Bhushan Steels or PDF

BHUSHAN STEEL AND STRIP LIMITED
EIA / EMP FOR 3.1 MTPY INTEGRATED STEEL PLANT

AT
AT MERAMANDALI, DIST. DENKANAL
(ORISSA)
MECON LIMITED
RANCHI – 834 002
BHUSHAN STEEL AND STRIP LIMITED
EIA / EMP FOR 3.1 MTPY INTEGRATED STEEL PLANT

AT
AT MERAMANDALI, DIST. DENKANAL
(ORISSA)
MECON LIMITED
RANCHI – 834 002
11.S2.Q6BK September’ 2007

Bhushan Steel & Strips Limited
EIA/ EMP Study for Modification-cum-Expansion
of Integrated Steel Plant from1.5 to 3.1 Mtpy,
at Meramandali, Dhenkanal, (Orissa)
CONTENTS
Sl. Description Page No.

No.
1. INTRODUCTION 1 – 1 to 1 – 8
2. PROJECT DESCRIPTION & ANNEXURES 2 – 1 to 2 – 31

2 sheets
3. PRESENT ENVIRONMENTAL STATUS & ANNEXURES 3 – 1 to 3 – 22

7 sheets
4. ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION 4 – 1 to 4 – 28

MEASURES
5. ENVIRONMENTAL MANAGEMENT PLAN (EMP) 5 – 1 to 5 – 30
6. EMP IMPLEMENTATION AND MONITORING. 6 – 1 to 6 – 8
7. DISASTER MANAGEMENT PLAN (DMP) 7 – 1 to 7 – 24
8. SOCIO-ECONOMIC IMPACT ASSESSMENT 8 – 1 to 8 – 15
9. ORGANISATION AND MANPOWER 9 – 1 to 9-4
10. ENVIRONMENTAL COST & PROJECT BENEFITS 10 – 1to 10 - 4
11. CONSULTANT CREDENTIALS 11-1 to 11-4
© 2007 MECON Limited. All rights reserved (i)

LIST OF FIGURES
Fig. Description Chapter No.

No.
2-1 PROCESS FLOW DIAGRAM 2
3-1 WIND ROSE DIAGRAM (3 SHEETS) 3
4-1 FLOW CHART OF IRON MAKING PROCESS 4
4-2 ISOPLETH OF SPM, SO2 & NOx 4
LIST OF DRAWINGS
Sl. Description Drawing No.
No.
1. GENERAL LAYOUT OF PLANT DRG.No.MEC/11/14/Q6AT/DE/GN/50/0001
2. WATER BALANCE DIAGRAM DRG.No.BSSL/0/ISP/7-1 REV.-1
3. THE MATERIAL FLOW SHEET DRG.No.MEC/Q671/11/18/01
4. LOCATOR MAP SHOWING Drg. No. MEC/Q6BK/11/S2/01
MONITORING STATIONS
© 2007 MECON Limited. All rights reserved (ii)

1.0 INTRODUCTION
1.1 General
The Indian steel industry has recorded remarkable performance in recent years.
The industry is now capable of producing high quality materials to stringent
international specification for high-end applications. 21st century is widely
perceived to be the century of Asia and India is looked upon as one of the
economies with most promising prospects. This possesses a formidable
challenge as well as an opportunity to the Indian corporate sector. Bhushan Steel
& Strips Limited (BSSL) as the leading steel maker is in position to fulfill its role in
the nation’s quest for higher growth and development in the new millennium.
BSSL is the dominant player in steel producer in the country having its plants at
Shahibabad (UP) and Khapoli in Maharastra state etc. The national steel policy
has set a target of 60 million tonnes (MT) of steel production by 2010 and to
increase it to a level of 100 million tonnes by 2018. The major steel producers in
India are planning to expand their capacities in the tune with the national steel
policy formulation. BSSL is also not exception to that and therefore intends to
increase the capacity of its Steel Plant at Meramandali, Dhenkanal (Orissa) from
its present capacity of 1.5 MT per annum to 3.1 MT per annum of steel products.
The developments of industrial projects play a key role in the economic growth of
any country. Industrial process is invariably involving the conversion of raw
materials and resources into semi finished and / or finished products. During this
process, residues in the form of wastes will be formed. If the residues are not
recycled/ re-utilised they become waste and have to be discharged into
environment as pollutants. The degree to which the pollutants affect the physical
environment depends upon their quantitative and qualitative characteristics as
well as the receiving media.
© 2007 MECON Limited. All rights reserved 1-1

Iron is perhaps the most important metal to the mankind and its principal alloy,
steel, is widely used for domestic, agricultural, industrial and defense purposes.
Per capita steel consumption is a major indicator of economic status of any
country. The growth of the steel industry significantly contributes to economic
growth as it generates employment both directly and also due to development of
downstream industries.
However, any industrial development process is accompanied by some

environmental problems. Proper planning at the conceptual stages can minimize
many of these problems. Once an industry is commissioned it becomes difficult
and expensive to retrofit pollution control equipment, as such incorporation of the
same at conceptual stage is the best alternative.
Setting up of an industry has both positive and negative impacts on the

environment. The negative impacts include environmental degradation and
adverse socio economic changes. It is the responsibility of scientists and
environmentalists to document the likely impacts so that they can be identified
and attempts are made to minimise the effects due to negative impacts and
maximise benefits due to the positive impacts. In this regards Environmental
Impact Assessment (EIA) and Environmental Management Plan (EMP) has been
considered as one of the most important documents for utilisation by all the
concerned to understand the environmental implications due to the proposed
development activity and take decisions in the best interest of the Environment.
1.2 Purpose of the Report
The purpose of EIA study report is to take stock of the prevailing quality of
environment, to assess the impacts of proposed industrial activity on
environment and to plan appropriate environmental control measures to minimise

adverse impacts and to maximise beneficial impacts. The following major

objectives have been considered:
y Assess the existing status of environment.

y Assess the impacts due to the modification-cum-expansion of project.
y Suggest pollution control and ameliorative measures.
y Prepare an action plan for implementation of suggested ameliorative
measures.
y Suggest a monitoring programme to assess the efficacy of the various
adopted environmental control measures.
y Assess financial considerations for environmental control plans.
In pursuance of Government of India Policy, under ‘The Environment (Protection)

Act 1986’ and Orissa State Pollution Control Board (OSPCB), the proposed
modification-cum-expansion will require clearance from environmental angle.
Bhushan Steel & Strips Limited entrusted MECON LIMITED (MECON) to prepare
an Environmental Impact Assessment and Environmental Management Plan
(EIA/EMP) report for their proposed modification-cum-expansion plant at
Meramandali, Dhenkanal in Orissa. The present report, an EIA/EMP report is
prepared based on monitored data for one season covering three months
(summer season). The present report is prepared in accordance with the
guideline of MOE&F & OSPCB.
For carrying out the Environmental Impact Assessment (EIA) study, the area
falling within 7 km radius of project site at Meramandali area has been
considered for generation of base line data with respect to present air quality,
water quality, noise level, soil quality, ecology, socio-economic and meteorology
etc. The site studies were carried-out during summer season in April, 2006 to
June 2006.

This EIA report has been prepared on the basis of environmental data generated
in and around the existing plant site during the summer season in the month of
April 2006 to June 2006. The data regarding meteorological conditions, air
quality, water quality, noise levels, soil quality, ecology and socio-economic
environment were generated in the study area falling within 7km radius with the
plant site as center.
An in-depth analysis of the baseline environmental data generated by actual field

monitoring and collected from various secondary sources has been carried out
for identifying and predicting the probable environmental impacts due to the
expansion of project. Reasonable assumptions have been made, wherever data
is found lacking. Based on the findings a suitable environmental management
plan has been suggested.
1.3 Project & Project Proponent
Bhushan Steel & Strips Limited (BSSL) is the project proponent. M/s Bhushan
Steel & Strips Limited (BSSL) is a reputed producer in the secondary steel
sector, with consumption of more than a million tonnes of HR steel coils without
themselves producing any HR steel coil. Therefore, depending on the availability
of funds, BSSL can plan to go for an integrated 3.1 Mt/yr HR steel coils plant as
backward integration without the botheration on the marketability of the products.
With the sound financial status of BSSL, the expected growth in consumption of
iron and steel in the country and no problem in marketability of HR coils, as
mentioned above, M/s BSSL have decided to install an integrated HR coils plant
and be in the primary steel sector. Hence, BSSL is contemplating to modify and
expand the existing 1.5 Mtpy integrated steel plant to 3.1 Mtpy level at
Meramandali in Dhenkanal district (Orissa).

