation & installation of water

and air pollution control systems

3 Land Land Conversion of Land acquired is declared as



Page 149 of 262

S

N.

Impact

Topics

Impact On Impact Due To Adopted Measures

resources environment,

Aesthetics

existing land use

pattern

Industrial land

4 Noise Habitats Use of equipment

having operating

sound level more

than the statutory

level.

Noise Control measures as required

have been envisaged. All noise levels

will be maintained within the

permissible statutory limits.

5 Hazardous

Substance

Habitat,

Surrounding

environment

Release of

hazardous

chemicals

Incorporation of different process

control systems, Safety features,

Alarm arrangements, and follow up of

Disaster management / Emergency

response plan

6 Transportati

on

Habitat,

Surrounding

environment

Release of pollutant,

Improper traffic

management.

Use of vehicles meeting the statutory

norms related to emission, transport

by railway freight, proper traffic

management.

7 Social &

Economic

Human,

livelihood,

Education etc

Influx of people,

Settlement, Stress

on existing

infrastructure etc.

No negative impact envisaged since

site is already a planned town.

Moreover, additional social

improvement activities have also been

planned by the project management in

the region.

8 Cultural

resources

Human Influx of people,

Settlement

No negative impact envisaged since

site is near to Koppal town

4.3 Irreversible and Irretrievable Commitments of Environmental Components

The project is not expected to create any irreversible and irretrievable impacts because

of the following:

The project is coming within the allocated land by Karnataka Government for

industrial use.

No forest land is involved.

No rehabilitation of site dwellers is required.

All the impacts created by the project can be mitigated by adoption of suitable

mitigation measures.



Page 150 of 262

4.4 Assessment of Significance of Environmental Impacts

General

The assessment of effects of a particular action judgment must be made as to whether

these effects are “Significant”. Significance is a relative concept, which reflects the

degree of importance placed on the impact in question. Having identified the events

associated with the proposed activity and their potential consequences, the next issue

required to be addressed is the extent to which these make the proposed activity

environmentally significant. In developing the criteria for determining this, the criteria

outlined in the different guidelines for determining the level of environmental impact were

considered.

The criteria entail an assessment of the level of certainty in the prediction of an activity’s

potential environmental consequences (Predictability Criterion), combined with an

assessment of the degree to which these consequences can be managed

(Manageability Criterion).

The predictability criterion involves determining the level of certainty in the prediction of

different issues for each of the events and their potential environmental consequences

associated with the activity.

The manageability criterion focuses on the extent to which the potential environmental

consequences can be either avoided or minimised in terms of size, scope and duration.

It is based on the recognition that minimizing the environmental impact of an activity

primarily entails managing the environmental consequence(s) of those activities by

either avoiding them in the first place or by mitigating them to as low as reasonably

practical. From the significance scores for the predictability and manageability criteria,

the level of environmental significance for each of the potential events associated with

the proposed activity can then be determined as High, Medium or Low on the basis of

environmental significance matrix.

The steps followed for assessing the significance are presented schematically in Fig. 4.4

below. The aspect of environment and their environmental consequences considered

are presented in Table 4.7.



Page 151 of 262

Table 4.7: Events and their Environmental Consequences

Aspect of

Environment

Category of

Impact

Type of Event Likely Consequences

Physical

Environment

Air Impacts Emissions to air (e.g. dust,

SO2, NOx gases etc)

Health risk to local community;

Greenhouse effect.

Soil Impact Soil earthworks Reduction in visual/aesthetic sight of

area.

Surface &

Ground

Water

Impacts

Water extraction Water shortage to local community,

agriculture and ecosystem.

Spills into water bodies (e.g.

oil or chemical spills)

Inconsumable water to the local

community and ecosystem.

Altering drainage patterns Reduced water capacity of natural

water bodies. Increased soil erosion.

Fauna

Impacts

Disturbing terrestrial or aquatic

species

Endangering species; Displacing

species

Flora

Impacts

Disturbing native flora

Clearing native vegetation

Threaten biological diversity Destroy

fauna habitats; Threaten biodiversity

Social

Environment

Community

Resource

Impacts

Use of public resources Degradation of public infrastructure

(e.g. roads)

Change in land use Disadvantage groups within the

community; Loss of recreational

amenity of a region

Change visual attributes of

area

Reduction in aesthetic and

recreational value of area

Cultural

Impacts

Change demographic

structure of an area

Changes to community make up;

Changes in community cultural

identity and values

Community

Health

Impacts

Air emissions Health problems in the community

Noise and vibration Discomfort to local community;

Water contamination Health risk to local community

Potentially hazardous

operations (e.g. high-pressure

pipelines, hazardous

substance storage)

Health and safety risk to local

community

Economic

Environment

Community

Welfare

Altering economy of a region Changes to the standard of living in

the region;



Page 152 of 262

Aspect of

Environment

Category of

Impact

Type of Event Likely Consequences

Impacts Altering employment rate

within a community

Changes to the standard of living;

Social instability/stability

Changes in employment levels;

Natural

Resource

Impacts

Disturbance of natural

resources of other industries

in the region

Changes in level of viability of other

industries, Changes to industry types

within Region

Altering existing land use. Changes to land value;

Criteria for Determining Significance

Issues considered under the predictability criterion are given in Table 4.8.

Table 4.8: Issues Considered under Predictability Criterion

a) Size of event(s) & consequence(s):

The accuracy of the predicted quantity of potential pollution discharge on a unit or total

basis, the amount of population, land, fauna and flora disturbed, and the size of the

potential consequences of such events.

b) Scope of consequence(s):

For example, the accuracy of the predicted extent to which the potential consequences

extend beyond the confines of the area or region of direct disturbance.

c) Duration of event(s) & consequence(s):

This includes the accuracy of the predicted timeframe (i.e. short or long term) over which

the event and their potential consequences are expected to last.

d) Likelihood of events

The likelihood at which the events that can potentially result in the consequences are

estimated to occur.

e) Stakeholder Concerns of event(s) & consequence(s)

The extent to which the stakeholder perceptions, views and concerns of the events and

their consequences associated with the activity is known.

As a first step, the level of certainty in the prediction of these issues has been

determined and categorized as either Low, Medium or High as defined in Table 4.9.



Page 153 of 262

Table 4.9: Level of Certainty in the Prediction of Activity Events and their

Associated Consequences

Low Extreme uncertainty in the prediction of the issue. Well-informed decision-

making is very difficult to make.

Medium Some uncertainty in the prediction of the issue. Sufficient confidence in the

accuracy of the data to make informed decision-making possible.

High Insignificant uncertainty in the prediction of the issue. Confidence in making

an informed decision is very high.

The level of certainty for the above issues for each event is then determined. For ease of

assessment, the results have been tabulated as shown below in Table 4.10



Page 154 of 262

Identify events associated with the proposed activity and any potentially environmentally adverse

consequences associated with these events

Predictability Criterion Assess the level of certainty in the prediction of the activity events and their associated adverse

environmental consequences in relation to their:

Size

Scope,

Duration,

Likelihood and

Stakeholder Concerns

Manageability Criterion Assess the level to which any adverse consequences for each event can be managed in relation to:

Being avoided;

Likelihood of occurring;

Duration;

Size and scope;

Cumulative effects;

Stakeholder concerns

Determine the environmental significance scores for each event against the predictability and

manageability criterion (Table 4.11 to 4.15 respectively).

Ascertain the level of environmental significance (Low, Medium or High) for each event

(environmental significance matrix: Table 4.16).

Classify level of Environmental Impact of the overall proposed activity on the basis of the level of

environmental significance of each event.

Fig. 4.4: Steps for Assessment of Significance of Environmental Impacts



Page 155 of 262

Environmental Significance Against Predictability Criterion

Once the level of certainty of each of the issues is determined, it is then possible to

assess the environmental significance of each of the events associated with the activity

against the predictability criterion. The environmental significance is determined and

assessed on a scale of 1 to 5 as described in Table 4.10.

The significance score can then be tabled into the “significance score” column of the

predictability criterion Table 4.11.

Table 4.10: Predictability Criterion Significance Score

Significance

Score

Predictability Criterion

1 All of the issues outlined in Table 4.7 have been fully addressed; all

events and their consequences associated with the activity have been

accurately predicted to a high level of confidence.

2 There is a mixture of high and medium certainty of the issues. No issue

is of low certainty.

3 All issues are of medium certainty.

4 There is low certainty in at least 1 of the issues for either the events or

their potential environmental consequence(s).

5 There is low certainty in all of the issues for either the events or

consequences.

Table 4.11: Predictability Criterion Table

Step 1 Each of the events of the proposed

activity and their associated consequences

are assessed against certainty (Low,

Medium or High as described in Table 4.9) in

the prediction of: •the size; •scope; •duration;

•likelihood; and •stakeholder concerns Step

2 Significance Score of 1 to 5 is assigned for

each event using Tables 4.9 & 4.10. Siz

e

Sc

op

e

Du

rati

on

Fre

qu

en

cy

Sta

ke

ho

lde

r

Co

nc

ern

s

Sig

nif

ican

ce s

co

re

NATURAL ENVIRONMENTAL IMPACTS

Impact on Soil Earthworks High High High High High 1

Contamination (e.g. spills) High High High High High 1

Air Impacts Air emissions Mediu

m

Med. Med Med. High 2



Page 156 of 262

Step 1 Each of the events of the proposed

activity and their associated consequences

are assessed against certainty (Low,

Medium or High as described in Table 4.9) in

the prediction of: •the size; •scope; •duration;

•likelihood; and •stakeholder concerns Step

2 Significance Score of 1 to 5 is assigned for

each event using Tables 4.9 & 4.10. Siz

e

Sc

op

e

Du

rati

on

Fre

qu

en

cy

Sta

ke

ho

lde

r

Co

nc

ern

s

Sig

nif

ican

ce s

co

re

NATURAL ENVIRONMENTAL IMPACTS

Surface/Groun

d Water

Impacts

Water contamination Mediu

m

Med. Med. Med. High 2

Water extraction High High High High High 1

Altering drainage patterns High High High High High 1

Fauna Impacts

Disturbance to species High High High High High 1

Disturbance to habitats High High High High High 1

Flora Impacts

Disturbing native flora species High High High High High 1

Clearing extensive areas of native vegetation High High High High High 1

SOCIAL IMPACTS

Community Resource Impacts

Public infrastructure High High High High High 1

Land use High High High High High 1

Changes to visual attributes of area High High High High High 1

Cultural Impacts

Changes to demographic structure of area High High High High High 1

Community Health Impacts

Air quality changes Medi Med. Med. Med. High 2

Noise and vibration High High High High High 1

Changes to water quality High High High High High 1

Hazardous operations introduced Med. Med. Med. Med. High 2

ECONOMIC IMPACTS

Community Welfare Impacts

Wealth and employment High High High High High 1

Natural Resource Impacts

Disturbance of natural resources of other

industries

High High High High High 1

Altering existing land use High High High High High 1



Page 157 of 262

Manageability Criterion

This criterion focuses on the extent to which the potential environmental consequences

can be either avoided or minimised in terms of size, scope and duration. It is based on

the recognition that minimizing the environmental impact of an activity primarily entails

managing the environmental consequence(s) of those activities by either avoiding them

in the first place or by mitigating them to as low as reasonably practical. That is, any

event will have an impact of some sort on the natural, social or economic aspects of the

environment within which it occurs. However, the severity of the impact(s) depends on

the extent to which the consequences to the environment can be eliminated or

minimised. Therefore, the manageability criterion assesses the level to which the

environmental consequences of each event can be either avoided or mitigated.

Issues Under Manageability Criterion

In assessing the level to which the environmental consequences can be managed the

issues given in Table 4.12 may need to be addressed.

Table 4.12: Issues Considered under Manageability Criterion

a) Avoidance of Consequences

The extent to which the associated consequences of the various activity events

can be totally avoided.

b) Likelihood of Event Occurring

The likelihood or probability of an event occurring must also be addressed. If the

likelihood of such an event or sequence of events occurring has been managed

so as to be very low and acceptable to other stakeholders, then it could be said

that this is being managed appropriately and therefore of low significance

c) Duration of Consequences

Whether the consequences can be managed to be short-term needs to be

addressed – short-term needs to be defined in the context of the environment

within which the potential consequences are likely to occur. That is, concepts

such as the resilience of the environment would come into consideration.

d) Size and Scope

Consideration should be given to the extent to which the size and scope of the

consequences can be managed, for example area of land, amount of flora and

fauna or number of people affected by an activity. Consideration should be given

to the size and intensity of the impacted environment relative to the undisturbed

surroundings. Also, whether the consequences are potentially catastrophic in

terms of human and environmental well-being, for example wide scoping and

irreversible consequences.



Page 158 of 262

e) Cumulative Effects

This includes any cumulative effects of the consequences, for example, the

number of individual activities, which individually may not pose a significant

environmental risk but collectively their potential consequences may be very

significant in a particular region.

f) Stakeholder Concerns

The level of severity of the environmental consequences perceived by

stakeholders (e.g. the outrage effect).

Table 4.13 outlines some basic questions, which can be used to address the above

issues.

Table 4.13: Questions for Addressing Issues under Manageability Criterion

Issues Questions

Avoidance of

consequences

Can the potential adverse environmental consequences be avoided; or are

there is no such consequence? (Yes or No)

Likelihood of

event

What is the probability of an event occurring, which may result in the

adverse environmental consequence(s)? (Low, Medium or High on the

basis of the results of the risk assessment carried out in accord with

relevant standards)

Duration of

consequences

Are the consequences likely to be Short, Medium or Long term?

Size and

scope

Can the consequences be managed so as to be small or confined to a

designated area? (Small or Confined?) If they are not small or confinable

are the consequences potentially catastrophic? (Wide Scoping and

Irreversible).

Cumulative

effects

Is it likely that the potential consequences of the proposal in conjunction

with those of other existing activities are likely to pose a higher and

unacceptable risk to the environment than if the individual activities were

carried out on their own?

Stakeholder

concerns

Is there any major concern of other stakeholders on any of the

consequences of the proposed activity?



Page 159 of 262

Environmental Significance Against Manageability Criterion

Once the potential environmental consequences have been addressed in relation to the

above issues, the level of environmental significance of each of the events associated

with the proposed activity can then be assessed against the manageability criterion. As

with the predictability criterion, the environmental significance for the manageability

criterion is assessed on a scale of 1 to 5 as described in Table 4.14

Table 4.14: Manageability Criterion Significance score

Significance

Score

Manageability Criterion

1 Adverse consequences of the various events associated with the

proposed activity can be totally avoided, or it is highly unlikely that the

events will ever occur.

2 Adverse consequences can be managed to be short-term. Short-term

needs to be defined in the context of the environment within which the

potential consequences are likely to occur.

3 Adverse consequences are not or cannot be managed to be short-

term, but they can be confined so as to be insignificant in terms of size

and scope relative to the surroundings.

4 Adverse consequences in conjunction with those of existing activities

pose significant cumulative effects. Or Consequences are significant in

terms of duration and/or size and scope relative to surroundings.

5 Consequences are potentially catastrophic. Or There is high

stakeholder concern on the severity of the consequences.

Catastrophic in this context means wide scope and long term or

irreversible consequences such as death or serious injury to many

individuals or permanent adverse change to the environment.

A step-by-step outline of the use of Tables 4.13 & 4.14 to assess the level of

environmental significance for each of the events associated with the proposed activity

against the manageability criterion is suggested as follows.

Step1: Where potential adverse consequences can be totally avoided; or where there

are no adverse consequences associated with the events of the activity; or where there

is a low likelihood of an event occurring which would lead to adverse consequences

being realized then the event can be considered as being of low significance. In this

case a significance score of 1 should be assigned.

Step 2: Where potentially adverse consequences cannot be totally avoided or where



Page 160 of 262

their likelihood of being realized is not low, consideration needs to be given to the

duration of the consequences. If the consequences can be managed to occur only for

short term in the context of the environment within which they will occur. In such cases a

significance score of 2 should be assigned.

Step 3: If the consequences are not short term, then the question of whether or not they

can be confined within a designated area, which is relatively small, compared to the

surrounding environment needs to be addressed. If they can be confined to being small,

then a significance score of 3 is assigned. If they cannot be confined to being small and

are significant in terms of size and scope relative to surroundings and/or duration, then a

significance score of 4 is assigned.

Step 4: Before assigning a 2 or 3 significance score, the question as to whether the

consequences may pose a significant risk to the environment as a result of the

cumulative effects with the consequences of other existing activities needs to be

considered. If it is considered that the cumulative effects are a significant risk, a

significance score of 4 should be assigned.

Step 5: In the case where the consequences are potentially catastrophic in terms of

being wide scoping and irreversible, or where there are major concerns by other

stakeholders of the consequences, then a significance score of 5 should be assigned.

The significance score can then be entered into the “significance score” column of the

manageability criterion Table 4.15.



Page 161 of 262

Table 4.15: Manageability Criterion Table

Step 1 The associated consequences of each of

the impacts are assessed against the following

issues: •the extent to which they can be avoided;

•the likelihood of events occurring which result in

the impacts being realized •their duration; •the size

and scope the consequences; •the cumulative

effects of the consequences; and •stakeholder

concerns Step 2 Each of these issues are

addressed using the questions given in Table 4.13.

Step 3 Significance Score of 1 to 5 is assigned for

each impact-using Table 4.14.

Av

oid

an

ce

Lik

elih

oo

d

Du

rati

on

Siz

e &

Sc

op

e

Cu

mu

lati

ve E

ffe

cts

Sta

ke

ho

lde

r C

on

cern

s

Sig

nif

ican

ce S

co

re

PHYSICAL ENVIRONMENTAL IMPACTS

Soil Impacts

Earthworks Ye

s

Lo

w

Me

d.

Sma

ll

N

o

No 2

Contamination (e.g. spills) Ye

s

Lo

w

Me

d.

Sma

ll

N

o

No 2

Air Impacts

Air emissions Ye

s

Lo

w

Me

d.

Sma

ll

N

o

No 2

Surface/Ground Water Impacts

Water extraction No Lo

w

Me

d.

Sma

ll

N

o

No 1

Water contamination Ye

s

Lo

w

Me

d.

Sma

ll

N

o

No 2

Altering drainage patterns No - - - - - 1

Fauna Impacts

Disturbance to species No - - - - - 1

Disturbance to habitats No - - - - - 1

Flora Impacts

Disturbing native flora species No - - - - - 1

Clearing extensive areas of native vegetation No - - - - - 1

SOCIAL IMPACTS


Public infrastructure No - - - - - 1

Land use No - - - - - 1

Changes to visual attributes of area No - - - - - 1

Cultural Impacts



Page 162 of 262

Step 1 The associated consequences of each of

the impacts are assessed against the following

issues: •the extent to which they can be avoided;

•the likelihood of events occurring which result in

the impacts being realized •their duration; •the size

and scope the consequences; •the cumulative

effects of the consequences; and •stakeholder

concerns Step 2 Each of these issues are

addressed using the questions given in Table 4.13.

Step 3 Significance Score of 1 to 5 is assigned for

each impact-using Table 4.14.

Av

oid

an

ce

Lik

elih

oo

d

Du

rati

on

Siz

e &

Sc

op

e

Cu

mu

lati

ve E

ffe

cts

Sta

ke

ho

lde

r C

on

cern

s

Sig

nif

ican

ce S

co

re

PHYSICAL ENVIRONMENTAL IMPACTS

Changes to demographic structure of area No - - - - - 1


Air quality changes Ye

s

Lo

w

Me

d.

Sma

ll

N

o

No 2

Noise and vibration No - - - - - 1

Changes to water quality Ye

s

Lo

w

Me

d.

Sma

ll

N

o

No 2

Hazardous operations introduced Ye

s

Lo

w

Me

d.

Sma

ll

N

o

No 2

ECONOMIC IMPACTS


Wealth and employment No - - - - - 1


Disturbance of natural resources of other industries No - - - - - 1

Altering existing land use No - - - - - 1

Environmental Significance

From the significance scores for the predictability and manageability criteria, the level of

environmental significance for each of the potential events associated with the proposed

activity can then be determined as High, Medium or Low on the basis of environmental

significance matrix presented in Table 4.16.



Page 163 of 262

Table 4.16: Matrix for Determining Level of Environmental Significance

Scores Manageability Criterion

1 2 3 4 5

Predictability Criterion 1 L L L M H

2 L L L M H

3 L M M H H

4 L M M H H

5 L M M H H

H = High; M = Medium; L = Low

As observed in Table 4.16, it is proposed that where adverse environmental

consequences can be avoided or where it is very unlikely that an event will occur which

would result in such consequences (i.e. a Score of 1 against the manageability criterion),

then the significance of the individual event associated with the proposed activity can be

considered to be low regardless of the predictability score.

The significance matrix provided in Table 4.17 can be developed so as to set the three

levels of significance at other positions within the matrix.

Table 4.17: Activity Environmental Significance Table

Description Predictability

Criterion

Score 1-5

(Table 4.10)

Manageability

Criterion

Score 1-5

(Table 4.15)

Level of Environmental

Significance H: High M:

Medium L: Low (Table

4.16)

NATURAL ENVIRONMENTAL

IMPACTS

Soil Impacts

Earthworks 1 2 L

Contamination (e.g. spills) 1 2 L

Air Impacts

Air emissions 2 2 L

Surface/Ground Water Impacts

Water extraction 1 1 L

Water contamination 2 2 L

Altering drainage patterns 1 1 L

Fauna Impacts

Disturbance to species 1 1 L

Disturbance to habitats 1 1 L



Page 164 of 262

Description Predictability

Criterion

Score 1-5

(Table 4.10)

Manageability

Criterion

Score 1-5

(Table 4.15)

Level of Environmental

Significance H: High M:

Medium L: Low (Table

4.16)

Flora Impacts

Disturbing native flora species 1 1 L

Clearing extensive areas of native

vegetation

1 1 L

SOCIAL IMPACTS


Public infrastructure 1 1 L

Land use 1 1 L

Changes to visual attributes of area 1 1 L

Cultural Impacts

Changes to demographic structure of

area

1 1 L


Air quality changes 2 2 L

Noise and vibration 1 1 L

Changes to water quality 1 2 L

Hazardous operations introduced 2 2 L

ECONOMIC IMPACTS


Wealth and employment 1 1 L


Disturbance of natural resources of

other industries

1 1 L

Altering existing land use 1 1 L



Page 165 of 262

4.5 Technological Details of Environmental Mitigation Measures

Introduction

The proposed steel plant may be accompanied by certain undesirable consequences

requiring mitigative measures. Since the objective of environmental impact assessment

is to ensure that development proceeds hand in hand with ecological conservation so as

to achieve sustained growth, it becomes imperative that a proper mitigative vis-à-vis

environmental control measures are adopted at the planning and implementation stage

itself. Environmental control measures are necessary for any major proposed steel

projects to maintain environmental balance and to check possible harmful effects. These

control measures are of multidisciplinary dimensions and varies with type of projects. It

has already been indicated earlier in the EIA part that a number of environmental factors

needs to be considered covering ambient air quality, water pollution, solid waste

management, social factors, etc. The environmental control measures thus envisaged

for the proposed plant are described in following text.

To ameliorate the adverse impacts of the project and for scientific development of the

local environment, a comprehensive Environmental Management Plan (EMP) is

necessary. This has been worked out based on present environmental conditions,

environmental impact assessment and environmental prediction. The EMP has been

made for formulation, implementation and monitoring of environmental protection

measures during and after commissioning of the proposed steel plant taking into

consideration of the following:

Mitigation of adverse impacts.

Housekeeping.

Occupational safety and health plan

Green belt development plan.

Carbon Credit Technology or CDM Projects Envisaged

Under Clean Development Mechanism (CDM) in steel sector the Green House Gases

(GHG) reduction projects which can be taken through the CDM route to accrue carbon

credits benefits as financial incentives for the efforts. Following are the areas which shall

be developed as CDM project activity and have been identified for availing carbon credit

in the proposed plant:

1. Top Pressure Recovery Turbine (TRT) in Blast Furnace

2. Coal dust injection in Blast Furnace



Page 166 of 262

3. Sinter Plant: Waste Heat Utilization

4. CDQ in Coke Oven

Project Concept Note (PCN) and Project Design Document (PDD) will be prepared after

detail engineering.

Top Pressure Recovery Turbine (TRT) in Blast Furnace

Top Pressure Recovery Turbine (TRT) is a power generation system, which converts the

physical energy of high-pressure blast furnace top gas into electricity by using a

pressure recovery turbine. Although the pressure difference is low, the large gas

volumes make the recovery economically feasible. The key technology of TRT is to

secure the stable and high-efficiency operation of the turbine in dusty blast gas

conditions, without harming the blast furnace operation. Two types of system are

available, Wet TRT system and Dry TRT system.

Benefits:

Generates electric power.

Excellent operational reliability, abrasion resistant.

Suitable for larger furnaces and higher temperature gases.

Coal Dust Injection (CDI) in Blast Furnace

Pulverized coal injection in BF replaces part of the coke used to fuel the chemical

reaction, reducing coke production, thus saving energy. The increased fuel injection

requires energy from oxygen injection, coal, and electricity and equipment to grind coal.

The maximum injection depends on the geometry of the BF and impact on the iron

quality (e.g., sulfur).

Coal dust injection system will be introduced involving handling, screening, drying and

pulverization system for coal. CDI has an economic as well as an environmental

advantage as it directs injection of coal into BF as reducing agent which reduces coke

requirement (for every Kg of coal injected approximately 0.8 Kg. of coke requirement is

reduced).

Benefits:

Reduces emissions of coke ovens by reducing coke making, as required for without

CDI.



Page 167 of 262

Increased costs of oxygen injection and maintenance of BF and coal grinding

equipment offset by lower maintenance costs of coke batteries and/or reduced coke

purchase costs, yielding a net decrease in operating and maintenance costs.

Decreased frequency of BF relining

Improved cost competitiveness with cost reduction of hot metal

High reliability and easy operation

Increased productivity

Sinter Plant Waste Heat Utilization

Waste heat utilization has been envisaged preheating the sinter mix before feeding to

sinter bed. For the same ignition furnace with post heat hood and pre-heating (before

ignition furnace) shall be installed just after the sinter mix drum feeder. Hot air from

waste heat recovery system of sinter cooler shall also be used for preheating of raw

material before ignition furnace and post heat hood after ignition furnace.

Benefits:

Fuel savings in terms of reduction in Coke consumption and steam

Exhaust heat recovery.

NOx, SOx and particulate emissions reduction

Increased productivity, yield, and cold strength

Use of Continuous Casting Technology

Hundred percent of the steel production through continuous casting facilities saves

considerable energy and protects environment. The major environmental advantages

are:

- Elimination of Soaking pits resulting in reduction in consumption of fuels and

Electricity.

- Considerable energy is saved vis-à-vis less energy generation and reduces pollutant

emissions.

- Less scrap production resulting in improved yield and less solid waste handling.

CDQ in Coke Oven

Coke oven is the equipment to carbonize coal to make coke and discharge periodically

coke at around 1000 deg. C. This coke is cooled by the inert gas instead of water. The

major advantages are:

- Power generation from sensible heat



Page 168 of 262

- Particulate emission

4.5.3 AIR POLLUTION: MITIGATION MEASURES

A number of environmental friendly features have been envisaged in the proposed steel

plant design due to which the anticipated adverse environmental impacts are either

avoided or minimized. The remedial and control measures planned to be adopted are

discussed briefly in the following sections.

4.5.3.1 Fugitive Dust Emission Control

Coke Oven and By-Product Plant

To minimize fugitive emissions from the Coke Ovens during charging, High Pressure

Ammonia Liquor Aspiration (HPLA) system has been considered for effective on-main

charging. The oven doors would be provided with special type of sealing device. The

coke side fugitive emission would be controlled by providing land-based pushing

emission control system, integrated with coke transfer car. Computerized Combustion

Control System (CCS) has been envisaged for the Coke Ovens to improve efficiency of

combustion. The measures considered to control the fugitive or secondary emissions

from the coke oven batteries for the proposed project is described below:

a. High Pressure Ammonia Liquor Aspiration (HPLA) System

To control charging emission from coke oven battery, high-pressure ammonia liquor

aspiration system (HPLA) has been envisaged. It shall consist of high-pressure

multistage booster pumps for ammonia liquor, spray nozzles and pipelines. The low-

pressure ammonia liquor shall be drawn from the liquor mains, pressurized to about 30

– 35 Kg / cm2 and injected into gooseneck while charging. The charging gasses

evolved shall be sucked into the gas collecting mains, preventing emission of dust and

smoke into the atmosphere.

b. Coal Charging Cars

AISL has intended to provide charging cars fitted with screw feeders and hydraulically

pressed sleeves. Feeding of coal into oven will be carried out with control speed by

screw feeders. During charging hydraulically, pressed sleeves will be helping to

eliminate leakage around charging holes. The charging cars shall be of modern single

spot type with hydraulic drives to cater to the needs. The charging cars shall be provided

with PLC and air-conditioned operators cabin. The charging cars shall also be equipped

with oven top vacuum cleaner which will help in proper up keeping of oven top.



Page 169 of 262

c. Hydro Jet Door Cleaners

During the coking process in the Ovens, the bitumen separates out mainly at the bottom

of the Oven and if there are any gaps in the door seal, Coal tar oozes out of the door. At

times, it is impossible to get the door back onto the Oven because of a buildup of

bitumen in the faces. This results in leaking doors allowing Coal gas and sulphurous

fumes to escape to the surrounding. It is therefore required to maintain clean door. AISL

have envisaged to provide hydraulic door cleaner system to reduce the pollution and

improved working environment. The system will be complete with high-pressure water

pump, tank, hose, nozzles etc. with pressure and volume control arrangement. The

hydro jet cleaning system will be used for door and the doorframe cleaning with facility of

hydro pressure up to 600 Kg/cm².

d. Leak Proof Oven Door

Leak proof oven door will be installed the Coke Oven batteries. Doors shall be leak proof

with flexible sealing strips and other modified features to ensure leak proof sealing. The

doors shall be of heat resistant cast iron provided with spring-loaded latches and spring-

loaded sealing strips.

e. Pushing Emission Control (PEC)

Pushing emission control (PEC) system has been envisaged to capture the emission of

hot coke dust and other pollutants when coke side door of a coke oven is opened and

coke is pushed out of the oven and dropped into the coke car. In the PEC system the

dust recovery hood unit /assembly will consists of two suction hoods and connecting

duct piece. The coke car hood shall extend over the hot coke car and shall be open to

the top face of the hot coke car as well as to the discharge face of the coke guide car.

This hood will suck dust-laden gas when hot coke is dropped from coke guide car into

the hot coke car during coke pushing operation and will be a part of the coke guide car

machine. The other suction hood i.e. the oven door hood shall be movable inside a

telescopic sleeve and shall move /extend over oven door area to extract smoke and dust

arising /emitting when the door is taken off the oven for coke pushing operation. The

telescopic sleeve of the oven door hood and the coke car hood shall be joined into a

connecting duct piece which shall be extended over stationary collecting duct positioned

along the full length of the coke oven battery. The collecting duct shall be open on top for

its full length. The opening shall be internally braced with grating to provide support for a

special high temperature rubber belt. The actual connection between the moving dust

recovery hood unit / assembly and the stationary collecting duct shall be achieved by

means of belt raising tripper car movable on the collecting duct along the length of the

collecting duct.



Page 170 of 262

The pushing emission thus collected in the moving suction hoods and evacuated into the

stationary collecting duct shall be taken into a dust control system (Wet Scrubber / Bag

Filter) before discharging through a stack / chimney of suitable height.

f. Dry-fog Dust Suppression System in Coke Cutter / Coke Conveyor

When temperature of the Coke reaches normal, Dry fog type dust suppression system is

proposed for the coke cutting house / coke conveyor transfer points to suppress the

coke dust and other dust particles in the major areas like Transfer towers, Coke crushing

station, Coke screening station, etc.

The Duel Fluid Dust Suppression "DFDS" (water atomization with compressed air) Dust

Control System works on the principle of agglomeration. Dust particles released from

a material handling or processing plant, which become air borne, are made to pass

through a blanket of extremely fine fog. The dust particles and the micro-sized fog

droplets collide and adhere to each other, thus increasing their mass. After a series of

such collisions, the mass becomes heavy enough to cause settlement of the

agglomerates on to the larger mass of the material being handled.

Coal Handling and Coke Sorting Plant

The following air pollution control system will be installed in coal handling and coke

sorting plant:

Water sprinklers for wagon tipplers

Dust Extraction system (Bag Filter based) for coal crusher house

Dust suppression system at crusher feeding point – Duel Fluid Dust Suppression

(DFDS)

DFDS Dust suppression system (compressed air and water) for coal handling plant

Dust Extraction system with Bag Filter in coke sorting plant

Raw Materials Handling (RMHS) Section

To control the fugitive dust emissions at the stock piles on the ground, conveyor transfer

points, vibrating screens, etc which would be major source of fugitive dusts, both water

sprinkling and dry fogging (DFDS) would be adopted for dust suppression. The DFDS

system generates a layer of fine water droplets (fog) that a dust particle cannot pass

through without colliding with water droplet. It does not use any chemicals as dust

suppressant agent. DF requires only compressed air and water pressure for atomization

through specially designed nozzles. DF is applicable for coal dusts, coke dust, ore dust

etc which are non-reactive with water – if the material is not hot.



Page 171 of 262

For lime dust abatement, conventional dust extraction (DE) would be adopted. The Dust

Extraction system will comprise of pulse jet type bag filter, centrifugal fan with motor and

other accessories, suction hood, duct work, stack, etc. will be provided. The pollution

Control Facility at RHMS can be summarized as:

Stock Pile & Wagon Tripler – Plain water spray

Rest all transfer point – DFDS

All crusher House – Bag Filter based Dust Extraction.

DE system with bag filters in case of crusher house of lime/dolo handling plant.

Sinter Plant

There will be plant de-dusting system for different material transfer points in Sinter Plant

Stock House and sinter screening and transport (to maintain proper work-zone

condition). The ESP system will comprise of fan, ESP, suction hood, ducts and stacks.

BF: Stock House and Cast House De-dusting System

The DE system based on fabric filter / electrostatic precipitator (ESP) would be provided

for room air cleaning such as BF Stock House and BF Cast House fume extraction.

The fans will suck the air from the hoods of the working cast house and there will be no

suction from hoods of the standby cast house except partial suction of air from tap hole.

Pneumatic / Electrically operated dampers shall be provided in duct line to prevent idle

suctions from non-working cast house. Variable inlet vane type pneumatic / electrically

operated dampers are also to be provided at fan inlet.

Air laden with fumes of iron oxides will be cleaned in electrostatic precipitator before

being discharged into atmosphere through stack with the help of centrifugal fans. The

centrifugal fans are to be provided after ESP and before stack for sucking the air. The

suction shall be taken from different points like taphole, skimmer, slag runner, iron

runner, tilting runners and from BF top charging conveyor discharge. Dust concentration

of inlet air to ESP is 3-5 gm/ Nm3

Collected dust at ESP hoppers will be taken to storage hopper and from there dust will

be disposed by truck. Clear height below storage hopper shall be 4.5 m to facilitate truck

entry.

Dust concentration at stack outlet shall be less than 50 mg/Nm³. Work zone dust

concentration shall not exceed 5mg/Nm³.



Page 172 of 262

SMS

Material Handling Operations

The SMS would be one of the prime sources of fugitive dust emissions during material

handling operations, charging / tapping / blowing, argon rinsing, steel pouring, de-

slagging etc. Air pollution control system comprising of suction hood, duct and bag filters

are provided in the SMS for bulk material charging system, mixer, desulphurization and

LF.

Lime and Dolomite Plant

In Lime and Dolomite Plant - raw material bunker building, lime / dolo sizing plant, Dust

extraction (plant de-dusting system) system will be provided. In lime / dolomite DE

system will comprise of pulse jet type bag filter, centrifugal fan with motor and other

accessories, suction hood, duct work, stack, etc.

4.5.3.2 Point Source Dust Emission Control

Wherever there is fuel gas fired combustion systems like coke oven batteries, BF stoves

and reheating furnace of mills, where cleaned fuel gases are used, no dust emission

control devices are proposed.

Process Dust Emission Control

In case of BF, BOF top gas having calorific value and contains large amount of dust. To

clean the gas wet scrubbing / ESP will be installed for cleaning fuel gases. However, as

per process requirement at regular intervals fuel gases will be burnt in the flare stacks.

All efforts will be made to utilize the fuel gases.

In case of Sinter plant and lime / dolo kilns, the waste gases contain large amount of

dust and will require ESP/bag filter to arrest the particulates and emit the clean flues to

the atmosphere. The ESP/Bag filters will be designed to limit the emissions to less than

50 mg/Nm3. However, in order to meet the statutory ground level concentration limits for

SO2, NOx and other gaseous pollutants, suitable stack heights will be provided for

proper dispersion. All stacks will be provided with port-hole and working platform so that

stack monitoring can be done as per norms of statutory authority.

All bag filters shall have bags with non-adhesive coating to avoid blinding of bags and no

air infiltration into bag house including ducting shall be ensured. However, the suitability

of non-adhesive coating for specific application will be examined during detailed

engineering. Pug mills shall be provided below dust silos to prevent secondary pollution /



Page 173 of 262

fugitive emission during unloading of dust. The collected dust from bag filters shall be

transported to nearby material handling system. In case this is not feasible, the same will

be transported by trucks to consumer points such as sinter plant.

Sinter Plant

A centralized de-dusting system with dry type electrostatic precipitator (ESP) will be

provided for raw material preparation and handling and sinter screening and transport

area. ESP system will comprise of multiple fields and its accessories such as dust

disposal system, electrics and control, instrumentation, interlock, supports etc.

Blast Furnace

A number of measures have been considered to control the emission from the blast

furnaces:

Coal Dust Injection (CDI)

Coal dust Injection (CDI) in BF has been planned at the rate of about 150 Kg/t hot metal.

The CDI has an economic as well as an environmental advantage. Direct injection of

coal as reducing agent facilitates replacing part of the required coke. It is considered that

for every Kg of coal dust injected approximately 0.8 Kg of coke requirement is reduced.

Thus, a considerable amount of coke production can be avoided.

Gas Cleaning System

A gas cleaning plant comprising of dust catcher, scrubber and wet ESP will be installed.

EOF/BOF – Convertors / LF

BOF Gas Cleaning System

The dust cleaning (of primary gases) system will be of venturi scrubber type.

Secondary Refining

During secondary refining process, the gases generated during mixing and de-

sulphurisation process will be contaminated with dust. A centralized secondary dust and

fume extraction system for Converters and LFs will comprise of Bag Filter suction hood,

ducts and stacks.



Page 174 of 262

Lime and Dolomite Plant

In Lime and Dolomite Plant, the waste gas cleaning will be conducted through dust

extraction system comprising of pulse jet type bag filter, centrifugal fan with motor and

other accessories, suction hood, duct work, stack etc.

4.5.3.3 Gaseous Emission Control

SO2 Emission Control

The main sources of sulphur dioxides from the steel plant operations are the

metallurgical coal used in the coke ovens. In consideration to this, it is proposed to use

low sulphur blended coal (S < 0.5 w/w). A major portion of sulphur present in coal or

coke would be fixed in BF and BOF slag. The balance sulphur in the form of H2S is

present in coke oven gas would be partly removed in the byproducts plant to 3 - 4gm/N

cu m of H2S. For power generation it is envisaged to use relatively sulphur free fuel

gases hence no significant emissions from power plants are envisaged. The other

source of sulphur dioxide emissions is from the sinter plant, where the sulphur present in

coke is reflected as sulphur dioxide in the waste gases. The emissions can be reduced

by using metallurgical coal with low sulphur (<0.5%) and also be incorporating waste

heat recovery systems.

NOX Emission Control

The source of NOX is fixed nitrogen in coal. During coking, nitrogen is converted to

ammonia and is present in coke oven gas. The ammonia is removed in the byproducts

plant so that the generation of NOX is reduced in furnaces where coke oven gas is used

as fuel.

Other than this NOX, there would be thermal NOX during combustion of fuels. It is

therefore proposed to have combustion control devices by adopting waste gas

recirculation and introducing secondary air in the combustion process. For this using low

NOx burners so as to minimize the formation of NOX will be installed to limit combustion

temperature in different units as feasible.

Carbon Monoxide Emission Control

The source of carbon monoxide generation is from the waste gases from the combustion

operations. The control of air/fuel will be adjusted in such a way that formation of carbon

monoxide is minimised in presence of excess oxygen in the flues.



Page 175 of 262

4.5.3.4 Summary of Proposed Air Pollution Control (APC) Measures

In line with the above stated proposals for air pollution prevention and control of the

emissions from proposed production facilities, a summarized list of required APC

measures is presented in Table 4.18. Air pollution control measures envisaged above

will be designed suitably so as to meet the air emission norms. The table indicates

design target and control measures at respective sources.

Table 4.18: Emission Norms for Air Pollution Control (APC) Measures

Sl.

No

Production

Unit/

Facilities

Proposed Emission Control Devices Design Target

Non-Point Sources Point Sources

1. Coal Handling

/ Coke Sorting

Plant

Dust suppression: water

sprinkler & DFDS

DE system bag filter

based: Coal crusher

house / Coke sorting

plant.

- Dust outlet: < 50 mg/N

m3

Work zone Dust level:

< 5 mg/ m3

2. Raw Materials

Handling

Section

- Covered conveyor

- Dry Fogging

- Water sprinkling

- Bag filter - DE system

DE Stacks Dust outlet: < 50 mg/N

m3


< 5 mg/ m3

3. Coke Oven

Battery

- On-main charging by

HPLA

- Coke side dust extraction

Combustion

Stack

Fugitive Emissions:

5% PLD

1% PLL

4% PLO

BaP:

Work Zone (Battery

Top): 5 ug/m³

Other Units in Coke

Ovens: 2 ug/m³

Stack emissions:

SPM < 50 mg/ m3

SO2 < 800 mg/ m3

NOx < 500 mg/ m3

4. Sinter Plant - Raw feed proportioning

building, Sinter Cooler,

Air Cleaning by DE

- Waste flue gas

cleaning by ESP

- Sinter Process

Dust outlet: < 50 mg/N

m3



Page 176 of 262

Sl.