1.4 Nature, Size, Location of the Project
The nature of project is ferrous metallurgical industries and fall under the
category of primary metallurgical industry including sponge iron manufacturing
and further processing to secondary metallurgical industry for HR coil product in
flat category.
The size of the project is 3.1 Mtpy of steel product through DR-BF-EAF-Rolling
mill route. M/s Bhushan Steel & Strips Limited (BSSL) is intending to modify the
existing 1.5 Mtpy integrated steel plant to 3.1 Mtpy level at Meramandali in
Dhenkanal (Orissa). This steel plant is based on the Directly Reduced Iron (DRI)
- Electric Arc Furnace (EAF), Blast Furnace –Ladle Furnace & RH-OB -
continuous casting – rolling mill route with waste heat recovery based captive
power plant(CPP).
The site is located between latitude 20°46’41” to 20°49’20” N and longitudes

85°15’22” to 85°16’21” E at Meramandali block of Dhenkanal district of Orissa.
Land measuring about 1664 acres falling under villages Sibpur, Narendrapur,
Itapo, and Asanabani in district Dhenkanal in Orissa had been selected for steel
plant. The plant is situated about 5 km from Meramanadali Railway Stations (on
Angul – Cuttack broad gauze main railway line). The National Highway no. 42
touches northern side of plant. The plant is 18 km from Angul and 42 km from
Dhenkanal. Nearest Railway station is Meramanadali on Eastcoast railway and
nearest port is Paradeep, which is more than 215 km away.
1.5 Project Importance to the Country/Region
The integrated steel plant is being set up with capital outlay of 6330 crores. This
will help the local economy directly as well as indirectly. The project will continue

to contribute to state as well as to national exchequer by way of taxes in the form

of excise duty, custom duty as most of the products are going to be exported.
Therefore project is having great importance to national economy.
In the state the project will generate jobs in the form of direct as well as indirect
employment for local people and local economy will flourish due to income
expenditure in the local market.
1.6 Scope of Study
This report shall contains various information’s on the existing environmental

attributes, including air, water, noise, solid waste, soil quality, ecology and socio-
economic patterns etc. The report evaluates the predicted impact of the
proposed plant activities on the environment. It also cover the various remedial
measures considered by plant management like air pollution control systems,
complete recycling of process cooling water, green belt development plans and
reuse of solid waste and other environmental management system which are
useful for control of environmental degradation due to the proposed steel plant. A
detailed coverage of the emission sources, emission control equipment,
background air quality levels, predicted air quality levels, meteorological
measurements, dispersion model and all other aspects of pollution have been
provided in this report. The draft Draft EIA/EMP has been discussed for the
adequacy and completeness in its the 69th Meeting of the Expert Appraisal
Committee (Industry) held during 4th – 6th July, 2007 for preparation of final
EIA/EMP. The EAC (I) recommended the following additional TORs for inclusion
in the revised EIA/EMP:
1. Point-wise compliance to the conditions stipulated for the existing 1.5 MTPA
plant by the MoEF.

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

• Environmental Management Plan(EMP)

• EMP Implementation and Monitoring.
• Disaster Management Plan(DMP)
• Social Impact Assessment
• Cost considerations and project benefits
• Consultant credentials etc
1.7 Acknowledgment
MECON wishes to place on record its deep appreciation for the trust reposed in
MECON by BHUSAN STEEL & STRIPS LIMITED (BSSL) for the EIA/EMP study
and also for the active interest and the help extended by the concerned officials
of BSSL. The Co-operation extended by the officials of various State and Central
Government agencies is also gratefully acknowledged.

2.0 PROJECT DESCRIPTION
2.1 General
M/s Bhushan Steel & Strips Limited (BSSL) is proposing to modify and expand
1.5 Mtpy integrated steel plant to 3.1 Mtpy level at Meramandali in Dhenkanal
(Orissa). The steel plant is based on the Directly Reduced Iron (DRI) - Electric
Arc Furnace (EAF), Blast Furnace –Ladle Furnace & RH-OB - continuous casting
– rolling mill route with waste heat recovery based captive power plant(CPP).
The land measuring 1664.56 acres had been acquired by Orissa Industrial
Infrastructure Development Corporation (IDCO) and was transferred to Bhushan
Steel & Strips limited to set up integrated steel plant. A detailed report was
prepared earlier for selection of plant site at Meramandali and was the best site
as per the availability of Water, Power, infrastructure facilities and raw materials
particularly coal. Coal is one of the major raw materials for steel and power
generation and is available in Talcher coalfield within 45-50 km of Meramandali
site. This was one of the major factors for deciding this site for the steel plant.
2.2 Type of Project

The proposed project is an expansion–cum-modification of existing 1.5 Mtpy
integrated steel project at Meramandali, Dist Dhenkanal (Orissa). The plant is in
implementation stage and after the detailed analysis and economy of scale has
given impetus for modifying some of the facilities earlier proposed during 1.5
Mtpy stage and adding few other facilities to reach the level of 3.1 Mtpy
integrated steel plant.
2.3 Need for the Project

The steel industry in India is poised for faster growth in the decades ahead as the
industrial and economic development of the country gains pace. Indian Steel

industry is also emphasizing its presence in the global market. The domestic
market growth outlook for finished steel has been estimated and is given below.
Domestic Market Growth Outlook

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

BSSL has initiated several steps as part of their backward integration programme
and this is one such step to establish 3.1 Mtpy integrated steel plant.
2.4 Location (Maps Showing General Location, Specific Location, Project

Boundary, Project Site Layout)
The Plant is located between latitude 20°46’41” to 20°49’20” N and longitudes
85°15’22” to 85°16’21” E at Meramandali block of Dhenkanal district of Orissa.
Land measuring about 1664 acres falling under villages Sibpur, Narendrapur,
Itapo, and Asanabani in district Dhenkanal in Orissa. The locator map showing
general topography and related feature is attached vide drawing no.
MEC/Q6BK/11/S2/01 sheet 1 of 1. The land is situated about 5 km from
Meramandali Railway Stations (on Angul – Cuttack broad gauze main railway
line). The National Highway no. 42 touches northern side of plant site. The plant
site is 18 km from Angul and 42 km from Dhenkanal. Nearest Railway station is
Meramandali on Eastcoast railway and nearest port is Paradeep, which is more
than 215 km away. The project layout is given in drg. No.
MEC/11/14/Q6AT/DE/GN/50/001 sheet 1 of 1 REV.-5.
2.5 Size or Magnitude of Operation

The size of the plant will be 3.1 Mtpy and plant operations shall confine to the
existing plant boundary and will not change the process route of operation as
given in the report.
2.6 Schedule for Approval & Implementation
Project planning
The project envisages expanding existing project upto a 3.1 Mtpy Steel plant at
Meramandali, Orissa by M/s. Bhushan Steel & Strips Limited. The project will
involve the following main technological units:

Coal Washery (2.4 Mtpy)

Sinter Plant ( 1 x 177 m2)
DR Plants (14 x 170,000 tpy)
Blast Furnace ( 1 x 1681 m³)
SMS – I
Induction Furnace (12 x 15t)
Ladle Furnace (4 x 30t)
Billet Caster (2 x 2 strand)
SMS – II (Part)
Electric Arc Furnace (2 x 60t)
VD / VOD Unit (1 x 60t)
Conventional Slab Caster (1 x 1 stand)
SMS – II (Balance)
Electric Arc Furnace (2 x 180t)
Twin Shell CONARC Furnace 145 MVA
RH – OB Unit (1 x 180 t)
Conventional Slab Caster (1 x 1 strand)
Semi – continuous Hot Strip Mill
Pig Casting machine ( 2 x 2000 tpd)
Slag Granulation Plant
Power Plant (33 + 77 + 45MW)
Lime & Dolomite Plant
Oxygen Plant
In addition to the above main technological units, suitable supporting facilities

have also been envisaged like raw material handling facilities, compressed air

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

xvii) Required services and auxiliary facilities

xviii) Matching Raw Materials Preparation Plant (RMPP)
The total plant schedule was expected to be completed by 2005 – 06.
Proposed Modification-Cum-Expansion of Plant
BSSL is now intends to augment their steel production capacity from 1.5 Mtpy to
3.1 Mtpy by suitable modification-cum-expansion in existing units proposed
earlier. These are as follows:
• One blast furnaces of capacity 1681 m3 instead of 1250 m3 earlier proposed

with cast house slag granulation facility,
• 2x2000tpd Pig casting machine
• One sinter plant of capacity 177 m2 instead of 100 m2 earlier proposed,
• Six additional DR kiln of 170000 tpy capacity
• The configuration also changed in SMS and casting facilities
• Three no Walking beam furnaces in the hot strip mill based on BF gas mixed
with LPG/Propane or mixed gas
• Two limited recovery coke oven battery of 0.45 Mtpy each to meet the coke
requirement of steel plant
• Lime and Dolo shaft to meet the flux requirement.
• 2.4 Mtpy coal washery instead of 3.2 Mtpy Coal Washery.
To supplement the auxiliary demands one 950 tpd Oxygen plant and
augmentation of raw material handling facilities is envisaged
The Plant Configuration at 3.1 Mtpy Stage
The ultimate plant facilities after the modification-cum-expansion shall be as

follows:

Table-2.1: The Plant Facilities at 3.1 Mtpy level

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

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

Ore Slab Billets
Plant
COLD PIGS
Hot Strip Mill
Re-heating
HR COILS Furnace
CC BILLETS
PRODUCTION FACILITIES PLANNED IN 3.1 MTPA EXPANSION

The Material Flow Sheet corresponding to the ultimate stage of implementation

of the project is given in the Drg.No.MEC/Q671/11/18/01 sheet 1 of 1 and the
major facilities of the respective production units with their technical parameters
have been detailed in the following table.
Table-2.2: Major plant facilities and their capacities