No

Production

Unit/

Facilities

Proposed Emission Control Devices Design Target

Non-Point Sources Point Sources

System comprising of

ESP

De-dusting by

ESP

- Sinter process:

low NOx

burners


< 5 mg/ m3

5. Blast Furnaces - BF Stock House by DE

system

- BF Cast House by DE

system: ESP

- BF Stove

Stack

- BF Stove: low

NOx burners

Dust outlet < 50 mg/N

m3


< 5 mg/ m3

6. Steel Melting

Shop

SMS Material Handling -

DE system by Bag filter

- Centralized

secondary

fume

extraction

system for

converters /

LFs with Bag

filter.


m3


< 5 mg/ m3

7. Lime & Dolo

Plant

- Lime Plant Raw Material

Bunker Building - De-

dusting by Bag Filter.

- Lime sizing plant – De-

dusting by Bag Filter.

Waste flue gas

through Bag

filter (fabric)


m3


< 5 mg/ m3

8 Bar & Rod Mill

Reheating

Furnace

- Low NOx

burners


m3

9 Power Plant - - Low NOx

burners

- ESP


m3


< 5 mg/ m3

4.5.4 WATER: MITIGATION MEASURES

Treatment of waste water generated from the proposed Integrated Steel Plant will be

done as given in following sections. Further, several waste water recycling measures will

be adopted as briefed in following sections to minimize fresh water intake.



Page 177 of 262

Treatment of Coke Oven Effluent Stream

This would be the only toxic effluent stream, which requires physico-chemical as well as

biological treatment. Raw coke oven effluent would be first stripped off in ammonia still

by alkali addition in a stripping column. The effluent after bringing down the ammonia

load below 100 mg/l would be stored in balancing reservoir. From the balancing tank, the

effluent would require separation of floating and emulsified oil. Thereafter three-stage

aeration with addition of nutrients and maintaining desired bacteriological population

followed by clarification for removal of phenol and ammonia in waste. The treated

effluent would be pumped to the settling pond for reuse within the plant in Coke

quenching and greenbelt.

Gas Cleaning Plant Waste Water

The BF and BOF gas cleaning scheme would be of the conventional venturi type which

have become the bench mark for similar application. The effluent coming out of the wet

scrubber would be contaminated with high concentration of suspended solids. The slurry

effluent would be clarified in the clarifier to recover clarified water for recycling to the wet

gas scrubber after cooling in the cooling tower. The contaminated water coming from

gas cleaning plant is collected in the flash mixer. Coagulants are added in the flash

mixing tank and then water is supplied into thickeners (high rate type) for further

treatment. The clean overflow water is collected in clean water sump and pumped back

to gas cleaning plant. The settled sludge in the thickeners is pumped to sludge storage

tanks and vacuum filter unit for drying and the cakes are disposed suitably.

Treatment of Caster Effluent and Mill Effluents

The wastewater is generated in the continuous casting units mainly due to machine /

Mould cooling and may be contaminated with suspended solids and traces of oil. The

effluent from the mill would be collected first in scale pit which is a large settling basin to

separate out the floating oil and settable iron scales. The clean water is passed through

sand filters to remove finer particles, after which the water is recycled in the process.

The back wash from the filters is sent to the settling tank for removal of particulates. The

settled sludge is sent to sinter plant for agglomeration. Quality of this discharged water

will be continuously checked and as required will be treated to meet statutory norms.

Treatment of Plant Sanitary Wastewater

The sanitary wastewater would be treated in sewage treatment plant details of which is

submitted after detailed engineering stage.



Page 178 of 262

Treatment of Waste Water from Indirect Cooling Circuit Streams

In the proposed project the waste water generated from indirect cooling circuits of sinter

plant, blast furnace, BOF and rolling mill are not normally contaminated with any major

pollutants. However occasional discharges are made as bleed off when there is built up

of dissolved solids in the circulating water due to repeated circulation. The dissolved

solids are mainly different salt constituents of calcium and magnesium already present in

water. Thus, major portion of water will be re-circulated after necessary physical

treatment e.g. settling, cooling etc.

Cooling Tower Blow Downs from Direct Cooling Circuit Streams

It is noted that the re-circulating water in cooling towers gets contaminated with the dust

& dissolved solids, necessitating blow down. It is proposed that all cooling towers be

provided with side stream pressure filters to reduce the volume of blow down. The

cooling towers shall be designed to operate at high cycles of concentrations to conserve

water.

Summary of Proposed Wastewater Treatment Scheme

In view of the above stated proposals for wastewater treatment and disposal for various

production facilities, a summarized list of the same is presented in below:

SN Production Unit/ Facilities Outlet Effluent Characteristics

mg/l

1. Coke Ovens By-Products

Recovery Plant

pH 6.0 – 8.5

Suspended Solids <100

Phenol < 1.0

CN- < 0.2

N2 < 50

BOD, 3 days at 27oC < 30

COD < 250

Oil & Grease < 10

2. BF-Gas Cleaning Plant TSS< 100

3. BOF-Gas Cleaning Plant TSS< 100

4. Other Plants, such as Sinter

Plant, BF & SMS

pH 6.0 – 9.0

Suspended Solids < 100

Oil & Grease < 10

5. Plant Sanitary Effluent Treatment

Plant

B.O.D< 20

Coli-form < 500 MPN/100 ml



Page 179 of 262

Reuse of Waste Water

Some of the measures taken to reuse the wastewater generated in the plant will be:

The wastewater generated from BF gas cleaning plant after physical treatment will

be reused in the system.

Cooling Tower blow downs of indirect cooling water system shall be used for slag

quenching and as make up to direct contaminated cooling water circuits and surplus

if any would be stored in the treated wastewater lagoon for in-plant use (e.g. Green

belt, floor washing, plant road dust suppression etc).

Blown down water from Blast Furnace re-circulation system will be reused in Slag

Granulation Plant as make-up water to SGP re-circulation water system.

Blow down water from BOF re-circulation system will be reused in SMS slag yard for

spraying on hot slag.

Blow down water from power plant will be reused for Pig Casting Machines.

Through cascaded reuse of blow-down, the water scheme ensures practically zero-

discharge from the industrial water circuit. However, in such huge operation of ISP some

water will be discharged, which will meet the statutory norm.

4.6 RAIN WATER HARVESTING

While developing the Plant General Layout for plant commissioning, it will be ensured

that rain water is harvested from building rooftops. Run-off water from the office areas &

shop roofs will be collected and stored for future use. Proper functioning of the systems

provided will be ensured by regular monitoring.

4.7 ENERGY CONSERVATION MEASURES

Energy conservation measures will be implemented so as to bring energy saving and

also possible CDM benefits. This will include providing VVF drives for higher capacity

motors, LED lamps etc.

4.8 SOLID WASTE: MITIGATION MEASURES

Different types of solid wastes are generated from Integrated Steel Plant. The source of

solid waste generation along with their re-use, re-cycle, utilization and disposal

methodology are presented below:



Page 180 of 262

Solid Waste Generation their Re-Use, Re-Cycle, Utilization and Disposal

S

N

Type of

Solid

Waste

Re-utilization Dumpe

d for

Future

Use

Recycle Re-use

Within Plant Sold

1 BF slag - Sold to Cement

manufacturers / glass

manufactures

2 EOF/BOF

Slag

- Granulated and

partly used in

plant

- Balance will be

crushed &used for

making roads, civil

works, etc.

- Will be sold to parties for

building roads (aggregate

for road making, Rail

Track ballast, land filling,

after conditioning), civil

engineering works, etc.

- Soil conditioner as it

contains P2O5, especially

at places where PH is

acidic as in heavily

leached soils of Ranchi

region.

- Used in sinter @of 3%

only due to high P2O5.

3 EOF/BOF

Scales &

Scrap

Reused in

sinter plant

as sinter mix.

- -

4 Mill Scrap Used in BF - -

5 Waste

Refractory

- Used in Plant for

making refractory

mortars in captive

mortar shops

- Making / repairing

plant roads

Sold as material for making

road embankment or for

filling low lying areas

6 Lime/dolo

mite Fines

Re-used in Sinter

Plant

7 Mill scale - Reused in Sinter

Plant (Oil content

from1 - 3%).

- Reused as a

reductant input

material in BF (Oil



Page 181 of 262

S

N

Type of

Solid

Waste

Re-utilization Dumpe

d for

Future

Use

Recycle Re-use

Within Plant Sold

content up to

15%)

8 BF Flue

Dust

Reused in

sinter plant

as sinter mix.

Used in pellet plant -

9 BF GCP

Sludge

- Reused in

sinter plant

as sinter

mix

Used in Sinter Plant -

10 BOF

Sludge

Reused in

sinter plant &

BF

Used in Sinter Plant -

11 Sinter

ESP Dust

Recycled in

Sinter plant

- - -

Recycle of waste means utilization of waste in the same process from which it has been

generated

R-use of waste means utilization of the waste in any process other than the process from

which the waste has been generated. The process utilizing the waste may be within the

plant or outside the plant. In case of utilization outside plant, the waste is sold to firm utilizing

the waste

Disposal means dumping of waste in designated areas.

The following shop wise specific management measures will be adopted for solid waste:

Sinter Plants

100% recycling of LD sludge, Mill scale, Lime and Dolomite dust, SP sludge, and ESP

dust.

100% recycling of return sinter fines

Complete utilization of 10 mm LD slag

BF Flue dust utilization in Sinter Plant.

Blast Furnaces

100% Cast House slag granulation for sale to Cement Plants. Recycling of LD slag

(10-40 mm size) for its lime content

Use of cast-able material in Cast House runners, in place of ramming mass, which

will reduce scrap generation by 1%.

Recycling of BF flue dust in sinter plant and sold.

Recycling of used refractory.



Page 182 of 262

Steel Melting Shops

Recycling of LD sludge will be explored.

LD slag – after granulation partly used in Sinter Plants, Blast Furnaces and Steel

Melting shop for conserving limestone & dolomite. Balance used for making roads,

civil works etc.

Refractory Material Plant

Under size limestone, dolomite & lime fines recycled 100% to Sinter Plant.

Utilization of refractory grog made from used refractory bricks for mortar

manufacturing of different grades (25% raw material input is from grog)

Ladle covering compound in SMS using LD Slag

Waste Mg-C bricks for production of new bricks for converter bottom, coating and

patching materials for converter vessels

Rolling Mills

100% recycling of mill scales.

4.9 Green Belt Development: Mitigation Measures

Green belt, is an important sink for air pollutants, it also absorbs noise. Enhancing green

cover not only mitigates pollutants but also improves the ecological conditions /

aesthetics and reduces the adversities of extreme weather conditions. 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 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 / cover will serve the following purposes:

Compensate the damage to vegetation due to setting up and operation of the


Prevent the spread of fugitive dust generated due to project and allied activities.

Attenuate noise generated by the project.

Reduce soil erosion

Increases green cover and improve aesthetics.



Page 183 of 262

Selection of Species

The species for plantation shall be 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 like

Eucalyptus and Australian acacia will not be planted. The species for green belt /

vegetation cover development will be selected in consultation with State Forest

Department and State Soil Conservation Department. Mixed plantations will be done

keeping optimum spacing between the saplings. However, the species suitable for

planting in the area as recommended by Central Pollution Control Board in their

publication “Guidelines for Developing Greenbelts” (PROBES/75/1999-2000) are

given under various heads here under:

Plantation Scheme

Plant saplings will be planted in pits at about 2.0 m to 3.0 intervals so that the tree

density is about 1600 trees per ha. The pits will be filled with a mixture of good quality

soil and organic manure (cow dung, agricultural waste, kitchen waste) and insecticide.

The saplings / trees will be watered using the effluent from the sewage treatment plant

and treated discharges from project. They will be manured using sludge from the

sewage treatment plant. In addition, 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. Since, tests have shown that availability of phosphorus, a limiting nutrient, is low,

phosphoric fertilizers will also be added. The saplings will be planted just after the

commencement of the monsoons to ensure maximum survival. The species selected for

plantation will be locally growing varieties with fast growth rate and ability to flourish

even in poor quality soils.

A total of about 33% of the project area will be developed as green belt or green cover in

project area (including water bodies), township and other areas. The widths of the belt

around the plant will be erected all around the project boundary, depending on the

availability of space.

Vegetation/ Plantations

AISL has already started extensive plantation programme. The proposed Green belt /

cover development is shown in layout fig.



Page 184 of 262

A very elaborate green belt development plan shall be drawn for the proposed steel

plant. The areas, which need special attention regarding green belt development in the

plant area, are:

1. Steel Plant Area - Around Various Shops

2. Areas Plant Boundary

3. Vacant Areas in Plant

4. Around Office Buildings, Garage, Stores etc. and Along Road Sides

1. Steel Plant Area

Inside the steel plant works area, the region with high pollution load are areas around

Raw Material Yards, Coal Handling Yards, Lime / Dolo Calcination Plant, Blast Furnace,

Sinter Plant, Coke Ovens, Steel Melting Shop etc.

To arrest the fugitive emissions emitted from such polluting units, a two-pronged

approach will be adopted

Plantation all around the concerned units close to the source in available spaces to

arrest fugitive emissions at the source.

Plantation on NW and W of the concerned units: By taking the concerned unit as

centre and planting trees in a “V” in NW and W direction [i.e. downwind (D/W) of

predominant wind SE and E] at staggered distances in available spaces to arrest

fugitive emissions which have not been arrested by the green belt at the source.

As there will be limited space (in height) due to various overhead pipelines, thus small

and medium sized species are suggested and they should be planted depending on

the vertical height and lateral space available for the plant growth. The above-

mentioned areas / direction should be covered with pollution tolerant species (in the

space available around) as mentioned below:

Scientific Name Common Name

Acacia mangium Mangium

Acacia nilotica Babul

Annona squamosa Sharifa

Bougainvillea spp. Bougainvillea

Cassia auriculata Cassia

Duranta sp. Duranta

Ficus religiosa Peepal

Murraya exotica Kamayani



Page 185 of 262


Nerium sp Pink Kaner

Pithecolobium dulce Sweet Tamarind

Pongamia pinnata Karanj

Saraca Indica Ashok

Thevieta peruviana Yellow Kaneer

Zizyphus mauritiana Indian jujube

The plants in the steel plant works area should be periodically washed with

water spray, especially during dry and dusty seasons.

2. Areas Around Plant Boundary

Green belt is to be developed along the plant boundary.

(i) Curtain belt on the outermost boundary comprising tall trees with conical

canopy.

(ii) Middle belt of large size trees with globose and spreading canopy and

(iii) Inner belt with medium size trees with spreading or trailing canopy. The

desired minimum thickness of these belts should be as follows:

Location Width (m)

Outer belt (pollution attenuation) 30

Middle belt (pollution attenuation) 50

Inner belt (pollution attenuation and training of winds to middle

& outer belt)

20

However, the above-mentioned thickness of each belt may be proportionately

reduced or increased in view of the total space available for plantation work. The

list of plants to be used in each belt is given in the following paragraphs.

In the curtain belt the following species of trees be planted keeping a space of

2.5m from plant to plant as well as from row to row:



Albizzia lebbek Siris

Artocarpus heterophyllus Kathal

Azadirachta Indica Neem

Butea spp. Palas

Dalbergia sissoo Shisham



Page 186 of 262


Leucaena leucocephala Subabool

Pithecolobium dulce Junglee jilebi

Polyalthia longifolia Drooping Ashok


Syzygium cuminii Jamun

Tectona grandis Teak

In the middle belt - the following species of trees to be planted 3 m apart, from

tree to tree as well as from row to row:


Anthocephalus cadamba Kadamb


Cassia siamea Cassia

Ficus bengalensis Bargad


Lagerstroemia parviflora Lagerstroemia


Tamarindus Indica Imli

In the inner belt - the following species of trees and shrubs to be planted 2.0 m

apart from tree to tree as well as from row to row:


Acacia arabica Babul


Bougainvillea spectabilis Bougainvillea’s

Murriya exocitica Kamayani

Nerium sp Kaneer

Sarca Indica Ashok

Zizyphus spp Ber

3. Vacant Areas in Plant

Plantation in vacant areas will be selected from among the following species.

Plantation will be done in staggered trench manner 3.0m apart.



Page 187 of 262


Artocarpus heterophyllus Kathal





Mangifera Indica Mango


Syzygium cuminii Jamun


4. Plantation around Office Buildings, Stores, Garage etc.

The species recommended for plantation around various buildings will include:






Cassia fistula Amaltas

Cassia javanica Java-ki-rani

Cassia siamea Kassod Tree

Dalbergia latifolia Sisham

Delonix regia Gul mohar

Duranta sp. Duranta


Ficus religiosa` Peepal


Mangifera indica Mango


Polyalthia longifolia Ashok


5. Avenue Plantation

Double rows of avenue trees on the outer side of the footpaths are

recommended; an outer row of shade trees and an inner row of ornamental

flowering trees will be planted.



Page 188 of 262

Foliage Trees for Outer Avenue:



Azadirachta indica Neem

Dalbergia latifolia Sisham

Mimusops elengi Mimusops

Samanea saman Rain Tree

Syzigium cumnii Jamun

Tamarindus indica Imli


Flowering / Ornamental Trees for Inner Avenue:





Cassia fistula Amaltas

Cassia javanica Java-ki-rani

Cassia siamea Kassod Tree

Delonix regia Gul mohar

Duranta sp. Duranta



Polyalthia longifolia Ashok


Post Plantation Care

Immediately after planting the seedlings, watering will be done. The wastewater

discharges from different units will be used for watering the plants during non-

monsoon period. Further watering will depend on the rainfall. In the dry seasons

watering will be regularly done especially during February to June. Watering of

younger saplings will be more frequent. Manuring will be done using organic manure

(animal dung, agricultural waste, kitchen waste etc.). Younger saplings will be

surrounded with tree guards. Diseased and dead plants will be uprooted and

destroyed and replaced by fresh saplings. Growth / health and survival rate of

saplings will be regularly monitored and remedial actions will be undertaken as

required.



Page 189 of 262

Phase Wise Green Belt Development Plan

Green belt will be developed in a phase wise manner right from the construction

phase of the proposed project. In the first phase 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 the

office building area will be planted. In the third phase 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.



Page 190 of 262

CHAPTER-5: ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)

M/s AARESS IRON & STEEL LIMITED (AISL), has proposed integrated steel plant of

3.5 MTPA along with 295 MW power from waste gases at Halavarthi, Koppal,

Karnataka.

5.0 Analysis of Alternative Technologies

Alternate technologies were explored considering the following

Capacity of the Plant.

Conservation of scarce and costly energy input.

Amenability of available raw materials.

Cost consideration.

The availability of infrastructure facilities and logistics of operation are also kept in mind

while evaluating a technology for its possible adoption. And best suited available

technologies are used for the proposed project.

5.1 Alternate Sites/Site Selection

Smooth functioning of the plant depends on the availability of basic requirements. The

location of the project site is selected after detailed survey conducted with respect to

the following points:

Availability of land

Availability of raw material.

Availability of road and rail to facilitate transportation of the plant equipment, raw

material and finished products.

Availability of labor force during construction and operation phase

Accessibility of the site from environmental aspects.

No national park or wild life sanctuary exists within 10 km of the plant.

There are no sensitive places of archaeological, historical, cultural, and religious or

tourist importance within 10 km of the plant.



Page 191 of 262

CHAPTER-6.0: ENVIRONMENTAL MONITORING PROGRAMME

6.0 INTRODUCTION

The environmental monitoring and evaluation of the management measures envisaged

are critical activities in implementation of the Project. Monitoring involves periodic

checking to ascertain whether activities are going according to the plan. It provides the

necessary feedback for project management to keep the program on schedule. The

purpose of the environmental monitoring plan is to ensure that the envisaged purpose of

the project is achieved and results in desired benefits.

To ensure the effective implementation of the proposed mitigation measures, the broad

objectives of monitoring plan are:

To evaluate the performance of mitigation measures proposed in the EMP.

To evaluate the adequacy of Environmental Impact Assessment (EIA)

To enhance environmental quality.

To implement and manage the mitigative measures defined in EMP.

To undertake compliance monitoring of proposed project operation and

evaluation of mitigative measure.

6.1 ENVIRONMENTAL ASPECTS TO BE MONITORED

6.1.1 Several measures have been proposed in the environmental mitigation measures for

mitigation of adverse environmental impacts. These shall be implemented as per

proposal and monitored regularly as per schedule to ensure compliance to

environmental regulation and to maintain a clean environmental condition around the

steel plant.

A major part of the sampling and monitoring activities shall be concerned with long term

evaluation aimed at providing an early warning of any undesirable changes in the

environment or trends in the natural environment that could be associated with the plant

activity. This is essential to determine whether the changes are in response to a cycle of

climatic conditions or are due to impact of the plant activities. In particular, a monitoring

strategy shall be ensured that all environmental resources, which may be subject to

contamination, are kept under review and hence monitoring of the individual elements of

the environment shall be done.