Sl. Plant facility Capacity
No.
1 Coal washery 2.4Mt
2 Direct reduction plant 14 x 170,000 tpy
3 Iron ore crushing One No. double stage crushing circuit for
DR plant (4,862,000 tpy)
4 Sinter Plant 1 x 177m2
5 Blast furnace 1 x 1681 m3 useful volume
6 Pig casting machine 2 x 2000 t/d
7 Slag granulation plant 415,500 tpy
8 Primary steel making 1 x 180 t CONARC,
2 x 60 t EAF and 12 x 15t IF
9 Secondary refining 1 x 180t LF, 2 x 60t LF and 4 x 30t LF, 1x
60t VD/VOD unit, 1 x 180 t RH-OB
10 Lime and dolo plant (1 x 500 + 1 x 100) t/d lime and 1 x 500t/d
dole
11 Continuous casting 2 x 1 strand slab caster and 2 x 2 –
strand billet casters
12 Captive power plant (1 x 33 + 1 x 77 + 1 x 45) MW
13 Oxygen Plant 1 x 950 TPD
14 Hot Strip mill Conventional hot strip mill with 5-stand
finishing train (2.514 Mtpy HR coils) and

Sl. Plant facility Capacity

No.
provision for 6th & 7th stand in future.
15 Coke Oven Plant 2x0.450 Mtpy Limited recovery type coke
oven Batteries
Based on the envisaged product – mix, considered analyses of the required raw
materials and the facilities envisaged for the proposed project, a process – cum –
material flow has been worked out for the project.
Site and infrastructure

The proposed site for integrated steel plant complex is located at Meramandali,
Dhenkanal district of Orissa, which is about 18 km from Angul, 42km from
Dhenkanal and about 100km north-west of Cuttack city. The selected land for
site measures 1623 acres falling under villages Sibpur, Narendrapur, Itapo and
Asanabani. It lies 125km from capital city, Bhubaneshwar. The South – Eastern
Railway’s line connecting Angul and Cuttack railway station and the National
Highway NH-42 are passing on the north of the plant site. The nearest railway
station is Meramandali, which is about 4km from the plant. The river Brahmani
flows from north-west to south east on the northern side of the plant at a distance
of about 6km.
Power
The power requirement of the plant is about 410 MVA. It is envisaged that the
power for the main plant will be supplied by CPP running in parallel with grid over
a double circuit 220kv transmission line from Meramandali sub-station of
GRIDCO.
© 2007 MECON Limited. All rights reserved 2 - 10

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

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

Sl. Raw Material Size Qty.(tpy) Source

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

Ash content : 27.5%
Moisture content : 10%

For raw coal quality, following quality parameters has been assumed.
Ash Content : 39%
Moisture Content : ~ 9%
Thus total raw coal requirement has been worked out as 2,411,300 tpy catering
to the needs of DR kilns.
Direct reduction plant

The direct reduction (DR) plant will comprise of fourteen rotary kilns of capacity
170,000 tpy each along with related accessories including waste heat power
generating units and related facilities. The production program of the direct
reduction plant, as envisaged is given below:
Product Production, tpy

Sponge iron (DRI) lump (3-18 mm) 1,785,000
Sponge iron fines (-3 mm) 595,000
Technological parameters of each DR kiln and cooler
Diameter of Kiln (ID), m 4.8
Length of kiln, m 80.0
Kiln speed, rpm 0.25 – 0.75
Diameter of cooler (ID), m 3.6
Length of cooler, m 50.0
Production, t/d/kiln (max) 500
Generation of DRI fines (-3mm), % 25
Kiln off gas volume (after ABC) 109,764 (max)
(Nm3/hr) 93,300 (avg)
Working days / year, No. 340

The typical quality of DRI would be as follows.

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

S.No Item Description Unit Value

5 Annual working regime D/y 330
6 No. of working hours/ day H/d 24
7 Gaseous energy / consumption for Mj/t 100
ignition/ton of BF sinter
8 Coke breeze consumption/ton of BF Kg/t of 70
sinter skip
11 Cooler type / bed height Mm Circular cooler
having 26m Dia /
1400mm
12 Temperature of cooled sinter °C Below 100
13 Dust content in exhaust gases at stack Mg/Nm3 Below 50
Coke Oven Battery Complex

BSSL shall set up two-recovery type coke oven battery of 0.425 Mtpy capacities
each. The recovery type coke oven battery complex broadly consists of the
following units:
• Coal preparation Plant

• Coke oven battery
• Coke Handling plant
• By-Product Plant
• Effluent treatment Plant
The coal preparation plant has been envisaged to cater to daily requirement of
coke ovens. The imported coal will be received at port by ship and further
transportation of coal by rail to the plant site. The coal will be unloaded through
wagon tipplers and then stored in the open storage yard.

Each battery consisting of two blocks of 32 ovens each (64 ovens) has been
selected for this project. The major cold dimensions of the ovens will be as
follows:
Sl. No. Description Dimensions

1. Total Length of carbonization chamber 14080 mm
2. Effective length of carbonization chamber 13280 mm
3. Total height of carbonization chamber 4300 mm
4. Effective height of carbonization chamber 4100 mm
5. Average width 500 mm
6. Taper of carbonization chamber 20 mm
7. Central line distance of carbonization chamber 1200 mm
8. Effective volume of carbonization chamber 26.68 m3
9. Nos. of heating flues in heating wall 28
10. Central line distance of vertical flue of 480 mm
combustion chamber
The battery anchorage system will consist of bucks trays, tie rods, springs and
bracing and modern leak-proof oven casting equipment such as flash plates,
door frames, oven doors compatible to meet pollution control norms etc.
Gas off-takes: the system will comprise of ascension pipes, goosenecks,

isolation valves, gas collecting mains, necessary flushing liquor spraying. The
gas collecting mains will be provided on ram side only. Each oven will be
provided with stamp charging of cake.
Under firing system of ovens: the heating system for ovens will be so designed
that the battery can be heated with coke oven gas as well as blast furnaces gas.

The supply of heating gases will be provided through gas mains laid in the cellar
floor on the pusher side and coke side of the battery.
The following oven machines will be provided for the two batteries:
Sl. No. Description Quantity

1. Stamping and charging Car 2 sets
2. Pushing Car 2 sets
3. Dust guide car 2 sets
4. De-dust guide car 3 sets
5. Elec. Locomotive 2 sets
6. Quenching Car 2 sets
7. Stamping machine 2 groups
8. Hydraulic exchanger 2 sets
The coke guide car machine will be two spot operations. It will remove door,
clean the frame and also cleans the oven door. It will move to place the guide
cage at the oven, the door of which has been opened.
The coke-quenching car will be hauled by electric loco. The incandescent coke is
brought to a quenching station and sprayed with water for quenching, and after
quenching coke is discharged to coke wharf.
Quenching tower shall be of RCC construction with acid resistant brick lining and
arrangement for water spray system. Grit arresters along with vapour spray
system will be provided in quenching tower to contain quenching emissions.
Coke handling plant: coke-handling plant of 100 t/h capacity has been envisaged
to receive the run of oven coke from wharf through wharf conveyor. The coke will
be screened into the 3 fraction e.g. (-)10 mm, 10 mm – 25 mm and 25-80 mm.

By-Product Plant: the by product plant is designed to recover only essential by-
products like ammonia, crude tar. The plant will have a capacity to process
42000 Nm3/h of coke oven gas. The quantity of by-product will be as follows:
Sl. No. Description Units Quantity

1. Coke oven gas Nm3/h 42000
2. Ammonium Sulphate Tpy 9740
3. Crude Tar Tpy 40116
4. Sulphur Tpy 1626
The net calorific value of the coke oven gas is 4300 – 4500 Kcal/Nm3
Effluent Treatment Plant: The effluent treatment plant will be envisaged to treat
the effluent generated from coke oven battery and by-products plant (capacity 24
m3/h). The treatment plant is capable to treat phenolic water generated. Phenolic
water from ammonia column and other sources will be settled and freed from tar
and oil and treated for other toxicants to achieve the desired limit. The treated
liquor will be pumped to the quenching station where it will be used for quenching
of hot coke along with fresh water.
The surplus gas utilisation: The requisite quantity of coke oven gas will be
consumed by the battery itself for regular heating and balance quantity will be
supply to other users within the plant.
Dry Coke Quenching: As per directives of EAC, BSSL shall adopt dry coke
quenching within a period of 5 years from date of environmental clearance. Dry
coke cooling shall take the advantage of waste heat and generate power and
shall initiate for CDM benefits. The dry coke cooling technology is available
indigenously and could be utilized to avoid wet quenching. The detailed

technological features and plan shall be indicated to SPCB at the time of detailed
engineering.
Blast furnace Complex

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

Coal dust injection, kg/thm 150

Oxygen enrichment, % 4
Slag rate, kg/thm 321
Slag basicity, CaO / SiO2 0.95
Top pressure, kg/cm2 (g) 1.5
Hot blast temperature, Deg. C 1200
Blast humidity, g/Nm3 60
Blast volume, Nm3 / thm 959
Gas generation, Nm3 / thm 1560
Steel making and continuous casting shop

Two steel melting and casting shops have been envisaged namely SMS-I and
SMS-2. Under SMS-I, steel melting and casting shop has been designed to
produce about 1,313,100 tpy of liquid steel and cast the same into 600,000 tpy of
continuously cast billets and 670,600 tpy slabs.
Under SMS-2, steel melting and casting shop will produce 1,967,200 tpy of liquid
steel. The entire quantity of liquid steel will be cast to 1,908,200 tpy slabs.
SMS–1
SMS-I will consist of twelve (12) induction furnaces (IF) each of capacity 15t, four
(4) number of ladle furnace along with two (2) double strand billet caster. This
shop will have two (2) 60 t electric are furnace, two (2) 60 t ladle furnace, one (1)
60 t VD/VOD unit and one (1) single strand slab caster.
SMS-2
The SMS-2 will consist of one (1) twin shell CONARC of 180 t capacity, one 180 t
ladle furnace, one (1) RH-OB unit and one (1) single strand slab caster will be
installed to meet the annual production requirements.