During the operation phase, plant Environmental Management Division (EMD) shall

undertake all the monitoring work to ensure the effectiveness of mitigation measures

proposed. The suggestions given in the environmental monitoring programme shall be

implemented by the EMD by following an implementation schedule prepared in advance.



Page 192 of 262

In case of any significant variation in ground level concentration (GLC) in ambient air

quality, stack emission quality, work zone air quality and noise level monitoring results,

performance of effluent treatment facilities, wastewater discharge from plant etc shall be

discussed in the EMD and variance from standard norms shall be reported to higher

management for information and simultaneously corrective action also initiated at

departmental level. In addition to the monitoring programme the following shall also be

done to further ensure the effectiveness of mitigation measures:

Third party environmental audits shall be carried out once every year.

Internal environmental audits shall be carried out to check for compliance with

applicable norms by in-house experts once every year.

All necessary steps shall be taken 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. Some of

these measures shall be included in the plant design, such as:

- Direct injection of reducing agents pulverized coal into the Blast Furnaces.

- 100% utilization of Blast Furnace slag for slag cement.

- Hazardous waste authorization shall be obtained from KSPCB. Hazardous

wastes to be handled and disposed off strictly in accordance with Hazardous

Wastes (Management and Handling) Rules, 2008 and subsequent amendment.

- Specific water consumption to be brought down to less than 5 m3/t of crude

steel and all water conservation schemes shall be implemented.

- Promotion of periodic energy audits and its suggestion implemented.

- All major stacks to be provided with continuous stack monitoring facilities with

wide area network for connectivity to Regulator.

The other environmental aspects to be monitored to ensure proper implementation and

effectiveness of various mitigative measures envisaged during the design and

commissioning stage of the proposed plant and are described here under:

6.1.2 Regular Maintenance of Drainage System

The effectiveness of the drainage system depends on proper cleaning of all

drainage/channels. Regular checking will be done to see that none of the drains are

clogged due to accumulation of sludge/sediments. The catch-pits linked to the storm

water drainage system from the raw material handling areas will be regularly checked

and cleaned to ensure their effectiveness. This checking and cleaning will be rigorous

during the monsoon season, especially if heavy rains are forecast.



Page 193 of 262

6.1.3 Meteorology

It is necessary to monitor the meteorological parameters on regular basis for

assessment and interpretation of air quality data. The continuous monitoring will also

help in emergency planning and disaster management. The proposed plant shall have a

designated automatic weather monitoring station. The following data shall be recorded

and archived:

- Wind speed and direction

- Rainfall

- Temperature and humidity

6.1.4 Major Stack Emissions Monitoring

Schedule monitoring of stacks for PM, SO2, NOx in case of process stacks shall be

done to assess the performance of pollution control facilities installed for the concerned

unit. In case emissions are found to exceed the norms, the ‘on duty’ personnel shall

check the relevant process parameters and take appropriate corrective action. All major

stacks for the proposed plant will be provided with on-line monitoring system. After the

implementation of project, the stacks will be monitored as per plan given in Table 6.1.

Table-6.1: Major Stacks to be monitored after the Implementation of the Project

Shop / Unit Nos. of Stacks Monitoring Frequency

Per Month

1. Sinter Plants Process 4 Once

2. Coke Ovens 4 Once

3. Blast Furnaces Process 6 Once

4. Steel Melting Shop Process

(SMS-1 & 2)

5 Once

5. Bar & Rod Mill 1 Once

6. Wire Rod & Bar Mill 1 Once

7. Hot Strip Mill 2 Once

8. CRM 3 Once

9. Power Plants Process 3 Once

10. Raw material handling

section

1 Once

* Parameters = PM, SO2, NOX & CO

Further for the units commissioned during the proposed plant the following shall be

followed:

Along with the performance guarantee test of main plant equipment, performance

and guarantee test of pollution control equipment will be made before taking over the



Page 194 of 262

various units. EMD shall also be made 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

manufacturer.

6.1.5 Solid / Hazardous Waste Generation & Utilization

Maximum re-cycling and utilization of generated solid waste as per guidelines shall be

done. Hazardous waste shall be disposed off as per applicable statutory conditions and

ensured its proper disposal.

6.1.6 Green Belt Development Plan

The following Green Belt Development plan shall be made for implementation:

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.

A plan for post plantation care will be reviewed in every monthly meeting. Any

abnormal death rate of planted trees shall be investigated.

Watering of the plants, manuring, weeding, hoeing will be carried out for minimum 3

years.

6.1.7 House Keeping

The EMD will keep a very close monitoring of housekeeping activities and organizing

regular meetings of joint forum at the shop level (monthly), zonal level – (once in two

months) and apex level (quarterly). The individual shop concern will be taking care for

the house keeping of shops.

6.1.8 Occupational Health and Safety

Routine medical examination of personnel will be carried out in a systematic programme

at plant medical unit. A systematic programme for medical check-up at regular intervals

shall be followed for all workers to ascertain any changes in health condition due to the

working conditions.



Page 195 of 262

6.1.9 Socio-Economic Development

The proposed setting up of the integrated steel plant will improve the infra-structure and

other economic conditions of the area, thus improve the socio-economic development.

The communities, which are benefited by the steel plant, are thus one of the key

stakeholders for the steel plant. It is suggested that the plant management should have

structured interactions with the community to disseminate the measures taken by the

steel plant and also to elicit suggestions for overall improvement for the development of

the area.

6.1.10 The Waste Water Quality

Effluent characteristics at inlet and out let of Effluent Treatment Plant (ETP) dedicated to

different units shall be regularly monitored (as per Table 6.2) to assess the performance

of different effluent treatment facilities.

Table 6.2: Monitoring of Effluent Outlet & Inlet of ETP

Description Nos. of Locations Monitoring Frequency

Inlet and outlet of ETP of different

units

4X2 Once a month

* Parameters = pH, SS, Phenol, Cyanide, COD, BOD, DO, NH3-N, Temp., metals, O & G

6.1.11 Work Zone Air Quality

Work zone air quality will be monitored as per directives of KSPCB to assess the levels

of Particulate matter, NOx and SO2 in the work zone.

6.1.12 Work Zone Noise

The noise attenuation measures have been proposed at the design stage of the plant

itself. However, in case of high noise generating equipment which are not frequented by

the plant personnel, the area shall be cleanly marked as ‘High Noise” area and the

employees be provided with personal protective equipment like ear plugs/ear muffs.

Noise levels shall be measured at the source of generation.

After the implementation of the project, the noise level shall be monitored as given in

Table 6.3 and all preventive measures shall be followed. Work zone noise shall be

monitored at all units to cover all shift operations once in a year.



Page 196 of 262

Table 6.3: Noise Level monitored after Implementation

Description Nos. of Locations Monitoring Frequency

Work zone Noise At all shops eight hours per shift

continuous to cover all shift operations

once in a year

Once in a year to cover all

shifts

*Noise Level in Leq (A)

6.1.13 Ambient Air Quality (AAQ)

It is necessary to monitor the air quality at the boundary of the steel works specifically

with respect to particulates. It is proposed that continuous emission monitoring stations

(CEMS) be established at two locations of the integrated steel plant. The equipment

shall have facilities to monitor both PM10 and PM2.5 particulates apart from SOx & NOx.

After the implementation of the plant the ambient air quality shall be regularly monitored

as given in Table 6.4.

Table 6.4: Ambient Air to be monitored

Description Number of

AAQ Stations

Monitoring Frequency

1. Ambient Air Quality 5 Once (for 8 hours continuous) per

month

2. Online Particulate Matter

Monitoring at Steel Plant

Boundary

4 Continuous Emission Monitoring

Station

* Parameters = PM2.5, PM10, SO2, NOX, CO, O3, NH3, Benzene, BaP, Pb, As and Ni

6.1.14 Wastewater Discharge from Plant

The plant is designed based on zero discharge philosophy and shall try to stick to it.



Page 197 of 262

6.1.15 Ambient Noise Level

Ambient noise shall be monitored at 10 locations all along the boundary once in a

month.

6.1.16 Ground Water Monitoring

Ground water surrounding the plant and raw material storage shall be sampled from up

gradient and down gradient of the plant including slag dump area to check for possible

contamination and to ascertain the trend of variation in the water quality, if any. In case

any adverse trend is noticed, immediate remedial measures shall be taken. A total of

eight samples (two inside the plant area & six outside) shall be monitored once in a

month for the critical parameters.

6.2 MONITORING PLAN

6.2.1 General

The target of the EMD implementing the environmental monitoring plan on a short-term

basis would be to:

Interpret requirements of the EIA documentation into an environmental action

plan;

Assist project engineering team with the incorporation of EMP requirements in

contract specifications and contract terms and conditions;

Undertake and/or co-ordinate all internal compliance monitoring and evaluation

and external monitoring through suitable outside consulting firm;

Advice the top management on all matters related to environmental

requirements of the project;

The long-term objective of EMD would be to build environmental awareness and

support, both within and outside the plant premises. The other long-term tasks would be

to develop environmental training programme for the target groups of different units of

the plant.

The environmental monitoring plan contains:

Environmental monitoring programme

Performance indicators (PI)

Progress of Monitoring and Reporting Arrangements

Budgetary provisions

Procurement Schedules



Page 198 of 262

6.2.2 Performance Indicators (PI)

The physical, biological and social components identified to be particularly significant in

affecting the environment at critical locations have been suggested as Performance

Indicators (PIs). The performance indicators will be evaluated under two heads:

a) Environmental condition indicators to determine efficiency of environmental

management measures in control of air, noise and water pollution and solid waste

disposal.

b) Environmental management indicators to determine compliance with the suggested

environmental management measures.

The Performance Indicators and monitoring plans will be prepared for the project for

effective monitoring.

6.2.3 Environmental Monitoring Programme

The environmental monitoring plan during construction and operation stages shall be as

followed for each of the environmental condition indicator is given in table below:

The monitoring plan specifies:

Location of the monitoring sites

Parameters to be monitored

Frequency and duration of monitoring

Applicable standards

Responsibilities for implementation and supervision



Page 199 of 262

Table 6.5: Environmental Monitoring Programme

Environmental Issue/

Impacts

Mitigation Measures Contract

Documents

Reference

Location Time

Frame

Mitigation

Cost

Responsibility

Impleme

ntation

Supervisi

on

Construction Stage

Generation of

Dust

water spraying shall be use for minimizing

dust spread etc.

Project

Requirement

Construction site During

construction

stage

Project

preparation

cost

Contract

or

Projects

Solid Waste

disposal

Solid waste generated during construction will

be disposed in pre-designated dumping area.

-Do- Construction site

within plant and

dumping area.

-Do- -Do- -Do- -Do-

Air Quality at

construction site

Air Quality with respect to various pollutants

shall be monitored.

-Do- At construction site -Do- -Do- -Do- -Do-

Opération Stage

Environmental

Protection Measures

Environmental Protection Measures as

envisaged for controlling/abating pollution.

Project/

Statutory

requirement

Different units of

steel plant

Continuously Production

cost

Plant

Units/E

MD

Top

Managem

ent

Maintenance of

Storm Water

Drainage System

The drains will be cleared to maintain storm

water flow

-Do- Entire drainage

network of the plant.

Beginning

and end of

monsoon.

Production

cost

Contract

or

Civil

Maint.

Dept.

Stack emissions /

Performance of

pollution control

facilities

Out let of all process & de-dusting (major)

stacks in different units.

-Do- All units of the

proposed Plant

Throughout

operation

stage

-Do- -Do- -Do-



Page 200 of 262


Impacts


Documents

Reference

Location Time

Frame

Mitigation

Cost

Responsibility

Impleme

ntation

Supervisi

on

Particulate

Monitoring inside

Plant Boundary

Online PM Monitoring at two locations. -Do- Inside the plant Continuously -Do- -Do- -Do-

Solid / Hazardous

Waste generation

and utilization

Maximum re-cycling and utilization of

generated solid waste as per EMP

-Do- All units of the plant

generating &

utilization solid

wastes

-Do- -Do- Concern

ed Plant

Units/E

MD

-Do-

Green Belt

Development

Planning of green belt surrounding steel plant

boundary

-Do- Planting trees in the

open area

-Do- -Do- Horticult

ure

Depart

-Do-

House Keeping Cleanliness at work place Corporate

responsibility

All units of the plant -Do- -Do- safety

Dept

-Do-

Occupational Health Health of workers / Staff -Do- -Do- -Do- -Do- Plant

Medical

Unit

-Do-

Socio-economic

Development

Structured interactions with the community to

disseminate the measures taken by the steel

plant and also to elicit suggestions for overall

improvement for the development of the area

-Do- Stake Holders -Do- CSR cost Personn

el Dept.

/ EMD

-Do-



Page 201 of 262


Impacts


Documents

Reference

Location Time

Frame

Mitigation

Cost

Responsibility

Impleme

ntation

Supervisi

on

Performance of ETP Effluent Treatment facilities

installed at different units

Statutory

requirement

All units of the

plant

-Do- Environment

al Cost

plant

units/

EMD

-Do-

Work zone Air/Noise

Quality

At all units of the plant -Do- -Do- -Do- -Do- Safety

Dept.

-Do-

Atmospheric

Pollution (AAQ)

Ambient Air Quality with respect to various

pollutants shall be monitored as envisaged in

the pollution-monitoring plan.

-Do- As per specified

AAQ monitoring

programme

-Do- -Do- EMD -Do-

Ground Water

Quality

Changes in ground water quality will be

monitored in the up-gradient and down

gradient of the plant including slag dump will

be monitored

-Do- As per ground water

monitoring

programme

-Do- Env. Cost -Do- -Do-



Page 202 of 262

Table 6.6: Performance Indicators (PI) for Environmental Monitoring Plan

Environm

ental

compone

nt

Project Stage Parameters Location Frequency Standards Approximate

cost (Rs)

Implement

ation

Responsi

bility

Effluent

Quality

Operation

stage

Parameters as

specified by

statutory

agencies

At outlet of different

effluent treatment

plants

Once in a month IS :2490

IS:3025

4X1X12x7000

=Rs336,000

EMD or

through

approved

monitoring

agency

EMD

Work

zone Air

Quality

Operation

stage

As per applicable

statutory

standards

All units of the plant 8 hr per shift continuous

(to cover all shifts of

operation in a year for

each unit) per year.

Factories Act 20x3X12x8000

=Rs576,000

-Do- -Do-

Ambient

Air Quality

Operation

stage

PM2.5, PM10, SO2,

NOX, CO, O3,

NH3, Benzene,

BaP, Pb, As and

Ni

5 locations Once for 24 hr

continuous, over the

project period (once in a

month per year except in

monsoon) per year.

NAAQ

Standards

IS:5182

5X12X20,000

=Rs 1,200,000

-Do- -Do-

Ambient

Noise

levels

Operation

stage

As per National

Ambient Noise

Standard as per

Environmental

Protection Act,

1986 amended

2002

All along the

boundary

Once in a month during

the operation period.

Noise

Pollution

Control

Rules, 2000

10x12 x4,000

=Rs 480,000

-Do- -Do-



Page 203 of 262

Environm

ental

compone

nt

Project Stage Parameters Location Frequency Standards Approximate

cost (Rs)

Implement

ation

Responsi

bility

Ground

Water

Quality

Operation

stage

Critical

parameters as

per IS 10500

8 wells ( 2 inside + 6

outside)

Once in a month IS:10500 8X12x8,000

=

Rs 768,000

-Do- -Do-

Stack

émission

monitoring

Operation

stage

PM, SO2, NOx All major process

stacks of plant in

rotation

10 stacks in a month in

rotation

IS:11255 10x12x5000

= Rs. 600,000

-Do- -Do-

Total 39,60,000 Say 40,00,000

Total Monitoring Costs = Rs 40,00,000 per year during the operation year of the proposed plant



Page 204 of 262

6.2.4 Reporting System for Progress Monitoring

The reporting system is based on accountability to ensure that the measures

proposed as part of the environmental monitoring plan get implemented in the

project. The monitoring and evaluation of the management measures are critical

activities in implementation of the project. Monitoring involves periodic checking to

ascertain whether activities are going according to the plans. It provides the

necessary feedback for the project management to keep the programme on

schedule. The rational for a reporting system is based on accountability to ensure

that the measures proposed as part of environmental management plan get

implemented in the project. A reporting system for environmental monitoring plan is

given in Table 6.7.

Table 6.7: Reporting System for Environmental Monitoring Plan

S.

N.

Details Indicators Stage Responsibility

A. Pre-Construction Stage: Environmental Management Indicators and Monitoring Plan

1 Suitable location for dumping

of wastes has to be

identified.

Dumping locations Pre-construction Projects

2 Suitable location for

construction worker camps

have to be identified

Construction camps Pre-construction Projects

B. Construction Stage: Environmental Condition Indicators and Monitoring Plan

1. Dust suppression at

construction site

Construction site Construction Projects

2 The parameters to be

monitored as per frequency,

duration & locations of

monitoring specified in the

Environmental Monitoring

Programme

Air quality Construction Through

approved

monitoring

agency

C. Operation Stage: Management & Operational Performance Indicators

1 Solid waste generation,

utilization and dumping

As per guidelines of

statutory bodies

Operation EMD

2 Hazardous waste re-

utilization and dumping in

designated pits as specified

by statutory authorities.

As per the

notifications /

guidelines specified

by statutory

authorities.

Operation -Do-

3 Stack Emissions from

Process & de-dusting stacks

All parameters as

specified for stacks of

different units by

Statutory Authorities

Operation EMD/ Concerned

Plant Units

4 Meteorology, Ambient air

quality, Waste water

All parameters as

specified by Statutory

Operation EMD



Page 205 of 262

S.

N.

Details Indicators Stage Responsibility

discharge through plant

outfalls and Noise levels.

Authorities

6.2.5 Emergency Procedures

Emergency procedures will be formulated and implemented at design stage itself for

tackling of emergency situations arising out of the proposed operations.

Emergency situations arising out of non-functioning of the air pollution control

systems and inter-locking of the systems.

Emergency situations arising out of non-functioning of effluent treatment plant

and suitable storage facilities for effluent generation.

6.2.6 Budgetary Provisions for Environmental Monitoring Plan

Summary of Cost of Environmental Monitoring Plan

SN. Item Cost in Rs.

A. Capital Cost

1. Cost of Environmental Monitoring Equipment Rs. 50,000,000/-

Total Capital Cost Rs. 50,000,000/-

B. Operation Phase Recurring Cost in Rs.

/yr.

1 Environmental Monitoring Plan

Monitoring during operation @ Rs 40,00,000/yr. for the

operation phase of the proposed Integrated Steel Plant

40,00,000

Total 40,00,000

2 Contingency @ 5% of Monitoring during operation 200,000

Total Recurring Cost 42,00,000/-

*Note: estimates are on the basis of present cost (2016)

6.2.7 Budgetary Provisions for Environmental Protection Measures

Total capital cost of the project will be around Rs. 18,000 Crores. The environmental

protection measures included in the project cost as estimated are given in Table 6.8.



Page 206 of 262

Table 6.8: Cost of Environmental Protection Measures (Rs. Crores)

S

N

Environmental Protection Measures Recurring Cost per

annum

Capital Cost

(Rs. Crores)

1 Air Pollution Control 50.0 400

2 Water Pollution Control 15.0 80

3 Noise Pollution Control Included in item

no.1

Included in 1

4 Environment Monitoring Programme 0.46 5.0

5 Green Belt 0.10 8.0

6 Others (Solid waste management,

ventilation / air conditioning, firefighting

etc.)

42.0 307.0

Total 107.56 800.0

Note: estimates are on the basis of present cost (2016)



Page 207 of 262

CHAPTER-7: ADDITIONAL STUDIES

7.1 RISK ASSESMENT

7.2.1 Introduction

Industrial project activities, produce, treat, store and handle hazardous substances,

having a high hazard potential, endangering the safety of man and environment at

work place and outside environment. Recognizing the need to control and minimize

the risks posed by such activities, the Ministry of Environment & Forests have notified

the “Manufacture Storage & Import of Hazardous Chemicals Rules” in the year 1989

and subsequently modified, inserted and added different clauses in the said rule to

make it more stringent. Ministry of Environment & Forests has provided a set of

guidelines for effective implementation of these rules. The guidelines, in addition to

other aspects, set out the duties required to be performed by the occupier along with

the procedures. The rule also lists out the industrial activities and chemicals, which

are required to be considered as hazardous.

The proposed integrated steel plant will be engaged in the production of Steel from

iron ore. During the process of manufacture of iron & steel, many associated

materials, hazardous gases are generated which will be stored and used in the plant.

The major chemicals handled / stored by the plant include coke oven gas (COG),

blast furnace gas (BF gas), basic oxygen furnace gas (BOF gas), LPG, different acids

etc and other fuel storage. In view of this, activities are being scrutinized in line of the

above referred “Manufacture, storage and import of hazardous chemicals rules” and

observations / findings are presented in this chapter.

The assessment has been made in a systematic manner covering the requirements

of the above-mentioned rules. This section has been divided as follows:

i) Process description

ii) Applicability of the rule

ii i) Description of hazardous chemicals

iv) Hazard identification & risk analysis (HIRA)

v) Hazard assessment

vi) Consequence analysis including MCACA

vii) Brief description of the measures taken and

viii) On site emergency plan

7.2.2 PROCESS DESCRIPTION

The proposed steel plant shall follow the BF- BOF-Continuous Casting Route of steel

making. Iron ore lumps, sinters and, coke (made from cooking coal) and fluxes such

as limestone, dolomite are the major raw materials. The main steps in manufacturing

process are as follows:



Page 208 of 262

Coke Making - Coal Carbonisation

Coking coals are the coals which when heated in the absence of air, first melt, go in

the plastic state, swell and re-solidify to produce a solid coherent mass called coke.

When coking coal is heated in absence of air, a series of physical and chemical

changes take place with the evolution of gases and vapors, and the solid residue left

behind is called coke. Coke is used in Blast Furnace (BF) both as a reductant and as

a source of thermal energy. It involves reduction of ore to liquid metal in the blast

furnace and refining in convertor to form steel. The various stages of the steel plant

are described below:

Sintering

Sintering is a technology for agglomeration of iron ore fines into useful Blast Furnace

burden material. The raw materials used are as follows - Iron ore fines (-10 mm),

coke breeze (-3 mm), Lime stone & dolomite fines (-3mm) and other metallurgical

wastes. The proportioned raw materials are mixed and moistened in a mixing drum.

The mix is loaded on sinter machine through a feeder onto a moving grate (pallet)

and then the mix is rolled through segregation plate so that the coarse materials

settle at the bottom and fines onto the top.

The top surface of the mix is ignited through stationary burners at 1200oC. As the

pallet moves forward, the air is sucked through wind box situated under the grate. A

high temperature combustion zone is created in the charge -bed due to combustion

of solid fuel of the mix and regeneration of heat of incandescent sinter and outgoing

gases. Due to forward movement of pallet, the sintering process travels vertically

down.

Sinter is produced as a combined result of locally limited melting, grain boundary

diffusion and recrystallisation of iron oxides.

On the completion of sintering process, finished sinter cake is crushed and cooled.

The cooled sinter is screened and is dispatched to blast furnace.

Blast Furnace

The Blast furnace iron making process basically consists of the conversion of iron

oxide to iron in liquid form. This requires reductant for reduction of iron oxide and

heat for the above reduction reaction to take place and for melting the products of

smelting. The primary source to fulfill both these requirements is carbon (in the form

of coke). The blast furnace is a vertical counter-current heat exchanger as well as a

chemical reactor in which burden material charged from the top descend downward

and the gasses generated at the tuyere level ascend upward.

The top gas containing the flue dust is routed from the furnace top to the gas purifiers

and then to the consumption zones. The hot air for combustion is injected through

water-cooled tuyeres into the blast furnace. Hot metal is tapped through the tap hole,

which is opened by power driven drills into a train of ladles kept below the runner of



Page 209 of 262

the cast house. Slag comes along with the metal and is skimmed off with the help of

skimmer plate towards slag runner and is collected in slag thimbles. Raw material

(ore, sinter, coke) are screened before being charged into the blast furnace through

conveyors or skip. Air for combustion in the blast furnace is blown from turbo blowers,

which are preheated in hot blast stoves to temperatures around 1300oC, which is

then blown through tuyers into the blast furnace. Each blast furnace is equipped with

two or more stoves, which operate alternatively. Preheating of air helps in reducing

fuel consumption in the furnace.

Hot metal produced in the blast furnace is sent to Basic oxygen Furnace for steel

making or to Pig casting machines.

Pre-Treatment of Hot Metal

Hot metal from blast furnaces is treated to remove undesired elements like sulphur,

silicon or phosphorous before being transformed to steel. Desulphurising agents are

applied to reduce sulphur content of the metal.

Basic Oxygen Furnace/ Energy optimizing Furnace

The basic oxygen furnace (LD convertor) is a pear-shaped vessel lined inside with

refractory bricks. The vessel lining consists of tar bonded dolomite /magnesia carbon

bricks or other refractories. The vessel can be rotated 360 degree on its axis. Oxygen

is blown into the vessel with the help of water-cooled lance.

The 'heat' begins with the addition of scrap into the slightly tilted convertor, hot metal

is then added after straightening the convertor, and Oxygen is blown into the bath

through the lance. The necessary fluxes are added during blowing. Flux addition is

done automatically and precisely through bunkers situated above the convertor. A

sample is taken after blowing for 16-18 minutes and temperature is measured using a

thermocouple. The steel is tapped by tilting the convertor to the tapping side and

alloying elements are added via chutes while metal is being tapped. The convertor is

tilted to the charging side in order to remove the floating slag.

Reaction

During blowing operation, oxygen oxidizes iron into iron oxide and carbon into carbon

monoxide. The iron oxide immediately transfers the oxygen to the tramp elements.

The center of the reaction has temperatures of around 2000o-2500oC. The

development of carbon monoxide during refining process promotes agitation within

the molten bath. The reaction of the tramp elements with the oxygen and the iron

oxide developed in the center of reaction leads to formation of reactive slag. As

blowing continues, there is a continuous decrease of carbon, phosphorous,

manganese and silicon within the melt. Phosphorous is removed by inducing early

slag formation by adding powder lime with oxygen. The refining process is completed



Page 210 of 262

when the desired carbon content is attained. The steel produced in the basic oxygen

furnace is sent to continuous casting or for ingot teeming.

Continuous Casting

During continuous casting, the liquid steel passes from the pouring ladle, with the

exclusion of air, via a tundish with an adjustable discharge device into the short,

water-cooled copper mould. The shape of the mould defines the shape of the steel.

Before casting, the bottom of the mould is sealed with a so-called dummy bar. As

soon as the bath reaches its intended steel level, the mould starts to oscillate

vertically in order to prevent the strand adhering to its walls. The red-hot strand,

solidified at the surface zones, is drawn from the mould, first with the aid of a dummy

bar, and later by driving rolls. Because of its liquid core, the strand must be carefully

sprayed and cooled down with water. Rolls on all sides must also support it until it

has completely solidified. This prevents the still thin rim zone from disintegrating.

Once it has completely solidified, mobile cutting torches or shears can divide the

strand. Intensive cooling leads to a homogeneous solidification microstructure with

favourable technological properties.

From the process description it can be noticed that the process of manufacture

requires considerable thermal energy. This thermal energy is supplied through fuel

gasses generated in the plant e.g. Coke oven gas, Blast Furnace gas and BOF gas.

If there is any shortfall of these generated gasses then fuel gas is also supplied from

outside source also. In plant generation of fuel gasses will not meet the requirement

of proposed capacity. Therefore, use of LPG has been considered. Further Oxygen is

also required. Therefore, to run the plant, it is required to store all these chemicals

along with their distribution arrangement.

7.2.3 APPLICABILITY OF THE RULE

From the above description of the process, it is observed that the chemicals handled

and involved are:

(i) Blast furnace gas (ii) Coke Oven gas (iii) BOF Gas (IV) LPG

To decide whether the above-mentioned industrial activities are likely to come within

the scope of the above mentioned “Manufacture Storage and Import of Hazardous

Chemicals Rules” and the threshold quantities mentioned in the rules are used for

comparison as given in Table 7.1.



Page 211 of 262

Table: 7.1: Threshold Quantity & the Chemicals Stored and Handled

SN Chemical Stored /

Handled

Qty. Stored / Handled

(In Tons) And Storage

/ Handling Conditions

Whether

Included in The

List of

Hazardous &

Toxic Chemicals

Lower

Threshold

Qty. (In

Tons)

Upper

Threshold

Qty. (In

Tons)

1 Blast Furnace Gas

(Major Constituents

Carbon Monoxide)

768,960 m3 Gaseous,

Ambient temp & Press.

Yes 15 200

2 Coke Oven Gas

(Major Constituents

Hydrogen &

Methane)

103,732m3 Gaseous

Ambient temp & Press.

Yes 15 200

3 BOF Gas (Major

Constituents

Carbon Monoxide)

21,414m3 Ambient

temp &Press.

Yes 15 200

After comparison of the stored / handled and threshold quantities, it can be noticed

that majority of the chemicals are crossing the lower threshold quantities but are

below the upper threshold quantities. Accordingly, rule nos. 7,8,9,13,14, and 15 will

be applicable, whereas for the other chemical, the stored / handled quantities are

less than the lower threshold quantity. Accordingly, only rule 17 i.e. preparation and

maintenance of material safety data sheets for these chemicals are required. Rule -7

i.e. notification of site requires submission of a written report containing among other

information the followings:

a) Identification of major accident hazards

b) The conditions or events which could be significant in bringing one about

c) Brief descriptions of the measures taken

d) Area likely to be affected by the major accident etc.

7.2.4 DESCRIPTION OF HAZARDOUS CHEMICALS

The chemicals which are expected to be handled are presented in Table 7.1. The

Material Safety data sheets of different chemicals are presented below.

DATA SHEET

Carbon monoxide

CAS : 630-08-0

CO RTECS: FG3500000

Synonyms & Trade Names DOT ID & Guide :1016 119

Carbon oxide, Flue gas, Monoxide 9202 168 (cryogenic liquid)

Exposure NIOSH REL: TWA 35 ppm (40 mg/m3) C

200 ppm (229 mg/m3)

Limits OSHA PEL†: TWA 50 ppm (55 mg/m3)

http://www.cdc.gov/niosh/rtecs/fg3567e0.html

http://hazmat.dot.gov/pubs/erg/g119.pdf

http://hazmat.dot.gov/pubs/erg/g168.pdf



Page 212 of 262

IDLH Conversion

1200 ppm See: 630080 1 ppm = 1.15 mg/m3

Physical Description Colorless, odorless gas. [Note: Shipped as a non-liquefied or

liquefied compressed gas.]

MW: 28.0 BP: -313°F MLT: -337°F Sol: 2%

VP: >35 atm IP: 14.01 eV R Gas D: 0.97

FlP: NA (Gas) UEL: 74% LEL: 12.5%

Flammable Gas

Incompatibilities & Reactivities Strong oxidizers, bromine tri fluoride, chlorine tri

fluoride, lithium

Measurement Methods

NIOSH 6604; OSHA ID209, ID210

See: NMAM or OSHA Methods

Personal Protection & Sanitation

(See protection)

Skin: Frostbite

Eyes: Frostbite

Wash skin: No recommendation

Remove: When wet (flammable)

Change: No recommendation

Provide: Frostbite wash

First Aid

(See procedures)

Eye: Frostbite

Skin: Frostbite

Breathing: Respiratory support

Respirator Recommendations NIOSH

Up to 350 ppm (APF = 10) Any supplied-air respirator

Up to 875 ppm (APF = 25) Any supplied-air respirator operated in

a continuous-flow mode

Up to 1200 ppm:

(APF = 50) Any air-purifying, full-face piece

respirator (gas mask) with a chin-style, front- or

back-mounted canister providing protection against

the compound of concern† (APF = 50) Any self-

contained breathing apparatus with a full-face

piece (APF = 50) Any supplied-air respirator with a

full-face piece

Emergency or Planned Entry into Unknown Concentrations or IDLH Conditions

(APF = 10,000) Any self-contained breathing apparatus that has a full face-piece and

is operated in a pressure-demand or other positive-pressure mode (APF = 10,000)

Any supplied-air respirator that has a full face-piece and is operated in a pressure-

demand or other positive-pressure mode in combination with an auxiliary self-

contained positive-pressure breathing apparatus.

http://www.cdc.gov/niosh/idlh/630080.html

http://www.cdc.gov/niosh/nmam/pdfs/6604.pdf

http://www.osha.gov/dts/sltc/methods/inorganic/id209/id209.html

http://www.osha.gov/dts/sltc/methods/inorganic/id210/id210.html

http://www.cdc.gov/niosh/nmam/

http://www.osha-slc.gov/dts/sltc/methods/

http://www.cdc.gov/niosh/npg/protect.html

http://www.cdc.gov/niosh/npg/firstaid.html



Page 213 of 262

Escape

(APF = 50) Any air-purifying, full-facepiece respirator (gas mask) with a chin-style,

front- or back-mounted canister providing protection against the compound of

concern/Any appropriate escape-type, self-contained breathing apparatus

Important Additional Information About Respirator Selection

Exposure Routes

Inhalation, skin and/or eye contact (liquid)

Symptoms

Headache, tachypnea, nausea, lassitude (weakness, exhaustion), dizziness,

confusion, hallucinations; cyanosis; depressed S-T segment of electrocardiogram,

angina, syncope

Target Organs

Cardiovascular system, lungs, blood, central nervous system

DATA SHEET

METHANE ICSC: 0291 October 2000

Methyl hydride

CAS No: 74-82-8

RTECS No: PA1490000

UN No: 1971

EC No: 601-001-00-4

(cylinder) CH4

Molecular mass: 16.0

Types of

Hazard /

Exposure

Acute Hazards

/ Symptoms

Prevention First Aid / Fire Fighting

FIRE Extremely

flammable.

NO open flames, NO

sparks, and NO

smoking.

Shut off supply; if not possible

and no risk to surroundings,

let the fire burn itself out; in

other cases, extinguish with

water spray, powder, carbon

dioxide.

EXPLOSIO

N

Gas/air

mixtures are

explosive.

Closed system,

ventilation, explosion-

proof electrical

equipment and

lighting. Use non-

sparking hand tools.

In case of fire: keep cylinder

cool by spraying with water.

Combat fire from a sheltered

position.



Page 214 of 262

Types of

Hazard /

Exposure

Acute Hazards

/ Symptoms

Prevention First Aid / Fire Fighting

EXPOSURE

Inhalation Suffocation.

See Notes.

Ventilation. Breathing

protection if high

concentration.

Fresh air, rest. Artificial

respiration if indicated. Refer

for medical attention.

Skin On contact with

liquid: frostbite.

Cold-insulating

gloves.

On Frostbite: rinse with plenty

of water, do NOT remove

clothes. Refer for medical

attention.

Eyes On contact with

liquid: frostbite.

Safety goggles. First rinse with plenty of water

for several minutes (remove

contact lenses if easily

possible), then take to a

doctor.

Ingestion

SPILLAGE DISPOSAL PACKAGING & LABELLING

Evacuate danger area! Consult an expert!

Ventilation. Remove all ignition sources.

Personal protection: self-contained breathing

apparatus. NEVER direct water jet on liquid.

F+ Symbol

R: 12

S: (2-)9-16-33

UN Hazard Class: 2.1

EMERGENCY RESPONSE SAFE STORAGE

Transport Emergency Card: TEC (R)-20G1F

NFPA Code: H 1; F 4; R 0

Fireproof. Cool. Ventilation along the

floor and ceiling.

IMPORTANT DATA

Physical State; Appearance

Colorless, compressed liquefied gas, with no

odor.

Physical dangers

The gas is lighter than air.

Occupational exposure limits

TLV: Simple asphyxiant (ACGIH 2000).

MAK not established.

Routes of exposure

The substance can be absorbed into

the body by inhalation.

Inhalation risk

On loss of containment this gas can

cause suffocation by lowering the

oxygen content of the air in confined

areas.

Effects of short-term exposure

Rapid evaporation of the liquid may

cause frostbite.

http://www.ilo.org/public/english/protection/safework/cis/products/icsc/dtasht/symbols/fp.htm

http://www.ilo.org/public/english/protection/safework/cis/products/icsc/dtasht/riskphrs/12.htm

http://www.ilo.org/public/english/protection/safework/cis/products/icsc/dtasht/sftyphrs/02.htm






Page 215 of 262

Physical Properties Environmental Data

Boiling point: -161°C

Melting point: -183°C

Solubility in water, ml/100 ml at 20°C: 3.3

Relative vapour density (air = 1): 0.6

Flash point: Flammable Gas

Auto-ignition temperature: 537°C

Explosive limits, vol% in air: 5-15

Octanol/water partition coefficient as log

Pow: 1.09

Notes: Density of the liquid at boiling point: 0.42 kg/l. High concentrations in the air

cause a deficiency of oxygen with the risk of unconsciousness or death. Check oxygen

content before entering area. Turn leaking cylinder with the leak up to prevent escape

of gas in liquid state. After use for welding, turn valve off; regularly check tubing, etc.,

and test for leaks with soap and water. The measures mentioned in section

PREVENTION are applicable to production, filling of cylinders, and storage of the gas.

Other UN number: 1972 (refrigerated liquid), Hazard class: 2.1. Card has been partly

updated in October 2005. See section Emergency Response.

7.2.5 HAZARD IDENTIFICATION

Hazards associated with the above-mentioned chemicals are presented in Table 7.2.

Table-7.2: Type of Hazards

Name of the

Chemical

Type of

Hazard

Hazard Rating Remarks

Health Flammability Reactivity

Hydrogen 1, 6, 9 0 4 0 Gas stored under

pressure at ambient

temp.

Carbon

monoxide

1,3,9 2 4 0 Gas stored under

pressure at ambient

temp.

Methane 1 4 0 Gas stored under

pressure at ambient

temp.

Note:

Type of Hazard

1. Flammable substance

2. Oxidizing substance, reacts with reducing agents

3. Emits a toxic gas or vapour

4. Emits an irritating gas or vapour

5. Emits a narcotic gas or vapour

6. Gas or vapour not dangerous other than displacing air

7. Causes skin irritation or burns

8. Toxic substance

9. Explosive material under certain conditions



Page 216 of 262

Hazard Rating

a. Health

None

Minor

Moderate, could cause temporary incapacitation or injury

Severe, short exposure may cause serious injury

Extreme, short exposure may cause death

b. Flammability

1 None, Material does not burn

2 Minor, material must be preheated to ignite

3 Moderate, moderate heating is required for ignition and volatile vapors

are released

4 Severe, material ignites at normal temperature

5 Extreme, very flammable substance that readily forms explosive

mixtures

c. Reactivity

None, stable when exposed to fire

Minor, unstable at high temp. or press and may react with water

Moderate, unstable but does not explode, may form explosive mixture

with water

Severe, explodes if heated or water added

Extreme, readily explosives under normal condition

From the above table it can be observed that BF, BOF and CO gases are most

`dangerous’ materials since all these are gaseous under ambient condition, all others

are liquid at ambient condition. Further, among BF, BOF and CO gas, are stored

more or less under ambient temperature and pressure. The catastrophic potential of

a hazardous substance depends both on toxicity and volatility. The ambient

temperature vapour pressure of a substance is used as a measure of the ability to

become air borne.

7.2.6 HAZARD ASSESSMENT

In the earlier section, type of hazard associated with different type of chemicals and

the event of release of these chemicals is being identified. It has also been identified

the category of hazard associated with different chemicals.

Hazardous situation arising due to:

Failure in the monitoring of crucial process parameters e.g. pressure,

temperature, flow quantity etc.

Failure in the utilities e.g. cooling water

Failure control elements e.g. pressure, temperature level, flow controllers etc.

Failure of components such as pumps, compressor etc.

Failure of safety systems, safety valves / relief valves, sprinkler systems,

alarm etc.



Page 217 of 262

Mechanical failure of vessels or pipe work due to excessive stress, over

pressure, corrosion etc.

Wrong operation, failing to adhere to the safety norms etc.

EFFECTS OF THE ABOVE HAZARDS

The effect of accidents in these areas will be confined to the facilities only and can be

controlled within the areas by the operating personnel themselves.

At the extreme it may require the resources of the whole facility to control the effects

but these are not at all expected to spill over to the community.

7.2.7 HAZOP Study

It is suggested to have HAZOP Study for the fuel distribution network handling

facilities prior to commissioning, for last minute corrections in the design of the

systems from fail safe angle. The HAZOP analysis for the fuel handling system will be

carried out and suitable measures will be implemented for safe operations.

Electrical safety: Adequately rated and quick response circuit breakers, aided by

reliable and selective digital or microprocessor based electro-magnetic protective

relays would be incorporated in the electrical system design for the proposed project.

The metering and instruments would be of proper accuracy class and scale

dimensions.

7.2.8 CONSEQUENCE ANALYSIS

In this section, accident consequence analysis to determine the consequence of a

potential major accident on the installation, the neighborhood and the environment

are being discussed by evaluating the consequence of incidence involving hazardous

materials vis-a-vis LPG. Consequence analysis also involves assessment of release

quantity which is again dependent upon chemical, storing condition, type of release,

duration etc. Catastrophic flammable material normally involves the air borne release

of these materials. A potential catastrophic release of flammable material would

involve air borne release and subsequent explosion or fire i.e. a sufficiently large fuel

– air mixture within flammable mix rapidly developed and finds a source of ignition.