Hot Strip Mill

The mill will primarily comprise a slab charging table fed by slab charging cranes
located in the slab yard. Two 300 tph walking beam type slab reheating furnace
with slab charging and discharging equipment designed for cold as well as hot
charging of slabs, one 4-hi reversing roughing stand with attached edger, one
coil box, one hot crop shear, five 4-hi finishing stands, runout roller table
equipped with laminar cooling, two down coilers, coil handling facilities, coil
storage yards, necessary auxiliary facilities and roll shop equipment.
The mill will have an in-built capacity to produce about 2.5Mt of HR coils per
annum. Future provision for third reheating furnace, second roughing stand with
attached edger, 6th & 7th finishing stands and third down coiler has been
envisaged.
The broad technological parameters of the hot strip mill are given in Table–2.5.
Table-2.5: Technological parameters of hot strip mill

S. No Parameters Unit Value/feature
1 Capacity – HR coils tpy 2,514,300
2 Input material
A Type --- Continuously cast slabs
B Thickness mm 230
C Width mm 800 – 1680
D Length mm 10,300 max.
E Weight t ~31
3 Finished products
a Type HR Coils
b Strip thickness mm 1.6 – 20

S. No Parameters Unit Value/feature

c Width mm 800 – 1680
d Coil ID Mm 760
e Coil OD Mm 2,100 max.
f Coil weight t 30max.
Power Plant
Production of sponge iron in DR kilns generates huge quantities of the flue gases
carrying considerable sensible heat. The surplus gas of the 1681 m3 blast
furnace has considerable heating value. These fuels if not used properly would
be simply wasted leading to inefficient use of energy as well as causing disposal
problems and to some extent pollution hazard in the plant premises. Surplus
blast furnace gas which is having a good calorific value can also be utilized for
power generation. Thus a captive power plant would be an ideally suited
proposition of effectively make use of these waste fuels. The quantities and heat
content of the waste fuels are enough to produce about 155 MW power which is
more than the requirement of the entire complex. Besides, the facility will also
cater to the requirement of steam driven turbo blowers and process. Thus the
CPP would not make the plant independent of external source of electric power
but would also result in energy conservation and environment improvement. A
composite power plant cum blowing station comprising the following has been
envisaged.
1x33+1x77+1x45 MW steam turbo-generator and auxiliaries.

14x48.5 tph waste heat recovery boilers (WHRBs) and auxiliaries,
1x80 t/h blast furnace gas fired boiler (BFG) and auxiliaries.
Steam turbine driven blowers – 2x60%,
Deaerators – 4 nos.

Lime and dolo plant

The line and dolomite plant will comprise of 1No. vertical lime shaft kiln and 1 No.
dolomite shaft kiln of capacity 500 tpd each and 1 No. 100 tpd lime shaft kiln
which is being installed for SMS-1. The lime plant will have the following
production capacity as given below.
Sl. No. Item Qty. tpy.

1. Lime of size 15-55 for SMS 162,200
2. Calcined dolomite of size 15-55 for SMS 105,600
Technological parameters: Lime and Dolomite calcination unit

i) Nos. of Kiln - 3
ii) Kiln Capacity - 2 Nos. 500 tpd each and
1 No. 100 tpd.
iii) Kiln feed size, mm - 25-55
iv) Calcination temp. ºC - 950-1150
v) Specific consumption of - 850
fuel kcal/kg of burnt lime
and dolomite.
Oxygen Plant
Oxygen will be required mainly for blowing into the EAF & CONARC for steel
melting and for enrichment of blast in the B. F. complex. Oxygen will also be
required for further removal of carbon in RH-OB, tap hole opening in blast
furnace, and also to meet cutting and general repair needs in the SMS / CCM,
Sinter Plant, Rolling mills and other units of the steel plant.

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

It is proposed to install 77 MW and 33 MW captive power plants for in-plant

generation. The captive power plants will generate power at 11 kV. The 77 MW
CPP will by synchronized with the grid power supply at 220 kV at MRS through
100 MVA, 11/220 kV step up generator transformers. The 33 MW and 45 MW
CPP will be synchronized with the Grid power supply at 33 kV switchboard
located at Power Plant through 42 MVA and 60 MVA, 11/33 kV step up
generator transformers respectively. The 33 kV switchboards at PP will be
connected to the 33 kV switchboards at MRS through two Nos. tie line feeders.
Fuel oil and gas facilities

Blast furnace (BF) gas will be used mainly as fuel in stoves, sinter plant and
power plant. In addition to the above consumers, BF gas will also be used for
cast house runner drying; LRS, PCK, and PCI, semi-clean BF gas will be used
for BF top pressure equalization etc. BF gas will be distributed to the consumers
through a system of piping network, operating at a pressure of 600-800mm WC
Mixed gas has been proposed to be utilized as fuel for the reheating furnace.
Light diesel oil (LDO) is proposed to be utilized as fuel for the initial firing and
flame stabilization in the boilers. In addition to boilers, LDO will also be required
for DR plant and SMS. The daily requirement of LDO is estimated at 120 kl.
Hence 2 Nos. of 450 kl capacity each LDO storage tanks will be required to be
provided for storage of 7 days requirement.
LPG/ propane storage facilities have been envisaged for about 6 days
requirement of the gas for different consumers of SMS (CONARC and EAF/IF)
and BF. The hourly average requirement of LPG/propane is 2.2 tph. Two Nos.
cylindrical storage vessels, each having a capacity to store 150 t of LPG/propane
have been planned.

The Fuel Balance of the Plant

Sr. Name of Shop / Unit Annual CV of gas Hourly Fuel Consumption
3
No. hours of kcal/Nm (G cal)
operation Total BF Gas LDO/LPG
A. GENERATION
1 Blast Furnace 8400 932 220 220 -
Total Generation 220 220

B. CONSUMPTION
1. BF stoves 8400 932 102.59 102.59
2. Pre-heater 8400 932 15.0 15.0
3. PCI 8400 932 9.32 9.32
4. Minor Consumers 8400 932 1.63 1.63
5. Top Pressure 8400 932 16.76 16.76
Equalization
6. Sinter Plant 7920 2000 11.18 11.18
7 Reheating Furnace for 8400 9800 176.0 176.0
HSM kcal/kg
8. Lime Stone & 8400 9800 46.0 46.0
Dolomite Calcining kcal/kg
Plant
Total Consumption 378.48 156.48 222.0
To meet the requirement for pulverized coal injection (PCI) system of the blast
furnace complex following shall be provided in the building. Two Nos of
centrifugal compressors each of 70 Nm³/min capacity discharging air at 14.5
kg/cm2 (g) pressure are envisaged. Out of these two compressors one will be
working and one will be kept as a stand by. One No of service air receiver of
60m³ for PCI is envisaged. This air receiver shall be provided outside the
compressed air station.

Water supply facilities

The main source of raw water for the proposed steel plant will be river Brahmani,
which is about 6 km away from the plant site. It is proposed to construct an intake
structure on the river bank with necessary pumping and transportation facilities
up to the plant site. Water will be pumped from the intake pump house to the raw
water reservoir inside the plant through pipeline of approximate length 6 km. The
raw water reservoir shall have a storage capacity of 7 days’ requirement of the
plant.
The total requirement of fresh water from surface water source to meet process
make-up and drinking needs is estimated as 5400m³/h. Raw water, received at
the plant water reservoir, shall be treated through Clarifier/ Demineralisation
(DM) Plant / Softening plant before addition to the system as make – up. Water
will be further treated in a demineralised water plant and water softening plant to
meet the DM and Soft water demand of the plant.
The raw water and treated water shall be mainly used for the purpose of cooling,
steam generation and waste water for dust suppression in different production
units of the plant. Apart from this, small quantity of water shall also be used for
fire fighting, drinking and sanitary uses. Water balance for the plant is indicated in
the drawing DRG.NO. BSSL/0/ISP/7-1 Rev 0.
Manpower Planning
In order to operate and maintain the plant facilities, including its technical general
administration needs, the estimated manpower requirement at the full
development stage of the integrated complex has been estimated to be 2827.
Category wise breakup of manpower

Sl. No. Category Requirement

1 Managerial 29
2 Executive 310
3 Skilled 938
4 Semi-skilled 735
5 Unskilled 775
6 Clerical 40
Total : 2827
2.8 Mitigation Measures to Meet Environmental Standards
Environmental management
The steel plants are considered pollution causing units and to mitigate
environmental problems and meet the environmental norms prescribe by the
regulatory bodies process pollution control equipment are envisaged in the
design stage to comply the norms. The facilities planned for controlling the air
and water pollution are summarised in Table-2.6.
Table-2.6: Proposed facilities for control of air and water pollution

Sl. Shop/Unit Proposed Facilities
No.
1 Coke oven and by product plant Scrubbers, tall chimney, BOD plant etc.
2 Sinter plant Electrostatic precipitators, etc.