Flammable releases cause harms as a result of fire or explosion. Flammable vapour

cloud resulting from rapid, release of LPG is being calculated. Since the cloud center

cannot be predicted, a conservation approach has been followed and it has been

assumed that the cloud drift towards downwind from the point of release when the

danger of ignition occurs. Assuming that the cloud would drift in any direction, the

“Hazard Area” around LPG storage area has been established by drawing a circle of

radius equal to the distance, which may be affected due to heat intensity, if BLEVE

occurs. A `BLEVE’ can occur, if a pressure vessel becomes completely filled with

liquid. The temperature, rises and pressure relief capacity is insufficient to keep the



Page 218 of 262

internal pressure from exceeding tank strength. One of the hazards of a `BLEVE’ of a

pressurized tank containing liquefied gas is the fireball created by combustion of the

mixture of vapour liquid that is explosively dispersed by the sudden rupture. The

sudden expansion of compressed vapour and the large quantities of vapour suddenly

produced by liquid flashing combine to create a large ball of liquid droplets and

vapour. The heat created by the burning of the dispersed liquid and vapour causes a

powerful thermal updraft. As already explained, sudden release of a liquid stored at a

temperature above its boiling point will result in the instantaneous and adiabatic

vaporization of a fraction of the liquid. It is usually taken as half the tank capacity

while calculating the radiative flux incident, on a target some distance away from the

LPG tank. However, as the storage quantities along with its details have not yet

been finalized, the assessments have been made on the assumption that maximum

instantaneous release of total 50 tons release.

Unconfined vapor cloud explosion is one of the most serious hazards of LPG. A

vapour cloud explosion may cause harm by direct or indirect blast effects. The peak

incident pressure at different distance due to explosion of various quantities of vapour

cloud are being calculated and is presented in Table 7.3. The effect of this over

pressure is presented in Table 7.4.

Table 7.3: Over Pressure generation from vapour cloud explosion

Over Pressure (bar) Distance in meter

0.09 200

0.06 300

0.04 400

0.35 500

0.03 600

0.026 700

0.022 800

Table 7.4: Effect of Different Overpressure

Over Pressure

(Millibar)

Type of Damage

10 – 15 Typical window glass breakage

35 – 75 Windows shattered, Plaster cracked, Minor damage to some

building

70 – 100 Personnel knocked down

75 -125 Panels of sheet metal buckled

125 -200 Failure of walls constructed of concrete blocks or cinder blocks

200 - 300 Oil storage tank ruptured

400 - 600 RCC Structure severely damaged

350 - 1000 Ear drum rupture

2000 - 5000 Lung damage

7000 - 10,000 Lethal



Page 219 of 262

The heat radiation intensity at different distances for different quantities of releases is

presented in Table 7.5. The effect of thermal radiation on unprotected skin is also

presented below in Table 7.6.

Table-7.5: Heat radiation intensity at different distances for 50 t

Distance in meter Thermal load (Kw/m2)

120 117.3

130.9 92.6

141.8 76.1

152.7 63.9

163.6 54.6

218.1 28.9

327.2 12.0

436.3 6.5

545.4 4.1

1090.7 0.9

1636.1 0.4

2181.4 0.2

Table-7.6: Relation between Heat Radiation Intensity, Time and Effect on Man

Heat Radiation Level (Kw / m2) Duration (Secs) Effect

2.5 65 Blistering Starts

5 25 Do

8 13.5 Do

11 8.5 Do

18 4.5 Do

22 3 Do

10.2 45.2 Lethal (1%)

33.1 10.1 Do

146 1.43 Do

7.2.9 : ON-SITE EMERGENCY PLAN / DISASTER MANAGEMENT PLAN

The on-site emergency plan relates to the laid-down and well-practiced procedure

after taking care of all design based precautionary measures for risk control. This

plan is aimed for tackling any emergency situation, if arises.

Objective of the Plan

The emergency plan has been prepared to ensure the smooth working of the steel

plant complex. The main objectives of the plan are to take immediate actions to meet

any emergency situation making maximum use of combined in-plant and allied

resources for the most effective, speedy and efficient rescue and relief operations.

These are briefly enumerated below:



Page 220 of 262

1. Cordon and isolate the affected area for smooth rescue operation

2. Rescue and treat casualties and safeguard the rest

3. Minimize damage to persons, property and surroundings

4. Contain and ultimately bring the situation under control

5. Secure and safe rehabilitation of the affected area

6. Provide necessary information to statutory agencies

7. Provide authoritative information to the news media.

8. Ward off unsocial elements and prying onlookers.

9. Counter rumor mongering and panic by relevant accurate information.

Methodology

Keeping in mind the detailed information on the proposed steel plant, the plan is

formed on the following basis:

- identification of possible hazards in various units and their impact on the

surroundings

- Detailed information on the available resources and control measures.

7.2.10 INDUSTRIAL SAFETY AND FIRE FIGHTING

Some of the working premises of the plant have hazardous and fire-prone

environment. To protect the working personnel and equipment from any damage or

loss and to ensure uninterrupted production, adequate safety and firefighting

measures have been proposed for the project.

7.2.11 SAFETY OF PERSONNEL

All workmen employed in hazardous working conditions will be provided with

adequate personal safety appliance as applicable to the work like;

- Industrial safety boots

- Industrial helmets

- Hand gloves

- Ear muffs

- Welder's screens and aprons

- Gas masks

- Respirators

- Resuscitators

7.2.12 FIRE PROTECTION FACILITIES

Keeping in view the nature of fire and vulnerability of the equipment and the

premises, the following fire protection facilities have been proposed for the plant.



Page 221 of 262

Portable Fire Extinguishers

All plant units, office buildings, stores, laboratories, MCCs etc. will be provided with

adequate number of portable fire extinguishers. The distribution and selection of

extinguishers will be done as per IS:2190.

Hydrant System

Hydrants will be provided at suitable locations and in different levels inside the plant

buildings. Yard hydrants will be provided in the vicinity to meet the additional

requirement of water to extinguish fire. Sprinkler system for MRSS, Oil cellars also

have been provided.

Automatic Fire Detection System

Unattended vulnerable premises like electrical control rooms, cable tunnels, MCC, oil

cellars, etc. will be provided with automatic fire detection and alarm systems.

Manual Call Point Systems

All major units and welfare/administrative building will be provided with manual call

points for summoning the firefighting crew from the fire station for necessary

assistance.

Fire Station

The Fire station will be centrally located with adequate communication facilities and

trained man power. There will be one central fire station with fire tenders to extend

the necessary assistance required for fighting fire in any of the plant units and

associate premises. The following equipment will be provided in fire station/fire posts.

- Water tender

- Foam tender

- Portable pump

- Wireless set

- Hoses

7.2.13 PLANT DISASTER CONTROL

The On-Site Emergency Plan will be made available considering all the different units

of the proposed steel plant complex.

Organization

A Central Disaster Control Cell will be set up under the direct charge of the GM I/c

(safety). He will be the person nominated to declare any major emergency and would



Page 222 of 262

be in-charge of all operations in such situations. In his absence, GM (Maintenance)

would be the in-charge. He will be supported by the other nominated members of cell,

e.g., General Manager for Plant operations and service, Personnel, Security,

Administration and Medical Officer. In case of any major emergency, the Disaster

Control Cell would operate from Disaster Control Room. At the shop level, Deputy

General Managers, have been nominated as Controllers who will be assisted by

Manager, Shift-in-charges and trained key workers to deal with any minor

emergencies arising at the shop.

Information Flow

The following guidelines will be observed by any person after noticing a gas leak, fire,

etc. till help is made available from Central Disaster Control Cell or Shop level

Disaster Control Cell.

- Raise alarm

- Communicate to the control room about the incident/emergency.

- Communicate to fire station for relief in case telephone is available otherwise try

to attract attention by any available means.

- Attempts to close doors, windows or ventilators of the room to prevent any

contaminated air getting in.

7.2.13.1 CENTRAL DISASTER CONTROL ROOM

Upon receiving information from any site regarding emergency, the person operating

from the Disaster Control room will:

- Depute a person to rush to site and assess the situation.

- Inform fire, transport, safety, medical and concerned control room.

- Organize operating personnel and arrange for control over the situation.

- Keep the management informed about the gravity of the situation from time to

time.

- On receiving the call, the disaster control room would immediately direct the

different supporting service agencies as enumerated below:

- Security and Administration services: responsible for safety of the plant against

trespassers, saboteurs, information to Government authorities and in the

neighborhood provision of transport facilities, telecommunication facilities and fire

service facilities.

- Safety service: responsible for implementation of safety measures at work place

and occupational safety.

- Medical service: responsible for providing medical care to the injured or the

affected in an event of emergency.

- Stores: responsible for providing adequate number of tools, tackles and

accessories for proper emergency control.

- Preservation of evidence and taking of photographs, if necessary, for future

enquiries to determine the cause and taking further preventive actions.



Page 223 of 262

- Welfare: Provide food, clothes, shelter etc., as per requirements.

- Power and water supply: To ensure supply of firefighting water requirement and

provisions of power supply.

Alerted by news, all key personnel will arrive immediately at the respective reporting

place during emergency.

SHOP LEVEL DISASTER CONTROL CELL

The Controller at the shop level would take immediate charge of any emergency

situation and would assume full responsibility regarding mobilization of resources,

guide and help service agencies in properly carrying out their assigned duties. Being

from the operations side of the plant, he has full knowledge of the process aspects

and he would decide whether to stop the plant/process. He will be responsible for

overall co-ordination. In his absence, his Deputy would be Controller of the

operations. The duties of the Shop level Controller are enumerated below:

- Assess the scale of emergency and decide, if any possibility of major emergency

exists and inform the Central Control Room, if necessary.

- Direct Safe close down of plant or any operation, if necessary.

- Direct evacuation of areas in the vicinity, which may be endangered.

- Ensure key personnel are called in immediately and they start carrying out their

assigned duties.

- Direct rescue and firefighting operations from safe operation point of view.

- Direct the shop personnel to the designated places for safe assembly.

- Control rehabilitation of affected areas and any victim on emergency.

- Ensure complete safety before restarting the plant/ operation.

At Shop floor, teams of workers will be trained, who will be present at the incident site

for doing the needful. They will assist and extend help to the following:

- Fire brigade team in controlling fire.

- Operational staff in shutting down plant to make it safe.

- Search, evacuation, rescue team.

- Movement of vehicles for emergency control.

- Plant pollution monitoring staff for carrying out atmospheric tests.

- Medical team for providing necessary help.

- Any other special operation.

6.2.13.2.1 CONTINGENCY PLAN

It has been based on the following considerations:

- The plant general layout.

- The available resources.

- The analysis of hazards.

And is aimed at the

- Pre-emergency activities.



Page 224 of 262

- Emergency time activities.

- Post-emergency activities.

In the event of an emergency, the people from affected pockets would be directed to

move to safe assembly places nearby the units.

The following facilities will be provided.

- Security service

- Firefighting service

- Medical service

- Public relation service

- Telecommunication service

- Transport service

- Evacuation service

- Welfare service

An alarm system will be provided with a wailing type siren at a centralized place and

actuators at the strategic locations in the plant. Adequate number of telephones will

be provided in each unit at Shop floor so that a person can either directly raise the

alarm or ring up disaster control room from where the alarm can be raised directly.

The wailing siren will mark the beginning of the emergency while a continuous note

will mark the end meaning all clear signal.

All firefighting equipment like valves, fire hydrants, pumps, monitors, etc., will be

checked periodically to detect defective parts and such parts would be immediately

replaced. Mock drills will be conducted for training the persons and to check the

performance of men and equipment and also to keep them fit for any emergency. The

plant will be equipped with a separate Medical Centre with necessary

instrument/appliances, medicines and trained manpower. The Medical Officer will

maintain close liaison with different hospitals in the nearby city.

RESCUE AND REPAIR SERVICES

The responsibility of effective working of Rescue and Repair Services will be with the

incident controller.

Rescue Services

- To extricate persons from the debris of collapsed building/structure and save

human lives.

- To hand over the extricated persons to first aid parties.

- To take immediate steps as may be necessary for the temporary supports or

demolition of buildings and structures, the collapse of which is likely to endanger

life or obstruct traffic.

- To cut off supplies of water, gas, electricity to damaged buildings.



Page 225 of 262

Trained Rescue parties shall be formed at Shop levels, who will be provided with the

following equipment:

Self-contained oxygen breathing apparatus

Blower type gas mask

Resuscitators

Petromax lamp / Torches

Axe/hand saw

Bamboo ladder

Necessary Safety appliances

First aid box

Blankets

On-site emergency planning rehearsals need to be carried out from time to time. It

requires monitoring by experienced persons from other similar factories or by senior

officials from the State Inspectorate of Factories and/or the Directorate of Fire

Services, who can help in updating the emergency plan procedure.

OFF-SITE EMERGENCY PLANNING

Off-site emergency planning is normally under the jurisdiction of the district

administration. The designated official of the Steel Plant is required to have

co-ordination with the district administration for responsive action in off -site

emergency planning.

FIRE FIGHTING ORGANISATION AND PROCEDURE

There will be trained firefighting personnel and a Fire Officer under the Fire & Safety

Department. The following important instructions will be given for fire prevention and

tackling of any fire in the plant.

Overall control of the Firefighting operations will rest with the senior most officer

present at the scene of fire, who will be assisted by the operational and fire staff.

Close co-ordination and planning for fire protection will be done between Plant

Operations and Fire Service.

While turning out for fire calls, the fire staff will be guided to the correct location

immediately on their arrival.

In-charge of the section at Shop floor will explain special risks involved and

guide the In-charge of the Firefighting crew. He will, however, not interfere in the

method of firefighting operations.

No one would tamper with the sources of water supply/ fire hydrants or misuse

them in any manner. The passages/approach to/from fire hydrants to the fire

appliances would always be kept clear.



Page 226 of 262

Fire drills would be held in each, zone periodically under the direction of the Fire

Officer.

The organization and brief procedure for fighting small, major and simultaneous fire is

given below:

Degree of fire

emergency

Fire chief Siren code Persons

attending

Small fire

Major fire/Disaster

Simultaneous fire

Functional head in charge

of affected area

Head of the works

department

In-charge of affected area

No siren

Double

Wailings

Single wailing

Fire & safety

Department

On site emergency

plan

Persons already

present at the

scene of fire,

operators

Definitions:

Small fire : A fire in its incipient stage which is controlled by the first

line firefighting team.

Major fire : The fire is spreading to other equipment or areas and

which threatens to go beyond the control of first line

and second line firefighting teams.

Simultaneous fire : More than one fire occurring at the same time.

Fire Control Office : The Fire Control Officer will be in-charge at the scene

of fire. In case of small fire, Section Head/ Functional

Head of affected area will be fire Officer.

In major fire, Head of works will be Fire Control Officer.

In simultaneous fires, in-charges of the respective

affected areas will be Fire Control Officers.

Fire call : Fire call will be received at the fire station regarding

occurrence of fire and its location. The message will be

conveyed either by telephone or fire alarm or in person.

While giving Fire call message on telephone, the

person will

Give his name, Section & Department.

Exact location of Fire and if possible, nature of fire.

Confirm that the Fire call message is repeated by the

Control room attendant.



Page 227 of 262

When the call message is given by the Fire alarm, the

person would stand rear the Fire alarm to guide the

Firefighting team to the location of the fire.

Fire Siren Code : For small fire : No siren will be sounded.

For major fire : Double Wailing

For all clear : Steady siren for one minute.

Fire Fighting for Small Fire

The small fire will be tackled by the first line team which would comprise of the

persons already present at the scene of fire. However, the second line firefighting

team whose composition is given below will also report at the scene of fire

immediately after receiving the Fire Call of affected area at the time of fire. The team

will consist of the following:

Fire Control Officer

First line Fire Fighting team:

Operation/maintenance staff and/or other plant personnel working in the area

Second line Fire Fighting team:

Fire station shift-in-charge and trained firefighting personnel.

Ambulance driver with ambulance.

Functional head of affected area.

Shift Officer production

Security personnel.

Third line Fire Fighting team:

Fire Officer & Auxiliary Fire Fighting personnel.

All Departmental & Functional Heads.

Local Fire Brigade from Govt., if necessary.

Fire Fighting for Major Fire:

The major fire will be tackled by the first line, second line and the third line firefighting

teams. The fire chief in this case is the Head of works. The fire chief for small fire will

judge the nature of fire and in case of major fire, he will inform Fire Officer (either

himself or through responsible persons) to sound the fire sirens (double wailing type).

The team will consist of the following who will immediately report at the scene of the

fire.

1. Fire Officer

2. First, second and third line Firefighting team.

3. Auxiliary Fire Fighting personal

All the members of the auxiliary firefighting crew will have thorough training on the

job.



Page 228 of 262

Responsibilities of Fire Control Room Operator:

During fire Call:

To take correct message regarding location, type of fire etc., from the caller.

To repeat the message.

To inform firefighting personnel on duty immediately for turn out by hearing the

bell.

To ask the pump house operator to maintain adequate head in the fire water line.

To inform Telephone Exchange.

To inform first aid centre.

Responsibilities of Fire Fighting Personnel:

To report immediately at the scene of fire.

To take instructions from Fire Officer.

Responsibilities of Fire Officer:

To direct the deployment of Firefighting personnel and firefighting appliances.

To organize additional firefighting crew, if required, depending upon gravity of the

situation.

To guide plant employees in firefighting.

To co-ordinate between different groups of firefighting personnel & team of

trained workers from the department.

To control the spread of fire and rescue operation, if necessary.

To extinguish the fire.

To replenish the required firefighting material/ equipment.

To arrange relievers wherever necessary.

To assess the situation and arrange additional help if necessary, in co-ordination

with Disaster Control room.

To advice for all clear siren to be blown after the major fire emergency is over.

Responsibilities of Ambulance Driver:

To report to the scene of fire with ambulance immediately.

To carry the casualties, if any, to the medical centre as directed by Medical

Officer/Fire Officer at the earliest.

To park the ambulance without obstructing the firefighting operations and traffic.

Responsibilities of Security personnel at the manned gate:

To prevent entry of unauthorized persons.

To keep the gate open for emergency vehicles and officers and staff concerned

with firefighting and allied operations.



Page 229 of 262

Responsibilities of Telephone Operator:

To receive fire call messages.

To inform Shift Officer for all fires.

Responsibilities of Medical Officer during major fire:

To be available at the first aid centre for necessary medical advice.

To depute one of the medical staffs to the scene of fire to render any medical

assistance required at site.

Responsibilities of Head of the Personnel and Welfare Department during

major fire:

To arrange the transport of the firefighting personnel with minimum loss of time in

consultation with the Fire Control/Fire Officer.

To make arrangements for the refreshment/meals for persons engaged in

firefighting.

To inform the Fire Officer regarding the actions taken.

Responsibilities of Head of the Maintenance Department during major fire:

To report to Fire Chief and render all help that may be required from

Maintenance Department.

Responsibilities of Head of the Electrical Maintenance Department during

major fire:

To report to Fire Officer and render assistance to be required from Electrical

Department such as installation of equipment, provision of temporary lighting

etc.

Responsibilities of Head of the Materials Procurement Department during

major fire:

To arrange to man the stores for emergency issue of materials. If the materials

are not available in the stores or are likely to be exhausted during firefighting

operations, he would arrange for the same from other sources.

CLOUD BURST / LIGHTNING

Cloud burst / lightning may at times lead to minor to major emergency. In such an

emergency, actions indicated under fire and explosion will be undertaken.



Page 230 of 262

FOOD POISONING

In case of food poisoning in plant canteens, the following will be done:

Disaster Controller will inform Medical Officer for immediate first aid.

Medical Officer will contact other hospitals and seek their help, if necessary.

Security will help in evacuating the affected people to various hospitals, in

co-ordination with the Medical Officer.

MUTUAL-AID SYSTEM

At times the possibility of a major emergency (a situation out of control of plant

authority) cannot be ruled out. In such a case, the plant authority would declare it to

be a major emergency and total control would be transferred to the district level office

of contingency plan committee.

Necessary help would also be sought from Government sources having necessary

infrastructure for dealing with disaster.

7.3 SOCIAL IMPACT ASSESSMENT

7.3.1 Introduction

Social and economic development of a region is closely linked with the growth of

industrialization. Industrialization creates forward and backward linkages, which lead to

multi-dimensional development. AISL integrated steel plant at Koppal district,

Karnataka, is a step towards achieving such a developmental goal. The propose steel

plant will lead to a Bubble Effect in the vicinity of the plant. At the same time, extensive

activities under the Corporate Social Responsibility (CSR) will lead to a holistic

development of the area. The `steel project' as such, indicates a significant beak in

investment, which is likely to have widespread impact on the socio-economy of the

area surrounding it, through multiplier and linkage effects. Further development of the

area is expected due to the project.

7.3.2 Objectives

The proposed steel project will have a widespread impact on the social and economic

conditions of the people of the region in terms of direct and indirect employment, skill

diversification, infrastructure development, business development etc. On this

backdrop, the present study is directed towards the following objectives:

i) To assess the impact of the project on agricultural situation;

ii) To examine the employment and income effects of the project;

iii) To explore the possibility of local industrialization as an impact of the project;

iv) To assess the impact of the project on health situation

v) To assess the Corporate Social Responsibility of AISL



Page 231 of 262

vi) To judge peoples' perception regarding the project;

vii) To examine the impact of the project on tourism.

7.3.3 Methodology adopted for the study

The methodology adopted for the study is based on the following:

Review of Secondary Data

Review of secondary data, such as District Census Statistical Handbooks 2011 for

the parameters of demography, occupational structure of people within the general

study area of 10km radius around the proposed plant site. The secondary data

supplemented the primary data collected through direct field survey.

Field Survey

Baseline data on socio-economic parameters were generated using information

available with Govt agencies, census data etc.

Socio-economic survey was carried out covering all the villages / towns of the study

area to record awareness, opinion, apprehensions, quality of life and expectations of

the local people about the proposed plant. The opinion of local people about the

proposed steel plan was obtained through socio-economy survey of the villages /

towns in the study area.

A brief about the sampling design adopted for the field survey is described below.

The survey has been conducted through specially designed questionnaire covering

every aspect of the present study. In addition to the field data, secondary data /

information collected, compiled and published by different Governmental agencies /

departments were also collected and utilized appropriately.

Sampling

For selection of respondents from the study area, Two Stage Random Sampling has

been adopted. In the first stage, villages are selected and in the second stage,

households/ respondents are selected. From each selected village, the respondents

are selected randomly to account intra-village variability among the respondents for

the character under study. As the variability of the characters under in each strata

study does not vary widely among the households, a smaller sample size is expected

to represent the population.

Samples of 75 respondents were drawn from the study area. The sample covers an

estimated 300 persons.



Page 232 of 262

Composition of the Questionnaire

Households/respondents were interviewed with the structured questionnaire

specifically designed for

this study keeping in view

the objectives of the study.

The questionnaire consists

of following major sections:

a) Demographic profile

of the households

a) Educational status

b) Information on

agricultural

situation

c) Employment (sources of employment)

d) Income (income from various sources)

e) Information on family budget

f) Consumption and saving

g) Respondents' perception about the project

7.3.4 Profile of Koppal District

Socio-economic aspects

The study area covers within a radius of 10 km from the Project site. The 10

km radius study area around the project site comprises of 31 villages. The

socio-economic profile of the study area is presented based on site visits;

discussions with the villagers and the secondary data available.

Human Settlement and Demography

Demographic characteristics of the study area are represented by a number of

criteria, namely population composition, sex ratio, family structure, and age

distribution pattern. Attempt has been made to compare the demographic

features between the census data whenever corresponding data are available.

The area selected for the study constitutes 31 inhabited villages. The village

size as estimated from the number of inhabitants as per the 2011 census

indicated that 2 villages fall within 1-500 population size, 2 village fall in range

of 501-1000 population size, 12 villages fall in range of 1001-2000 population

size while majority of the villages i.e. 14 villages having population in the rage

of 2000-10000 and district headquarter Koppal is having population About

19988. Village Sangapur with population of 422 is the least populated village.

Socio Economic Characteristics of the Area

Community Profile: The population is distributed among 15,126 households in

the study area. The 31 inhabited villages have a population of 79,494

comprising of 40,574 males and 38,920 females. As may be observed from



Page 233 of 262

the graph below the composition of the society as far as males and their

counterpart’s female are concerned indicates healthy distribution.

The number of females per 1000 males is 959 when compared with the figures of

the Karnataka State 973 and for the nation 933 the study area found to be lesser

than State and greater than national figures indicating an equally composite society

of male and female.

The scheduled caste population of the study area on percentage basis is

21.08 % of the total population and scheduled tribe population is 6.96 %.

Socio-Religious Groups: In the project area, the predominant community is

of Hindus. The community is divided into several castes and sub-castes. They

are engaged in agriculture, animal husbandry, weaving and craft-related

activities. Some of them sell vegetables and work as laborer. They share

similar kind of

interdependency, kinship

relation and strong identity

with the all community.

There is communal

harmony in the region.

Literacy: The overall

literacy in the 31 villages of

the study area was 59.73%.

The male literacy in the

study area was 68.37%as

compared with State was

82.47% in this period, and the female literacy was 50.72% while it was 68.08% for

the State. The graphical representation illustrates comparative literacy of the study

area and Karnataka. It may be noted that percentage of literacy of study area was

less than as compared with State in both male and female.

Vocation-wise distribution of the population based on 2011 census data of the

study area is graphically represented below indicate that about 53.11% non-working

population is dependent on 46.89 % working population.



Page 234 of 262

Profession Percentage

1.

Total Main Workers

* Cultivators

* Agricultural Labour

* House Hold industry

* Other Workers

39.39

(22.54)

(29.26)

(2.97)

(45.24)

2. Marginal Workers 7.50

3. Non-Workers 53.11

As may be seen from these data, the percentage of main workers in the study area

was 39.39%, in 2011. The

percentage of cultivators

was 22.54% in area. On the

other hand, percentage of

agricultural laborers was

29.26% and 45.24% people

were engaged in other

activities. The percentage of

household industries was

lowest 2.97% in the study

area. The marginal workers

in the study area were 7.50%. The non-workers were 53.11% in study area.



Page 235 of 262

Table-7.7: The village wise demographic data as per 2011 census

S.N. Name of the village

No of

house

holds

Population Schedule

caste

Scheduled

tribe

Literate

Total Male Female Male Female

1 Chilwadgi 397 2204 1119 1085 308 622 706 424

2 Yettinhatti 272 1347 666 681 311 29 471 329

3 Gabbur 219 1230 642 588 234 5 397 244

4 Ginigera 1863 8449 4509 3940 2346 532 3232 2023

5 Lingadahalli 166 862 427 435 104 0 290 221

6 Kanakapur 505 2543 1319 1224 1020 224 981 671

7 Allanagar 257 1212 627 585 174 43 403 300

8 Basapur 389 2095 1085 1010 372 53 643 435

9 Kidadhal 177 1023 518 505 177 170 255 183

10 Koppal (Rural) 3806 18988 9629 9359 3652 648 7311 5918

11 Mangalapur 228 1340 678 662 129 89 429 308

12 Horthatanhal 179 1001 488 513 113 98 339 233

13 Bahaddurbandi 504 2872 1505 1367 209 159 1025 682

14 Huvinhal 159 885 427 458 116 118 257 199

15 Halavarthi 470 2477 1259 1218 445 50 696 432

16 Hireboganhal 471 2411 1271 1140 313 42 846 611

17 Kunikera 577 3471 1781 1690 2010 217 1047 597

18 Hoshall i 352 1996 999 997 258 76 685 452

19 Muddaballi 468 2450 1223 1227 387 188 913 677

20 Hyati 399 2314 1164 1150 304 427 799 615

21 Mell ikeri 82 484 237 247 225 49 143 109

22 Lachankera 574 3282 1675 1607 705 848 1176 755

23 Chikboganhal 266 1488 768 720 272 247 519 316



Page 236 of 262

S.N. Name of the village

No of

house

holds

Population Schedule

caste

Scheduled

tribe

Literate

Total Male Female Male Female

24 Karkihalli 407 2428 1221 1207 530 108 727 477

25 Tawargera 248 1236 598 638 148 99 422 313

26 Lebgera 349 2005 1001 1004 174 44 695 536

27 Sangapur 55 422 230 192 30 0 122 75

28 Bhimanur 234 1236 621 615 200 1 353 228

29 Halahalli 282 1624 817 807 823 13 564 446

30 Bevinhalli 460 2315 1173 1142 226 178 801 569

31 Hirekhasankandi 311 1804 897 907 444 152 495 364

Total 15126 79494 40574 38920 16759 5529 27742 19742



Page 237 of 262

S.

n.

Name of the

village

Total main

workers

Cultivator

s Agril lab

Hh

industry

Other

workers

Marginal

worker Non workers

M F M F M F M F M F M F M F

1 Chilwadgi 633 560 230 166 186 354 15 7 202 33 2 2 484 523

2 Yettinhatti 415 386 105 2 68 281 15 2 227 101 4 1 247 294

3 Gabbur 332 252 168 75 132 173 10 3 22 1 3 2 307 334

4 Ginigera 2324 643 282 97 192 269 45 20 1805 257 329 181 1856 3116

5 Lingadahalli 201 30 33 1 128 20 0 0 40 9 7 2 219 403

6 Kanakapur 719 389 101 59 11 17 26 18 581 295 18 16 582 819

7 Allanagar 289 125 50 26 29 14 7 5 203 80 75 86 263 374

8 Basapur 502 268 190 30 93 181 2 0 217 57 23 11 560 731

9 Kidadhal 284 207 71 29 114 152 4 1 95 25 4 1 230 297

10 Koppal (rural) 4852 2019 261 60 247 152 29

0

16

6 4054

164

1 445 302 4332 7038

11 Mangalapur 382 200 70 30 29 118 1 1 282 51 11 2 285 460

12 Horthatanhal 261 255 105 104 80 91 9 8 67 52 10 11 217 247

13 Bahaddurbandi 762 472 151 51 85 288 13 8 513 125 18 88 725 807

14 Huvinhal 250 194 75 1 21 97 0 0 154 96 11 49 166 215

15 Halwarti 666 586 231 37 303 512 0 2 132 35 17 29 576 603

16 Hireboganhal 484 120 185 21 71 59 16 1 212 39 225 433 562 587

17 Kunikera 871 491 450 58 250 359 18 13 153 61 85 271 825 928

18 Hoshall i 270 125 127 43 54 47 1 3 88 32 274 348 455 524

19 Muddaballi 655 323 325 38 215 255 9 4 106 26 90 165 478 739

20 Hyati 623 272 411 24 105 133 0 0 107 115 7 4 534 874

21 Mell ikeri 37 8 27 2 4 3 0 0 6 3 83 114 117 125

22 Lachankera 894 788 123 20 636 725 5 10 130 33 81 117 700 702

23 Chikboganhal 428 328 180 54 62 209 26 18 160 47 4 6 336 386



Page 238 of 262

S.

n.

Name of the

village

Total main

workers

Cultivator

s Agril lab

Hh

industry

Other

workers

Marginal

worker Non workers

M F M F M F M F M F M F M F

24 Karkihalli 629 588 379 376 152 184 7 1 91 27 76 70 516 549

25 Tawargera 318 333 146 24 116 296 6 0 50 13 38 37 242 268

26 Lebgera 543 488 311 194 52 252 7 1 173 41 9 36 449 480

27 Sangapur 75 10 35 3 1 1 0 0 39 6 63 103 92 79

28 Bhimanur 318 222 71 15 61 150 1 3 185 54 46 94 257 299

29 Halahalli 319 201 157 77 64 64 39 51 59 9 160 215 338 391

30 Bevinhalli 605 312 160 96 38 22 6 2 401 192 61 88 507 742

31 Hirekhasankan

di 112 66 23 11 40 44 4 0 45 11 366 435 419 406

Total 20053 11261 5233 1824 3639 5522 582 348 10599 3567 2645 3319 17876 24340



Page 239 of 262

Advantages to steel plants

i) Assurance of a reliable source of supply of spares and consumables;

ii) Supply on short-delivery schedules enabling maintenance of lower inventory;

iii) Saving foreign exchange through import substitution;

iv) Lower freight element in comparison to materials supplied by firm located far away;

v) Better service facilities

Advantages to small scale units

i) Availability of ready market;

ii) Availability of raw material source for steel/by-product consuming industries;

iii) Getting price preference over distant suppliers;

Availability of facilities from government;

Availability of infrastructure support from the steel plant

Proper utilization of these mutual advantages is expected to play a catalytic role in the

development of the region where the present project is proposed to be implemented.

The small scale industries that are likely to come in the vicinity of the steel plant can be

grouped into three - spares, metal based and chemical based. These will be

complemented by the service units.

The proposed project is expected to serve as center of significant small-scale industrial

economy around it complemented by the services sector. This is expected to play a major

role in the future economic and social development of this area.

7.3.5 Conclusions

On the basis of the overall results of the present impact assessment the following

conclusions are drawn:

The project is not going to cause significant damage to the existing agricultural

situation. Instead, it is likely to provide the farmers with supplementary income.

The project has very strong positive employment and income effects.

There is a great possibility of industrialization in the vicinity of the proposed steel plants.

This is likely to bring dramatic changes by transforming this backward area into an



Page 240 of 262

industrially developed one.

The project has good impact on health situation / status of the people

AISL shall contribute towards huge social development in the area through its CSR

providing benefits to a large number of stakeholders.

Overall peoples’ perception on the steel project is a mix of advantages and

disadvantages. On one hand, they expect job opportunities, market etc. as advantages

and on the other hand they are worried about the damage to agriculture.

7.3.6 Corporate Social Responsibility

Corporate Social Responsibility (CSR), is a form of corporate self-regulation integrated

into a business model. CSR refers to strategies of corporations or firms to conduct their

business in a way that is ethical, society friendly and beneficial to community in terms of

development. CSR is the deliberate inclusion of public interest into corporate decision-

making, and the honoring of a triple bottom line: People, Planet, and Profit.

Community Development (CD) refers to initiatives undertaken by community with

partnership with external organizations or corporation to empower individuals and

groups of people by providing these groups with the skills they need to effect change in

their own communities. These skills are often concentrated around making use of local

resources and building political power through the formation of large social groups

working for a common agenda.

The role of CSR in Community Development is any direct and indirect benefits received

by the community as results of social commitment of corporations to the overall

community and social system. The common roles of CSR in Community Development

are as follows:

To share the negative consequences as a result of industrialization.

Closer ties between corporations and community.

Helping to get local talents as an attractive employer for potential candidates.

Community development activities (including that for its employees) are very important

aspects for any organization like AISL. AISL has planned a large number of social

development activities under its CSR in the following areas:



Page 241 of 262

Women empowerment

Vocational training

Health

Environment

Infrastructure development

Sports

Art, culture and heritage

7.4 PUBLIC CONSULTATION

Socio-economic survey was carried out covering all the villages / towns of the study area

to record awareness, opinion, apprehensions, quality of life and expectations of the local

people about the proposed steel plant. The opinion of local people about the steel plant

was obtained through socio-economy survey of the villages in the study area.

The survey has been conducted through specially designed questionnaire covering

every aspect of the present study. In addition to the field data, secondary data /

information collected, compiled and published by different Governmental agencies /

departments were also collected and utilized appropriately.

For selection of respondents from the study area, Two Stage Random Sampling has

been adopted. In the first stage, villages are selected and in the second stage,

households/ respondents are selected. From each selected village, the respondents are

selected randomly to account intra-village variability among the respondents for the

character under study. As the variability of the characters under in each strata study

does not vary widely among the households, a smaller sample size is expected to

represent the population.

Peoples' perception regarding the project is a very important factor because it is the

people on whom the major part of the impact will fall. To this end, an opinion poll was

conducted as a part of field survey. With a view to cover the people’s perception in the

study area, an effort was made to collect the detailed information on this aspect during

the field survey. People of the area are mostly aware of the activities of the project,

specifically, the developmental ones. They are also quite aware of the it’s likely

advantages and disadvantages.

Conclusions



Page 242 of 262

On the basis of the overall results of the present impact assessment the following

conclusions are drawn:

Overall peoples’ perception on the project is good. However, few people have opinions,

which are not based on scientific / technical backing. However, based on the extensive

mitigation measures being adopted in the proposed steel project, there will be more

advantages. Proceeding of Public hearing is attached.

7.5 Corporate Environmental Responsibility:

An amount of 45 Cr. (0.25% of project cost) has been earmarked for Corporate Environmental Responsibility based on public hearing issues. The details of CER proposed are as follows:

Sl. No

Enterprise Social Commitment Activities

Yr1 Yr2 Yr3 Yr4 Yr5 Total (Rs. In Crs)

1 Health and Sanitation Facility 0.75 0.75 0.75 0.75 0.75 3.75

2 Education Facility 0.75 0.75 0.75 0.75 0.75 3.75

3 Public Infrastructure Development

2.75 2.75 2.75 2.75 2.75 13.75

4 Afforestation programs 0.5 0.5 0.5 0.5 0.5 2.5

5 Community Welfare/ development Activities

3.0 3.0 3.0 3.0 3.0 15.0

6 Community Soil and Water Conservation

0..75 0..75 0..75 0..75 0..75 3.75

7 Community Capacity Building including skills training

0.5 0.5 0.5 0.5 0.5 2.5

Total 9.0 9.0 9.0 9.0 9.0 45.0



Page 243 of 262

CHAPTER-8.0: PROJECT BENEFITS

8.0 INTRODUCTION

The growth of the steel industry significantly contributes to economic growth of any

country as it generates employment both directly and indirectly, also due to development

of downstream industries. Peripheral development of that area takes place and due to

more influx of money through the area, overall importance of the area increases and

overall infrastructure improves leads to further development of the area.

8.1 EMPLOYMENT POTENTIAL

Skilled and Semi-skilled

Skilled and Semi-skilled employment potential in terms of indirect employment of the

area will be non-marginal and will usually remain widespread across a long region. As

the proposed project takes place indirect employment is likely to grow further. The

project is expected to generate substantial indirect employment in other sectors such as

metal-based industries, small rolling units, scrap dealing units, service units etc. 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 of the

area.

Un-skilled

Unemployment for un-skilled workers is quite common in the study area. The proposed

project has employment generation potential by way of recruiting local people directly for

different activities of the project, specifically at the construction phase. It is expected that

substantial portion of the investment in this project will trickle down to the local people in

the form of employment and income generation activities.

8.2 OTHER TANGIBLE BENEFITS

Education

The local peoples’ interest towards education will increase due to the expectation of

getting jobs, especially from non-agricultural sources such as the industries in the

area.



Page 244 of 262

The proposed project is expected to increase such aspirations by bringing

opportunities of some direct & indirect employment for the local people.

The general awareness towards the importance of education is expected to increase

as a result of the proposed project.

The project will have positive impact on the level of education of the people of the

study area.

Industrialization Around the Project

Integrated Steel Plants by nature serve as the nuclei for development of small-scale

industries in the areas around them. These small-scale units usually have input-output

linkages with the steel plants. The demand for spares, assemblies and sub-assemblies by

steel plants are generally met through small-scale units located nearby. The proposed

project is likely to accelerate such industrialization through “Bubble Effects” in the study

area. It is to note that the small-scale units are usually labor-intensive and high-priority

industries from social point of view.

The proposed project is expected to serve as centre of significant small-scale industrial

economy around it complemented by the services sector. This is expected to play a major

role in the future economic and social development of this area.

Demand Pattern

The socio-economic survey indicates that the most people spend major portion of their

disposable income on food items. However, the people are heavily influenced by the

changing demand pattern of fast-growing Indian consumer society.

Consumption Behavior

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.

Revenue to Govt.

The project will contribute huge amount of money to Government in terms of taxes which

will be utilized for various social infrastructure developments.



Page 245 of 262

CHAPTER-9: ENVIRONMENTAL MANAGEMENT PLAN (EMP)

9.1 ENVIRONMENTAL MANAGEMENT PLAN (EMP): ADMINISTRATIVE ASPECTS

9.2 ORGANIZATION POLICY

The Aaress Integrated Steel Limited (AISL) recognizes the importance of Environmental

Management Plan (EMP) and it has been made the thrust area by management.

Therefore, the EIA report has envisaged all those activities, which are having pollution

potential. The necessary steps to control pollution in the proposed plant technically and

administratively and respond to impacts in the peripheral areas have been fully taken

care. It shall adopt a two-pronged strategy to abate pollution, as follows:

Installation of new state of art pollution control equipment at the design stage

itself.

By developing a very strong monitoring/analysis and inspection setup for

compliance.

The above objective has been intended to be achieved through the following:

a. Using automation & Computer control to have improvement on technology and

on working condition,

b. Use of appropriate quality of raw materials

c. Pollution Monitoring and Control,

d. Implementation of occupational health set up including regular medical

monitoring of employees,

e. A well-defined safety management system,

f. Preparation of Emergency/Disaster Management Plan and a properly trained

group to meet the emergency situations,

g. Green belt development inside the plant surrounding boundary wall.

h. Creating awareness in employees and public including student population

towards environmental preservation,

i. R & D activities in regard to specific pollution problems.

Project proponent has given maximum importance for adopting latest technologies for

keeping the pollution to minimum levels. A separate Environment Management

Department will be set up with an Environmental Laboratory with latest monitoring

instruments.



Page 246 of 262

9.3 IMPLEMENTATION OF MITIGATIVE MEASURES

Mitigative measures for air, water & noise pollution control, solid /hazardous waste

management have been envisaged in the proposed project. Various proposed mitigation

measures are given in chapter-4 (Impact & mitigation measures during operation phase).

Environmental mitigation measures are also a part of equipment and will be

commissioned along with the main equipment. Also, critical emission parameters have

been covered under the performance guarantee clause so that to ensure compliance.

9.4 ORGANISATION STRUCTURE

9.4.1 Administrative Set Up

A senior officer, of the rank of Dy. General Manager (DGM) will be the head of the EMD.

In his day to day work he is assisted by two Sr. Managers. DGM (EMD) shall reports to

the Executive Director (ED)/ Director (In charge). The organizational chart of EMD

(proposed setup) is given in Fig. 9.1. A laboratory has also been proposed to carry out

the environmental monitoring and surveillance programme of the plant.



Page 247 of 262

SR. ENVIRONMENT

SCIENTIST-ENV.LAB

Fig. 9.1: Organization Chart (Proposed) of Environment Management Department

9.4.2 Laboratory Set Up

A well-equipped state of art environmental laboratory will be set up inside the plant

premises. The personnel deployed in the laboratory will be given adequate training to

carry out necessary environmental monitoring as well as analysis of environmental

samples. The requirement of equipment for carrying out environmental monitoring and

frequency of the use of different equipment (as required for the environmental

requirements of proposed plant) are given in Table 9.1.