3 Blast furnace plant GCP, SGP, Electrolyte precipitator etc.
4 Steel melting shop Fume Extraction System, gas coolers, chimney
etc.
5 Material handling system Bag filters, dust suppression systems, etc.
6 Refractory materials plant Bag filters etc
7 Power plant Electrostatic precipitators, chimney etc.
8. DRI units Electrostatic precipitators, chimney etc.

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

The total project cost has been estimated to be Rs. 63300.0 Million (Rupees
Sixty three thousands three hundred million). The capital cost of environmental
control measures is Rs. 3481.5 Million.

BHUSHAN STEEL & STRIPS LTD., MERAMANDALI

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

Sl Name of Shop/ Unit Product Annual Annual Sp. Yeild/ Calorific Hourly Fuel Supply/ Consumption
No Output/ Input Hours of consumpti Value of ( Gcal / hr)
(x 1000T) Operation on GAS (Million kcal / hr)
(Gcal/t) kcal/Nm3 Total BF C.O. BOF Annual Fuel
GAS GAS GAS OIL / LPG
Lime Plant Burnt Lime 124 7920 0.890 9500 0.00 0.00 0.00 0.00 11800 t LDO
& dolo
Lime Plant Burnt Lime 272 7920 0.890 9800 0.00 0.00 0.00 0.00 24200 t LDO
& dolo
Burnt Lime 33 7920 0.950 9800 0.00 0.00 0.00 0.00 3200 t LDO
6 Hot Strip Mill
Reheating Furnace Slab(cold 1289 7200 0.400 2000 71.61 21.48 50.13 0.00
charge)
Slab(hot 1289 7200 0.250 2000 44.76 13.43 31.33 0.00
charge)
7 DR Kiln DRI 10t LDO
8 Captive Power Plant 10t LDO
9 DG Set 10t HSD
10 Losses
a) BF Gas - 3% 0.030 900 6.38 6.38 0.00 0.00
b) C.O.Gas - 1% 0.010 4200 1.76 0.00 1.76 0.00
TOTAL CONSUMPTION 373.67 203.33 170.34 0.00
SURPLUS (AVAILABLE) 14.95 9.47 5.48 0.00
BF gas generation : 2,36,400 Nm3/h @ 900 Kcal/Nm3

CO Gas generation : 46,450 Nm3/h @ 4200 Kcal/Nm3
Sinter Plant Consumption: 50,000 Kcal/t
Sinter Production: 1880,000 t/y (avg)
DC has guaranteed BF gas CV: 900 - 1000 Kcal/Nm3
50% slabs are hot charged at 600 °C
* Battery under firing has been considered by coke oven gas
Annual production SMS is for both phase A & phase

3.0 PRESENT ENVIRONMENTAL STATUS
Information on the existing environmental status is essential for

assessing the likely environmental impacts of the proposed
modification-cum-expansion of existing project.
In order to get an idea about the existing state of the environment,

various environmental attributes such as meteorology, air quality,
water quality, soil quality, noise level, ecology and socio-economic
environment have been studied/ monitored.
Study Period
It has been planned to carry out baseline environmental data generation for
air, water, noise and soil quality monitoring around the proposed plant site for
one full season covering three months of Summer (April-June’2006).
Study Area
The present report covers baseline environmental data generated in the study
area (10 km radius all around the plant site).
3.1 Baseline Monitoring of Environmental Component

In order to get an idea about the existing state of the environment, various
environmental attributes such as meteorology, air quality, water quality, soil
quality, noise level, ecology and socio-economic environment are being
studied/monitored. The present report covers baseline environmental data
generated during April to June’2006 for meteorology, air quality, water quality,
noise levels and soil characteristics. Meteorological, air, water, noise and soil
monitoring stations are marked in Drg.No. MEC/Q6BK/11/S2/01 sheet 1 of 1.
Sampling and analysis has been carried out by Environmental Engineering
Laboratory of MECON, Ranchi which is having accreditation from regulatory
authority Central Pollution Control Board (CPCB) New Delhi.

3.2 Meteorology
A meteorological station was set up at the roof top of MRS building within
the proposed plant premises. Meteorological data was generated during the
summer season monitoring period.
The following parameters were recorded at hourly intervals continuously

during monitoring period:
Wind speed
Wind Direction
Air Temperature
Relative Humidity
Cloud Cover
Rainfall was recorded on daily basis.
Table-3.1 gives wind frequency pattern of day-night (24 hours), day and night
respectively as monitored during the monitoring period.
Table-3.1: Summarized Meteorological Data for the Monitoring Period (Summer, 2006)
Month Wind speed m/s Temperature (°C) Relative humidity Rainfall (mm) Cloud
(%) cover
Max. Min. Mean Mean Max. Min. Highest Lowest Total 24hrs. No. of (Oktas
highest rainy mean)
days
April 2006 7.03 <0.44 1.29 28.4 48 19 73 17 - - - 2
May 2006 8.64 <0.44 1.59 34.7 46 20 92 20 - - - 2
June 2006 9.31 <0.44 0.85 32.8 45 18 96 23 4 - 4 2

Table-3.1: Wind Frequency Distribution at Meramandali

during Summer Season’2006
A. 24 hours Overall
Velocity Ranges (m/s) Sum
Direction
0.44<V<=2 2<V<=3 3<V<=5 5<V<=6 V>6 %
N 0.74 0.27 0.06 0.00 0.00 1.07
NNE 3.44 0.88 0.06 0.00 0.06 4.44
NE 2.16 0.47 0.27 0.00 0.00 2.90
ENE 7.90 1.62 0.67 0.06 0.06 10.31
E 8.29 1.89 1.15 0.00 0.06 11.39
ESE 10.46 1.75 0.47 0.00 0.00 12.68
SE 3.51 0.61 0.14 0.00 0.00 4.26
SSE 3.30 0.81 0.20 0.00 0.00 4.31
S 2.97 0.47 0.14 0.00 0.00 3.58
SSW 2.69 0.47 0.20 0.00 0.00 3.36
SW 2.69 0.40 0.14 0.00 0.00 3.23
WSW 5.67 1.15 0.74 0.00 0.00 7.56
W 4.92 1.42 0.81 0.00 0.00 7.15
WNW 2.97 0.94 0.27 0.06 0.00 4.24
NW 1.08 0.14 0.06 0.00 0.00 1.28
NNW 1.89 0.34 0.14 0.06 0.00 2.43
SUM % 64.68 13.63 5.52 0.18 0.18 84.19
CALM %(V< 0.44 m/s ) = 15.81
Figs-3.1: a the wind-rose diagrams at Meramandali for day-night

(combined)
B. Day Time (0600 – 1800 Hrs)


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

C. Night time (1800 – 0600 Hrs.)

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

From the above table predominant wind direction is found to be from North-
eastern to south eastern sector. During day time, East of South-East (ESE) is
the predominant wind direction (prevailing for about 10.77 % of the time),
followed by WSW (10.66 %) and W (10.39 %). Calm conditions prevailed for
13.54 % of the time. During night also the predominant wind direction is ESE
(14.58%), followed by E (14.38 %) and ENE (11.22%). Calm condition
prevailed for 18.11 % of the time. Overall (24 hours), the predominant wind
direction is also ESE (12.68 %), followed by E (11.39 %) and ENE (10.31 %).
Calm conditions prevailed for 15.81 % of the time.
Figs-3.1: a, b and c give the wind-rose diagrams at Meramandali separately

for day-night (combined), day and night time respectively, based on the
monitored data.

3.3 Air Environment

To quantify the impact of the proposed power plant on the ambient air
quality, it is necessary at first to evaluate the existing ambient air
quality of the area. The existing ambient air quality, in terms of
Suspended Particulate Matter (SPM), Respirable Particulate Matter
(RPM), Sulphur-dioxide (SO2), Oxides of Nitrogen (NOx), Carbon
Monoxide (CO), Lead (Pb) and Dust Fall has been measured through
a planned field monitoring.
To assess the ambient air quality level, 5 (five) monitoring stations

were set up. Of these five stations, one was within the plant premises
(Core Zone), while rest were outside the lease up to a maximum
distance of 10.0 km from core zone limit (Buffer Zone). Table-3.3 gives
location of the ambient air quality monitoring stations.
Table-3.3: Ambient Air Quality (AAQ) Monitoring Stations

Sl. Location Stn. Code Distance & Direction from center
No. of lease
1. Motanga A1 4.75 km E
2. Galpoda A2 4.5 km SE
3. Nalatangra A3 4.5 km W
4. Nuahata A4 4.75 km NW
5. MRS building A5 Core Zone
Monitoring Schedule
Samples of 24 hourly duration were taken for monitoring SPM, RPM, SO2
and NOx whereas for CO three one hourly sample was taken on each
monitoring day. Lead was also monitored in limited samples. Dust fall was
recorded as 30 days average at each AAQ monitoring station.