DGM (EMD)

SR. MANAGER SR.MANAGER/AGM (SE&FS)

MANAGER DY. MANAGER

JR. MANAGER JR. MANAGER

TECHNICIAN

DIRECTOR & CEO

TECHNICIAN

SR.ENVIRONMENT

SCIENTIST-ENV.

LAB

ANALYTICAL

CHEMIST - 4



Page 248 of 262

Table 9.1: Monitoring / Analytical Equipment / Usage for proposed plant

SN. Monitoring Equipment Parameter /

Function

Frequency Ambient

air

Fugitive

Emission

Stack Gas

Source

Emission Equipment Nos

Required

Air / Stack / Noise Monitoring

1. Respirable Dust

Samplers (RDS)

8 SO2, NOX, O3

NH3, As, Ni &

Benzo-a-pyrine

(BaP) -

sampling

24 hr

continuous;

Once per month

Yes -

2. PM2.5 & PM10 Sampler 4 PM2.5 & PM10

24 hr

continuous;

Once per month

Yes

-

3. Stack Monitoring Kit

(manual)

2 PM, SO2, NOX All stack Once

per month

No Yes

4. On line stack monitoring

along with accessories

for monitoring SO2, NOx,

CO2, CO & PM

All major

stack

Particulate

Matter, SO2,

NOx, CO2 & CO

Continuous No Yes

5. On Line AAQ Monitoring

Station

4 PM10, PM2.5,

SO2, NOX

Continuous Yes No

6. Flue Gas Analyzer 1 O2%

CO%

SO2 mg/m3

NOX mg/m3

NO mg/m3

CXHY PPM

Ambient temp

Once per month

for coke oven

battery stacks

No Yes

7. Sound Level Meter 1 Noise Level As and when

required

- -

8. CO Analyser (NDIR) 1 CO Once per month Yes -

9. Gas Chromatograph 1 Benzene (C6H6) Once per month Yes -

10. High Pressure Liquid

Chromatograph (HPLC)

1 Benzo-a-pyrene

(BaP) –

particulate

phase only

Once per month Yes -

Meteorological Monitoring

11. Automatic Weather

Monitoring Station

1 Meteorological

parameters

Continuous - -

Water Monitoring & Chemical Analysis



Page 249 of 262


Function

Frequency Ambient

air

Fugitive

Emission

Stack Gas

Source


Required

12. Ion Analyzer with auto-

titrate

1 NH3, CN, F Daily - -

13. Hot Air Oven 1 Moisture

content & drying

of samples

glassware

Regularly - -

14. Hot Plate 2 O&G Iron &

various purpose

like boiling &

digestion of

sample

Regularly - -

15. Muffle Furnace 1 Digestion at

higher temp, up

to 1000°C

As and when

required

- -

16. BOD Incubator 2 BOD Twice in a week - -

17. BOD Apparatus, 1 set of 6 BOD Twice in a week - -

18. DO Meter 1 BOD As and when

required

- -

19. Spectrophotometer with

COD Digestion

Assembly

1 COD,

Phenol

NO3 – N

PO4 - P

Daily - -

20. pH meter 2 pH Daily - -

21. Conductivity Meter 1 TDS Daily

22. AAS along with Graphite

furnace, Hydride

Generator and Cold

Vapour Technique

1 Heavy metals in

water & As & Ni

analysis in

ambient air.

As and when

required

- -

23. Digital Micro-Balance 1 Weighing Daily - -

24. Digital Top Load

Balance (Range 1 to

500g)

1 Weighing Daily - -

25. Filtration Apparatus 2 SS / MLSS Daily - -

26. Heating mental 2 Distillation Daily - -

27. Refrigerator 1 Preservation of

chemicals and

samples

Regularly - -

28. Fuming Chamber 1 For exhaust As and when - -



Page 250 of 262


Function

Frequency Ambient

air

Fugitive

Emission

Stack Gas

Source


Required

required

29. Water Bath 1 Evaporation of

sample

As when

required

- -

30. Vacuum pump 1 Hardness

alkalinity etc.

As and when

required

- -

31. Turbidity Meter 1 Turbidity As and when

required

- -

32. Filter Papers,

Glassware, Plastic

wares, Chemicals

In Lot

9.4.3 Functioning

Environmental monitoring programme and its 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 plant’s operations.

EMD will functioning in the plant to look after all environmental aspects, carry out day to

day environmental monitoring / inspection requirements and maintain records. Part of

the environmental monitoring programme is carried out through external agencies on a

part time basis. However, casual laborer etc. is employed for plantation, drain cleaning

etc as and when required.

The EMD carries out complete Air Monitoring, Noise Level Monitoring, Special

monitoring on water and air, effluent, solid waste management etc. Safety management

& Occupational health aspects will be dealt by Safety Engineering & Fire Services /

Factory Medical Officer (FMO). Green belt development aspects will be dealt by

horticulture department. Community welfare & peripheral development aspects will be

dealt by Personnel Department. The officers of EMD shall frequently analyse the data

and periodically assess the progress of the EMP.



Page 251 of 262

9.5 IMPLEMENTATION ARRANGEMENT

9.5.1 Institutional Implementation Arrangements

The proposed plant management will be responsible for implementation of all the

mitigation and management measures suggested in Environmental Monitoring

Programme. In addition, higher Management will also monitor the smooth

implementation of Environment Management Plan. The in-charge of EMD (Dy. General

Manager) will report all the environmental matters to higher management as per the

reporting schedule on prescribed formats. The higher management will supervise the

reported activity from time to time for smooth implementation of Environmental Mitigation

and Management measures and will take necessary actions, if required.

For successful implementation of the environmental management plan other agencies of

the State may also be involved, if required (for regulatory requirement or technical

support). The coordinating agencies, which may be involved for specific environmental

related activities, are given in Table 9.2.

Table 9.2: List of Coordinating Agencies, which may be involved for specific

Environmental Activities

State Level Agency SFD KPCB

Chairman

District Level DFO D.E.E.

Project Area: Plantation Programme

Study Area: Air, noise, water quality, waste water

discharge quality monitoring.

Project Area: Stack monitoring, work-zone air, work-

zone noise, effluents from outlet of effluent treatment

plants, fugitive emissions

Project Area: Solid / Hazardous Waste Utilization &

Dumping

Index:

SFD – State Forest Department

KPCB – Karnataka Pollution Control Board

DOH – Department of Health

DFO – District Forest Officer

DEE – District Environmental Engineer



Page 252 of 262

9.5.2 Co-ordination with Other Departments

The Environment Management Department (EMD) also co-ordinates with other

departments like Occupational Health, Safety Management, Project Engineering,

Horticulture, CSR, Town administration, Water Supply Department etc. and also do the

liaison work with external agencies like State & Central Pollution Control Boards.

9.5.3 Interaction with State Pollution Control Board /CPCB / MoEF&CC

EMD shall be in regular touch with KSPCB and shall send them monthly progress

reports in the prescribed format, as per the prevailing practice. Any new regulations

considered by State/Central Pollution Control Board for the Industry shall be taken care

of by EMD of the plant. Also, half yearly compliance reports will be sent to MoEF&CC as

per the guidelines in the prescribed format.

9.5.4 Training

The EMD, who would be responsible for the implementation of the EMP, needs to be

trained on the effective implementation of the environmental issues. To ensure the

success of the implementation set up proposed, there is a high requirement of training

and skill up-gradation. For the proposed project, training facilities will be developed for

environmental control. For proper implementation of the EMP, the officials responsible

for EMP implementation will be trained accordingly.

To achieve the overall objective of pollution control it is essential not only to provide

latest pollution control and monitoring systems but also to provide trained man power

resources to operate and maintain the same. So far, the practice with many plants is to

utilize the plant operations and maintenance crew for operation of systems. This has

shown adverse results due to lack of specialized knowledge in addition to priority

selection. Therefore, apart from the EMD, specific training will be provided to personnel

handling the operation and maintenance of different pollution control equipment. In-plant

training facilities will be developed for environmental control. Specialized courses at

various Research / Educational institutes will be organized.

The training will be given to employees to cover the following fields:

Awareness of pollution control and environmental protection to all.

Operation and maintenance of specialized pollution control equipment.

Field monitoring, maintenance and calibration of pollution monitoring instruments.

Laboratory testing of pollutants.



Page 253 of 262

Repair of pollution monitoring instruments.

Occupational health/safety.

Afforestation / plantation and post care of plants.

Knowledge of norms, regulations and procedures.

Risk assessment and Disaster Management.

9.6 ENVIRONMENTAL AUDITING

The proposed project will be audited by third party after commissioning in phases. This

will help in identifying any non-compliance through structured internal /external audits in

the area of environment and occupational safety & health areas and to take corrective

action.

9.7 WATER AND ENERGY CONSERVATION MEASURES

Rain water harvesting measures will be implemented for the proposed project to reuse

the rain water or to recharge the ground water as part of water conservation measures.

Proper functioning of the systems provided will be ensured by regular monitoring.

Energy conservation measures as per the design plan will be implemented so as to bring

energy saving and also possible CDM benefits.

9.8 OTHER MEASURES

The following activities will be carried out in a structured way for the benefit of the

surrounding people through close co-ordination with Personnel Department:

Improvement of social infrastructure through CSR activities like school buildings,

drinking water facilities, street lights, roads, sanitary facilities etc.

Community education & training.

Medical welfare.

Sports activities.



Page 254 of 262

CHAPTER-10: SUMMARY AND CONCLUSION

10.0 INTRODUCTION

In the design phase of the project, Environmental Impact Assessment (EIA) has been

carried out to assess the possible impacts of the proposed steel plant of AISL. In the

plant design itself, latest state of art technology has been envisaged so as to achieve the

desired air emissions and noise levels from plant operation. Further, maximum re-use

and re-utilization of generated solid waste and waste water has been envisaged.

Primary and secondary data are used, to assess the environmental impacts of proposed

steel plant. The potential environmental impacts are assessed in a comprehensive

manner. All the potential environmental impacts associated with different phases of the

implementation are assessed and impact predicted.

The EIA report has thoroughly assessed all the potential environmental impacts

associated with the project. The environmental impacts identified by the study are

manageable. The implementation of environmental mitigation measures recommended

in the report will bring down the anticipated impacts to minimum.

Site specific and practically suitable mitigation measures are recommended to mitigate

the impacts. Further, a suitable monitoring plan has been designed to monitor the

effectiveness of envisaged mitigation measures during the operation phase.

The introduction of state of art technology (including the technological mitigation

measures) during the design phase has limited the environmental impacts related with

the proposed project. The implementation and monitoring of effectiveness of the

environmental mitigation measures during the operation phase will be assigned to the

Environmental Management Department (EMD). An EMD, comprising of senior

management level officers will periodically assess and monitor the implementation of

mitigation measures, and will tackle the management bottle necks of implementation of

mitigation measures and environmental monitoring programme.

The project is categorized as Category “A” project as per Environmental Impact

Assessment (EIA) Notification: SO 1533, of 14-09-2006, which necessitates obtaining

the Environmental Clearance from MOEF&CC Expert Appraisal Committee (EAC).



Page 255 of 262

10.1 Need for the Project

In view of growing demand for steel products such as special alloy steel and HRC and

CR products in the country, AISL propose to install the integrated steel plant at Village

Halavarthi, District Koppal in Karnataka.

11. Plant Capacity, Cost and Implementation Schedule

AISL intends to establish the Iron and steel manufacturing capacity of 3.5 Mtpa along

with 295 MW power from waste gases and fuels available and produce a wide variety of

steel products to meet the requirements of the customers. The facilities will be built

within the company acquired land. With this, AISL will be in a stronger position to supply

a wide variety of steel products to the consumers in South and Central India. The

product mix that will be offered by AISL will include flat products, long products, wire

rods, re bars, besides the semis like billets and blooms.

It is envisaged to complete the installation and commissioning of the plant equipment for

start-up and production in 30 months for Phase-1 facilities. It is also envisaged to

complete the installation and commissioning of the plant equipment for start-up and

production in 36 months for Phase-2 facilities. The additional time is envisaged on

account of larger % of imported components at phase-2 and relative difficulty in

construction due to presence of an operating plant at the site. The time schedule is from

ZERO date which in this case is the date of placement of order for the major plant

equipment.

Capital cost envisaged for installation of the steel Plant has been computed as follows:

Phase-1: Rs. 5,325 Crores.

Phase-2: Rs. 12,654 Crores

Total Rs. 17,979 Crores.

10.3 Project Site and its Environs

The GPS coordinate as observed for the plant centre is given below: Longitude: 760 13’

58’’ E Latitude: 150 20’ 52’’ N, near Koppal district in the state of Karnataka. The site is at

a distance of 5 km WNW from Koppal, 30 km from Hospet and about 320 km from

Bangaluru by road. Nearest railway station to the steel plant is Ginigera about 3.5 km.

Broad gauge railway lines between Guntakal and Hubli are passing through this station.

The western port of Goa is 320 km.

The proposed plant site has the following advantages associated with it:

Road linkage: The site is very close to the National highway NH-63 connections

to the other main towns & cities of the country.



Page 256 of 262

Power: The propose plant shall have its own CPP of 295 MW, however the plant

shall be connected to Karnataka State Electricity Board for its power supply.

Water: The Company shall drawl the water from Tungbhadra reservoir for its

need during the production.

The nearest national airport is Bengaluru at about 300 km from plant.

10.4 Site Selection

The proposed plant site is selected based on the economy of scale and availability of

all utility at unit which could be shared.

10.5 Salient Features of the Project

The salient key success factors of the proposed project are:

a) AISL has good access to iron pellets from nearby group industry MSPL.

b) All major raw materials are available in the state itself, within 150 km of the plant.

c) The plant is well connected by road to market.

d) There shall be requirement of trained man power, which is available nearby.

e) The national Steel policy supports for setting up of new steel manufacturing unit in

the region.

10.6 Land

AISL shall be located in the land allocated by Karnataka Government near group

company MSPL pellet Plant. The 900acres of land is in possession of AISL and rest

are under advanced stage of processing.

10.7 Water

Source of water

The source of water for the plant unit will be from Tungbhadra Reservoir site. The total

requirement of fresh water from Tungbhadra water source to meet equipment cooling

and drinking needs is estimated to be 4170m3/h.

10.8 Environmental Impact Assessment Study

10.8.1 Baseline Status

As part of Environmental Impact Assessment study, baseline environmental monitoring

was carried out for summer – 2016 season, covering the months of March 1, 2016 to

May 29, 2016.



Page 257 of 262

Meteorology

It has observed that about 6.9 % of total time, the wind was calm i.e. the speed was less

than 1 km/h. The predominant wind directions were from E (12.1%), from SW (10.7%).

Average wind speed was 5.9 km/h during monitoring period and most of the time wind

speed was between 1 to 10 km/hr.

Air Environment

Ambient air quality of the study area has been assessed through a network of 9 ambient

air quality locations in study area.

Overall Ambient Air Quality of the plant area and its buffer zone is good and there are no

any abnormal values recorded. Concentrations of all monitored parameters are within

stipulated standards from MoEF&CC AAQ Standards. Some higher values of particulate

matters are result of heavy traffic movement over highways.NAAQ standards prescribed

for Residential, Rural & Other Areas.

Noise Environment

It has found that in the proposed plant buffer zone, noise levels are in the range of 38.0

– 55.5 dB(A) at all eight stations. Maximum levels of noise have recorded in day hours

which are natural as our most of activities have done in day hours.

Water Environment

The makeup water requirement for AISL complex shall be 4170m3/h. The water

requirement of project shall be sourced from Tungbhadra Reservoir.

Soil Environment

Five no of soil samples were collected to assess the soil quality in the 10 km study area

of plant site and it revealed soil of medium fertile quality.

Biological Environment

A study was undertaken to list out Flora & Fauna in the study area. From the study it

was observed that there are no endangered, endemic or threatened species in the

study area.

ENVIRONMENTAL IMPACTS ASSESSMENT AND MANAGEMENT PLAN

The proposed integrated steel plant may influence the environment in two distinct

phases namely:

During construction phase which is temporary and of short term



Page 258 of 262

During operation phase which may have long term effects

Construction Phase

The impacts during construction phase are for the short term. Hence the construction

impacts are expected to be minimal and very short terms.

Operation Phase

Air Environment

To prevent major impact on air environment AISL will install all the required pollution

control equipment with adequate capacity to meet the norms stipulated by the KSPCB

and CPCB.

Fixed and mobile water sprinkling systems shall be deployed and will be strengthened

during operation phase in internal roads for control of fugitive dust. AISL shall adhere to

the guidelines issued by CPCB.

Noise Pollution Control Measures

The major noise generating equipment will be provided with acoustic enclosures and

would be located in a closed building which considerably reduces the noise outside.

The proposed greenbelt development plan will further reduce the noise levels. With

encasement of the noise generating sources and greenbelt, AISL will comply with

ambient noise standards. All operations and maintenance personnel working near noise

prone areas would be provided with earmuffs & earplugs.

Water Environment and Control Measures

Water Consumption

The water requirement of the project is estimated to be 4170m3/h. This requirement will

be met from surface water sources.

Wastewater Generation

There will be small quantity of waste water generation from plant operation, however it

will be treated and recycled back in operations. There will not be any waste water

discharge outside the plant boundary. The only fresh makeup water shall be added to

makeup water system to compensate the water lost during evaporation.



Page 259 of 262

Domestic Wastewater Treatment & Disposal

Wastewater arising from sanitary and drinking water use will be treated in septic tank

and soak pit.

Land Environment and Control Measures

The project shall be located within the 1917.69 acres of land. Therefore, the overall

impact on land environment will be insignificant.

Solid Waste Generation

Major solid wastes will include ESP dust, BF and SMS slag, coal tar and ash from power

plant operation and the same is utilized as per the plan indicated in chapter-4.

Social Welfare Measures

Socio Economic Status in the study area is found to be moderate with respect to

livelihood, amenities etc. The management of AISL shall provide employment to 3811.

persons.

Drinking water supply is available in all the villages in the study area. In most of the

villages, water supply is through well water, Hand pumps have also been provided

wherever provision for tap water or well water is not available.

Tar roads connect the villages in the study area. The plant site is connected to the NH-

63 on Hospet-Koppal road. Locals in this area use bicycles, two-wheelers and auto

rickshaws for internal transportation. The site is accessible by road from the National

Highway.

Nearest airport is Bengaluru airport, the closest operating airport to the site.

Occupational Health Centre

AISL shall have Occupational Health Centre, which shall be manned round the clock by

a shift male nurse, house keeper and ambulance driver.

Occupational Health centre shall be provided with consultation room for the doctor, one

reception cum waiting area, one treatment room with two beds.

Statutory Health Check Up shall be conducted annually for employees and contract

workers working in core areas.



Page 260 of 262

Budget for implementation of Environmental Management Plan:

AISL will incur an amount of Rs 809 Cr for implementation of Environmental

Management Plan along with CSR activities.

Post Project Monitoring Plan

Environmental monitoring will be taken up to as per KSPCB/CPCB guidelines.

Conclusion

AISL shall comply with all the standards stipulated by various statutory bodies for

maintaining environmental quality within the norms.



Page 261 of 262

CHAPTER-11: DISCLOSURE OF CONSULTANTS ENGAGED

PECS established and NABET accredited Environmental Consultant and Engineers based in

Nagpur and working since last 27 years. We are having tie up with well-equipped laboratory for

field studies as well as for testing and monitoring of Air, Water, Noise, Soil and other related

activities of Environment of Mines and Industries.

PECS is having a qualified and experience staff comprising of trained professionals in their

respective fields. PECS is backed by the services of retired scientists form National

Environmental Engineering Research Institute (NEERI) and retired Engineers of Thermal Power

Stations and Coal India Ltd. A team of experience Geologists is with us for various surveys.

PECS is also having a computers and software facility for modeling purposes.

PECS is specialized in Environmental Services as mentioned below:-

o Environmental Impact Assessment (EIA)

o Environmental Risk Analysis and Assessment.

o Monitoring of Air, Water, Noise and Soil.

o Preparation of Documents for Clearance of Forest Land.

o Environmental Management Plan.

o Environment Audit Statement.

o Disaster Management Plan.

o Study and Treatment of Industrial Effluents.

o Design, Engineering and Commissioning of Effluent Treatment Plant,

Sewage Treatment Plant and Water Treatment Plant.

o Designing, Engineering and Commissioning of Air Pollution Control

Devices.

o Dust Suppression.

o Dealing with Solid Waste Management.

o Planning on Waste Recycle, Reuse and Control



Page 262 of 262

o Follow up with Explosive Department and IBM, HQ, Nagpur.

o Preparation of “ON SITE” and “OFF SITE” emergency plans and health

survey.

o Geo Hydrological, Ground and Surface Water Survey and Transit Survey.

o Rain water harvesting including design and execution.

o Clearing of Project form Ministry of Environment and Forest, New Delhi

(MOEF),) and State Pollution Control Board (SPCB)/SEIAA.

PECS has completed more than 50 projects in EIA sector successfully since its

incorporation.

PECS has been accredited by NABET/QCI vide letter no. QCI/NABET/EIA/1720

/RA0101 dated September 07, 2018.