Methods of Sampling and Analysis

The methods of sample collection, equipment used and analysis
procedure as followed are given in Table-3.4.
Table-3.4: Methodology of Sampling & Analysis and Equipment used

Sl. Parameters Instrument / Method followed Reference
No. Apparatus used
Suspended Respirable Dust CPCB
1. Particulate Matter Sampler (RDS/ Gravimetry Notification of
(SPM) HVS), Balance 11.4.94
Respirable Respirable Dust
CPCB notification
2. Particulate Matter Sampler (RDS), Gravimetry
of 11-4-94
(RPM) Balance
RDS/HVAS with Jacobs and
Nitrogen Oxides CPCB notification
3. Impinger tubes, Hochheiser modified
(NOx) of 11-4-94
spectrophotometer (Na-arsenite) Method
RDS/HVAS with
Sulphur di-Oxide Improved West & CPCB notification
4. Impinger tubes,
(SO2) Gaecke method of 11-4-94
spectrophotometer
RDS/HVAS, Atomic
Absorption Gravimetric followed CPCB notification
5. Lead in SPM
Spectrophotometer by AAS of 11-4-94
(AAS)
CPCB notification
6. Carbon Monoxide CO Analyser NDIR Method
of 11-4-94.
Results and Discussions
The results of AAQ are given in Annexure-3.1. The results when

compared with National Ambient Air Quality Standards (NAAQS) of
Central Pollution Control Board (CPCB) for “Residential and Rural
Areas” show that the average values of ambient air quality parameters
are well within the stipulated limit.

Dust Fall
Dust fall rates were recorded as 30 days average during monitoring

periods at five (5) AAQ monitoring stations. The results are given in
Table-3.5.
Table-3.5: Measurement of Dust Fall Rate

Station Location Station No. Results (g/m2/day)
Motanga A1 0.39
Galpoda A2 0.33
Nalatangra A3 0.34
Nuahata A4 0.41
MRS building A5 0.45
In absence of Indian Norms, the results have been compared with the
German norm published in TA Luft, 1986 which is as follows:
98 percentile value : 0.65 g/m2/d
The above results indicate that the dust fall rates at all the stations are
well within the compared German standards.
3.4 Water Environment

Water quality monitoring of the study area was carried out in order to
collect baseline data on existing water quality, which can be used to
predict the impacts due to the project on water regime. Grab samples
were collected from ten (10) locations comprising 7.0 ground water and
3.0 surface water samples which are listed in Table-3.6.

Table-3.6: List of Water sampling Stations

Sl. Stn. Surface / Ground
Location
No. Code Water
1 Ground Water from Sibapur GW1 Ground water
2 Ground Water from Sibapur GW2 Ground water

3 Ground Water from Khaliberana GW3 Ground water
4 Ground Water from Motanga GW4 Ground water
5 Ground Water from Kochilimara GW5 Ground water
6 Ground Water from Galpoda GW6 Ground water
7 Ground Water from Ganthigriha GW7 Ground water
8 Ground Water from Narendrapur Gw8 Ground water
9 Lingra Nadi SW1 Surface Water
10 Kisinda Jhor before joining river SW2 Surface Water

Brahmani
11 River Brahmani, D/s of Lingra nadi SW3 Surface Water
Samples were analysed following standard methods of analysis.
The results of analysis of ground water are given in Annexure-3.2.

The results have been compared with the drinking Water Quality
standards specified in IS:10500. From the results it is obvious that
except Iron in GW3 all the ground water quality parameters meet the
prescribed norms.
The results of analysis of surface water are also given in Annexure-3.3.

The results have been compared with the Water Quality Criteria as per
Central Pollution Control Board. It can be seen that water from these
sources can be compared with class C and used for drinking after
conventional treatment and disinfection.

Water Quality Criteria as per Central Pollution Control Board
Parameters Class A Class B Class C Class D Class E

pH 6.5–8.5 6.5–8.5 6.0-9.0 6.5–8.5 6.5–8.5
Dissolved oxygen (as O2), mg/l, min 6 5 4 4 -
BOD, 3 days at 27° C, max 2 3 3 - -
Total coliform organism, MPN/100 ml, max 50 500 5000 - -
Free ammonia (as N), mg/l, max - - - 1.2 -
Electrical conductivity, µmhos/cm, max - - - - 2250
Sodium absorption ratio, max. - - - - 26
Boron (as B), mg/l, max. - - - - 2
Class A: Drinking water source without conventional treatment but after disinfection
Class B: Outdoor bathing (organized)
Class C: Drinking water source after conventional treatment and after disinfection
Class D: Propagation of Wild life and Fisheries
Class E: Irrigation, Industrial Cooling, and Controlled Waste Disposal
Below E: Not meeting A, B, C, D & E Criteria
3.5 Noise Levels

In order to have an idea about the existing noise levels in the study area,
noise monitoring has been carried out at eight (8) locations, out of these 8
locations one location is in core zone and rest 7 are in buffer zone. All
these monitoring stations are listed in Table-3.7.
Table-3.7: Noise Monitoring Stations

Distance & Direction
Stn. Core Zone
Location (from Centre of
No. /Buffer Zone proposed project)
N1 Narendrapur Buffer zone 2.2 km N
N2 Shibapur outside lease area Buffer zone 1 km ENE
N3 Motanga Buffer zone 4.75 km E
N4 Kochilimara Buffer zone 2.25 km SE
N5 Near MRS building Core zone -
N6 Khaliberana Buffer zone 3.5 km NW
N7 Ganthigriha Buffer zone 2.0 km W
N8 Nalatangara Buffer zone 4.5 km W

Noise Monitoring Frequency

At each ambient noise monitoring station, Leq. noise level has been recorded
at hourly intervals for 24 hours. Readings were taken by keeping the noise-
recording instrument ON for fifteen (15) minutes for each reading.
Results and Discussions

The summarised monitoring results of noise level in ambient air given in
Table-3.8. The results have been compared with the standard specified in
Schedule III, Rule 3 of Environmental Protection Rules given in Table-3.9.
Table-3.8: Summarized Results of Noise Monitoring

Results
Stn.
Location Day (0600-2200 hr.) Night (2200-0600 hr.)
No.
Max. Min. Mean.* Max. Min. Mean.*
Narendrapur (Near
N1 74.7 64.7 70.9 67.1 57.7 63.1
Highway)
Shibapur outside lease
N2 54.3 44.3 50.8 44.4 39.2 41.5
area
N3 Motanga 48.3 44.2 46.8 45.8 40.0 42.5
N4 Kochilimara 56.8 45.8 54.3 48.5 40.7 43.8
N5 Near MRS building 68.8 58.3 66.1 62.8 58.1 59.8
N6 Khaliberana 47.6 42.7 46.2 43.5 39.7 41.3
N7 Ganthigriha 48.4 41.2 46.2 44.6 38.7 41.0
N8 Nalatangara 53.3 46.3 50.3 45.4 41.3 43.3
* Logarithmic Averages. All Values in dB (A).
Table-3.9: Ambient Air Quality norms in respect of Noise

(As Per Schedule III, Rule 3 of Environment Protection Rules)
Type of Area Day (0600 - 2200 hrs). Night (2200 – 0600 hrs.)
Industrial Area 75 70
Commercial Area 65 55
Residential Area 55 45
Silence Zone 50 40
All Values in dB (A)

At all the noise monitoring stations values of Leq. are well within their
respective norms.
3.6 Soil Characteristics

To assess the quality of soil in and around the lease area, soil samples
were collected from five locations during summer season for physico-
chemical analysis. Soil sampling locations are mentioned in Table-
3.10.
Table-3.10: List of Soil Sampling Locations
Sample No. Location Type of Land
S1 Motanga Agricultural
S2 Galpoda Agricultural
S3 Nuahata Agricultural
S4 Nalatangara Agricultural
S5 Shibpur Barren
The results of analysis are given in Tables 3.11, 3.12, 3.13, 3.14 & 3.15.
Table-3.11: Physical Properties of Soil
Sample No. Colour Texture Water Holding Capacity (%)
S1 Brown Loam 56
S2 Light Brown Loam sand 41
S3 Light Brown Loamy sand 46
S4 Dark Brown Loam 49
S5 Dark Brown Loam 53
Table-3.12: Chemical Properties of Soil

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

Soil pH plays an important role in the availability of nutrients. Soil

microbial activity is also dependent on pH. In the study area the soil pH
is acidic to neutral (6.3 <pH< 7.3).
Electrical conductivity (EC) is a measure of the soluble salts and ionic

activity in the soil. In the collected soil samples the conductivity ranged
from 67 to 326 µ mhos/cm.
Table-3.13: Chemical Properties of Soil

Available Nitrogen (kg/ha) 216 285 386 229 197
and Rating L M M L L
Available Phosphorus
54 38 26 5 7
(Kg/ha)
and Rating H H H L L
Available Potassium
756 220 847 419 554
(Kg/ha)
and Rating H M H H H
Organic carbon (%) 0.89 0.44 0.90 1.11 0.78
and Ratings H L H H H
Organic matter % 1.53 0.75 1.56 1.92 1.35
Rating based on :
Available Nitrogen <280 – Low; 280-560- Medium; >560 – High
Available Phosphorus <10 - Low; 10 - 25 - Medium; >25 - High
Available Potassium <120 - Low; 120 – 280-Medium; >280 - High.
Organic carbon <0.50- Low; 0.5 - 0.75 -Medium; > 0.75 – High
Phosphorus and Nitrogen are limiting nutrients. In the tested soil

samples, availability of Nitrogen varies from low to medium while
Phosphorus is either low or high. Potasium and Organic carbon
content are in general high.

Table-3.14: Exchangeable Cations

Calcium (meq/100gm) 17 5 46.9 8.9 31.2

% contribution to the Base
62.51 59.24 75.34 67.04 73.74
Saturation
Magnesium (meq/100gm) 7.6 2.0 12.9 3.4 9.8
27.96 23.70 20.56 25.28 23.16
Saturation
Sodium (meq/100gm) 1.45 0.97 1.33 0.48 0.60
5.34 11.49 2.14 3.58 1.42
Saturation
Potassium (meq/100gm) 1.14 0.47 1.22 0.55 0.71
4.19 5.57 1.96 4.10 1.68
Saturation
The above results show that the tested soil samples have moderate
quantities of calcium and magnesium whereas levels of exchangeable
sodium and potassium were relatively low.
Table-3.15: Available Micronutrients in Soil

Parameters S1 S2 S3 S4 S5 Remarks
Copper 1.35 1.28 1.36 1.21 1.26 1.44
Zinc 3.2 2.45 2.26 2.54 2.18 2.82
Iron 13.5 12.4 12.7 12.9 12.8 12.4
Manganese 22.5 18.5 19.6 25.0 24.3 21.5
( Values in mg/ kg).
Soil micro-nutrients also play an important role in plant growth and

can act as limiting nutrients. Soil micro-nutrient analysis can be
employed as a diagnostic tool for predicting the possibility of
deficiency of a nutrient and the profitability of its application. For this,
the critical limits of micro nutrients are fixed. The critical limits of
copper, zinc and iron are 0.20-0.66 mg/kg, 0.50-0.65 mg/g and 4.5-
6.0 mg/kg respectively. From the above Table it can be seen that
concentration of copper in all the soil samples are beyond the limit.
Zinc and iron is also high in all the soil samples.

3.7 Biological Environment
The study area is sparsely populated. The biotic environment can be

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

Table-3.16: Plants found in study area
Sl. Botanical name Common name

No.
1. Pheonix dactylifera Khajoor
2. Acacia arabica Babool
3. Zyziphus mauritiana Ber
4. Mangifera indica Mango
5. Borassus flabellifer Tad
6. Ficus bengalensis Bargad
7. Diaspyros melanoxylon Kendu
8. Azadirachta indica Neem
9. Bambusa arundinacea Bans
10. Butea frondosa Palasa
11. Albizzia lebbeck Siris
12. Cassia florida Chakunda
13. Artocarpus heterophylla Kathal
14. Madhuca indica Mahua
15. Annona squamosa Sharifa
16. Ficus religiosa Peepal
17. Holarrhena antydysentrica Korai
18. Anogeissus latifolia Dhav
19. Cassia fistula Sonnari
20. Vitex negundo Sindwar
21. Bombax ceiba Semal
22. Polyalthia longifolia Ashok
23. Nerium odorum Kaner
24. Prunus amygdalus Badam
25. Acacia auriculiflormis Auriculiformis
26. Aegla marmelos Bel
27. Saraca indica Ashoka

Sl. Botanical name Common name

No.
28. Shorea robusta Sal
29. Terminalia tomentosa Asan
30. Phyllanthus emblica Aonla
31. Terminalia belirica Bahera
32. Terminalia arjuna Arjun
33. Terminalia chebula Harida
34. Syzigium jambolana Jamu
35. Dalbergia sissoo Sisso
a. Forest Area
There is only one patch of forest, Jharbandh reserved forest, which is

in SE direction at 5.5 km from the project site. The forest is on hillocks
and is of mixed dry deciduous type, in highly degraded state. The tree
height varies from 2 to 5 m and trees are mostly like shrubs. The
common species are D. strictus, Cephalostachyum pergracile, H.
antidysentrica, A. indica, D. melanoxylon, F. bengalenisis, A. arabica,
A. latifolia, A. marmelos, A. squamosa, etc.
b. Agricultural land
The Irrigation facility is not proper in the study area, rainwater is the
main source of irrigation and thus paddy is the main crop grown in the
area. Other crops, which are grown, are Khesari, Groundnut, Moong,
Cajanus, Til, etc. where watering facility is available seasonal
vegetables are also grown.

c. Waste land
Wasteland in the study area is commonly seen in the area, is mostly

covered with species like Calotropis spp, Ipomea sp, Cassia tora,
Croton sp., Parthenium sp., Zizyphus sp., etc.
d. Grassland
Grassland in the study area is secondary in origin. The common

species found in the area are Dicanthium sp. Desmodium sp.,
Evolvulus sp, Cynodon dactylon, Cyperus sp., Imperata sp., etc.
e. Vegetation in and around human settlement
Near villages the vegetation pattern changes from rest of the area. The
common species grown near villages are Mangifera indica, Madhuca
indica, Sizygium sp., Artocarpus sp., Bambusa sp., Ficus spp.,
Azadirachta indica, Cassia siamea, Albezzia sp., Acacia auriculiflormis,
Nerium sp., Annona squmosa, Pheonix sp., Polyalthia sp., etc.
f. Avenue trees and Plantation
The roadside along NH 42 and other roads in the study area are
planted with trees in single to double rows. The common trees are
Acaccia auriculiformis, Azadirachta indica, Peltophorum, Syzigium sp.,
Mangifera indica, Bombax ceiba, Delonix regia, Cassia siamea, etc.
There are stretches of plantation done by CPP, NALCO, and other

industrial premises and residential areas, the common plants are,
cassia siamea, Leucaena leucocephala, Dalbergia sisso, Sarca indica,

Delonix regia, Azadirachta indica, Acacia auriculiformis, Mangifera

indica, Prunus amygdolus, Callistemon lanceolatus, etc.
g. Wild life and avifauna
There is only a small patch of Jharbandh forest falling into the study
area. Which is also in highly degraded state and do not support good
wild life? The common wild life found in the study area is given Table-
3.17. and Table-3.18
Table-3.17: List of Wild life species in the study area
Sl. Common Scientific Name Status Schedule of

No. Name Wildlife Protection
Act in Which Listed
1. Mongoose Herpestes edwardsi - IV
2. Spotted deer Axis axis - III
3. Wild boar Sus scrofa - III
4. Monkey Macaca mulatta - II
5. Hare Lepus nigricollis - IV
6. Porcupine Hystrix indica - IV
7. Jackal Canis aureus - V
8. Squirrel Funambulus palmarum - IV
Table-4.18: List of common birds found in the region
Common Botanical Name Status Schedule of Wildlife

Name Protection Act in Which
Listed
Greying goose Anser anser - IV
Comb duck Serkidiornis sp. - IV
Blue rock Columba livia - IV
pigeon Francolinus - IV

Common Botanical Name Status Schedule of Wildlife

Name Protection Act in Which
Listed
Black patridge francolinus - IV
Red jungle fowl F. pondicerianus - IV
Mynas Gallus gallus - IV
Parkeet Acridothere tristis - IV
Bagula Psitiacula eupatria
h. Aquatic life
There are a number of ponds in the villages in the study area. On

visual observation these ponds seems to be oligo-trophic to meso-
trophic in nutrients status. The common rooted plants and hydrophytes
on the edges of these pons are Nelumbo sp., Potamogeton sp.,
Aponogeton sp.,Ipomea sp., Dichanthium sp., etc. The water in these
ponds are colourless to slight greenish in color.
There are three major rivers in the study area, Brahmni, Krishnajhor
and Nandirajhor. Out of these Nandirajhor River is the most polluted
due to the industrial effluent in the area. River Brahmni receives the
water of Nandirajhor.
The common fishes found in the area are Labio rohita, Catla catla,
Cirrhina mrigala, Calabasu sp., Cyprnus carpio, Grass carp, Silver
carp, Wallago attu, etc.
The Phytoplanktons in the rivers are basically dominated by

filamantous forms. The dominant ones are, Chaetophora sp.,
Cladophora sp., Pithephora sp., Oscillatoria so., Spirogyra sp.,
Cymbella sp., etc.

The Zooplanktons are basically dominated by Crustaceans and

Rotifers. The dominant ones are Crustaceans : Crustacean eggs,
Moinodaphina, Chydorus, Cyclops. Rptifers : Brachionus, Rotiferan,
etc. Others : Nematodes, Dipteran larvae, etc.
i. Animal husbandry
From the records of Veterinary hospitals it is found that there are

symptoms of fluorosis and high fluoride content in urine and blood
samples of few cattles in the study area. The fluorosis prone villages in
the study area and their distance direction are given in Table-3.19. The
reason for fluorosis in these villages may be attributed to high fluoride
content in ground water in few pockets. The reason for high fluoride
content in water is yet to be ascertained.
Table-3.19: Name of villages and their distance / direction

from project site in which Cattle are affected with fluorosis
Sl. Name of village Distance (km) / direction from project

No. site
1. Gotamara 6.3;NW
2. Banarapal 5.6; NW
3. Chaurhia 6.3; WNW
4. Jhanjiribahal 5.6; NW
5. Garhasantil 6.3; W
6. Amana 5.6; W
7. Taltali 6.8; W
8. Sanjapahara 4.1; W
9. Bodibahal 2.8; W
10. Garhasantri 3.1; W
11. Nalatangara 4.0; W
12. Bhagabatpur 3.4; W
13. Narendrapur 3.1; W
14. Nauhata 4.4 NW
15. Budapank 4.4; NNW
16. Sanjaparha 4.4; W
17. Ganthigarhia 1.33; W
18. Santri 5.9; W

Chapter-3
Annexure-3.1
Summerised Ambient Air Quality results of Meramandli for Summer Season'2006
Results in µg/m3
Permissible AAQ
SPM RPM SO2 NOx CO
standard
Industrial 500 150 120 120 10000
Residential 200 100 80 80 4000
Monitoring Arth. Arth. Arth. Arth. Arth.
Min. Max. Min. Max. Min. Max Min. Max. Min. Max.
Location Mean Mean Mean Mean Mean
Motanga 81 198 110 40 82 54 <10 17 - 15 39 29 875 1456 1111
Galpoda 70 133 93 37 66 47 <10 <10 - 14 43 24 823 1296 976
Nalatangra 81 208 119 41 97 59 <10 11 - 13 36 26 634 1168 924
Nuahata 76 162 103 40 87 53 <10 16 - 13 48 26 1796 3488 2485
MRS building 84 260 137 47 116 63 <10 16 - 15 38 22 1369 3859 2415

Chapter-3
Annexure-3.2
Results of Ground Water Analysis
Sl. Parameters Norms*

No. Sibapur Village Sibapur Village Khaliberana
Requirement Permissible limits (within lease (outside lease GW3
(desirable in the absence of area) GW1 area)GW2
limits) alternate source
Date of sampling 26.04.2006 26.04.2006 26.04.2006
Essential Characteristics
1 Colour, Hazen Units. 5 25 <5 <5 <5
Unobjection
2 Odour - Unobjectionable Unobjectionable Unobjectionable
able
3 Taste Agreeable - Agreeable Agreeable Agreeable
4 Turbidity, NTU, Max. 5 10 <5 <5 <5
5 pH value 6.5 to 8.5 No Relaxation 7.1 7.2 7.6
Total Hardness
6 (as CaCO3), mg/l, 300 600 264 276 300
max
Iron (as Fe), mg/l,
7 0.3 1 0.26 0.15 0.02
max.
Chloride
8 250 1000 28 24 30
(as Cl),mg/l, max.
Fluoride
9 1 1.5 1.23 1.34 0.68
(as F), mg/l, max.
Desirable characteristics
Total Dissolved
10 500 2000 471 496 502
Solids, mg/l, max.
Calcium
11 75 200 48 48 77
(as Ca), mg/l, max.
Magnesium
12 30 100 35 38 26
(as Mg), mg/l, max.
Copper
13 0.05 1.5 <0.01 <0.01 <0.01
(as Cu), mg/l, max.
Manganese
14 0.1 0.3
(as Mn), mg/l, max.
Sulphate
15 200 400 44 43 34
(as SO4), mg/l, max.
Nitrate
16 45 100 0.73 0.76 26
(as NO3), mg/l, max.
Phenolic compounds
17 (as C6H5OH), mg/l, 0.001 0.002 <0.001 <0.001 <0.001
max.
Mercury,
18 0.001 No relaxation <0.0005 <0.0005 <0.0005
(as Hg), mg/l, max.
Cadmium
19 0.01 No relaxation <0.005 <0.005 <0.005
(as Cd), mg/l, max.
Selenium
20 0.01 No relaxation <0.005 <0.005 <0.005
(as Se ), mg/l, max.
Sl. Parameters Norms*
No. Sibapur Village Sibapur Village Khaliberana
Requirement Permissible limits (within lease (outside lease GW3
(desirable in the absence of area) GW1 area)GW2
Date of sampling 26.04.2006 26.04.2006 26.04.2006
Arsenic
21 0.05 No relaxation <0.03 <0.03 <0.03
( as As), mg/l, max.
Cyanide
22 0.05 No relaxation <0.01 <0.01 <0.01
(as CN), mg/l, max.
Lead
23 0.05 No relaxation <0.05 <0.05 <0.05
(as Pb), mg/l, max.
Zinc
24 5 15 ND ND ND
(as Zn ), mg/l, max.
Anionic Detergents
25 (as MBAS), mg/l, 0.2 1 <0.1 <0.1 <0.1
max.
6+
Chromium (as Cr ),
26 0.05 No relaxation <0.01 0.05 <0.01
mg/l, Max.
27 Mineral oil mg/l, Max. 0.01 0.03 <0.1 <0.1 <0.1
Alkalinity ( as
28 200 600 242 268 260
CaCO3), mg/l
Aluminium (as Al ),
29 0.03 0.2 <0.01 <0.01 <0.01
mg/l
Boron (as B), mg/l,
30 1 5 <0.01 <0.01 <0.01
max.
* Drinking Water Specification, IS : 10500 (1991) & Amendment no.1, January’1993
Sl. Parameters Norms* Motanga Kochilimara Galpoda

No. GW4 GW5 GW6
Requirement Permissible
(desirable limits in the
limits) absence of
alternate
source
Date of sampling 26.04.2006 26.04.2006 26.04.2006
1 Colour, Hazen Units. 5 25 <5 <5 <5
Unobjectiona Unobjectionabl Unobjectionabl Unobjectiona
2 Odour -
ble e e ble
3 Taste Agreeable - Agreeable Agreeable Agreeable
4 Turbidity, NTU, Max. 5 10 <5 <5 <5
5 pH value 6.5 to 8.5 No Relaxation 6.8 7.5 6.6
Total Hardness
6 300 600 416 404 284
(as CaCO3), mg/l, max
7 Iron (as Fe), mg/l, max. 0.3 1 0.46 1.1 0.54
Chloride
8 250 1000 97 66 54
(as Cl),mg/l, max.
Fluoride
9 1 1.5 1.32 1.04 0.78
(as F), mg/l, max.
Sl. Parameters Norms* Motanga Kochilimara Galpoda
No. GW4 GW5 GW6
Requirement Permissible
(desirable limits in the
limits) absence of
alternate
source
Date of sampling 26.04.2006 26.04.2006 26.04.2006
Total Dissolved Solids,
10 500 2000 762 625 556
mg/l, max.
Calcium
11 75 200 67 35 82
(as Ca), mg/l, max.
Magnesium
12 30 100 60 77 19
(as Mg), mg/l, max.
Copper
13 0.05 1.5 <0.01 <0.01 <0.01
(as Cu), mg/l, max.
Manganese
14 0.1 0.3
(as Mn), mg/l, max.
Sulphate
15 200 400 56 24 36
Nitrate
16 45 100 0.59 6 4
Phenolic compounds
17 0.001 0.002 <0.001 <0.001 <0.001
(as C6H5OH), mg/l, max.
Mercury,
18 0.001 No relaxation <0.0005 <0.0005 <0.0005
(as Hg), mg/l, max.
Cadmium
19 0.01 No relaxation <0.005 <0.005 <0.005
(as Cd), mg/l, max.
Selenium
20 0.01 No relaxation <0.005 <0.005 <0.005
Arsenic
21 0.05 No relaxation <0.03 <0.03 <0.03
Cyanide
22 0.05 No relaxation <0.01 <0.01 <0.01
(as CN), mg/l, max.
Lead
23 0.05 No relaxation <0.05 <0.05 <0.05
(as Pb), mg/l, max.
Zinc
24 5 15
Anionic Detergents
25 0.2 1 <0.1 <0.1 <0.1
(as MBAS), mg/l, max.
6+
Chromium (as Cr ),
26 0.05 No relaxation <0.01 <0.01 <0.01
mg/l, Max.
27 Mineral oil mg/l, Max. 0.01 0.03 <0.1 <0.1 <0.1
Alkalinity ( as CaCO3),
28 200 600 380 350 272
mg/l
29 Aluminium (as Al ), mg/l 0.03 0.2 <0.01 <0.01 <0.01
30 Boron (as B), mg/l, max. 1 5 <0.01 <0.01 <0.01
* Drinking Water Specification, IS : 10500 (1991)

& Amendment no.1, January’1993
Sl. Parameters Norms* Ganthigriha Narendrapur
No. GW7 GW8
Requirement Permissible limits
(desirable in the absence of
Date of sampling 26.04.2006 26.04.2006
1 Colour, Hazen Units. 5 25 <5 <5
2 Odour Unobjectionable - Unobjectionable Unobjectionable
3 Taste Agreeable - Agreeable Agreeable

4 Turbidity, NTU, Max. 5 10 <5 <5
5 pH value 6.5 to 8.5 No Relaxation 7.4 7.3
Total Hardness
6 300 600 576 328
(as CaCO3), mg/l, max
7 Iron (as Fe), mg/l, max. 0.3 1 0.06 0.28
Chloride
8 250 1000 103 34
(as Cl),mg/l, max.
Fluoride
9 1 1.5 1.2 1.29
(as F), mg/l, max.
Total Dissolved Solids,
10 500 2000 992 589
mg/l, max.
Calcium
11 75 200 61 79
(as Ca), mg/l, max.
Magnesium
12 30 100 103 32
(as Mg), mg/l, max.
Copper
13 0.05 1.5 <0.01 <0.01
(as Cu), mg/l, max.
Manganese
14 0.1 0.3
(as Mn), mg/l, max.
Sulphate
15 200 400 80 47
Nitrate
16 45 100 6 9
Phenolic compounds
17 0.001 0.002 <0.001 <0.001
(as C6H5OH), mg/l, max.
Mercury,
18 0.001 No relaxation <0.0005 <0.0005
(as Hg), mg/l, max.
Cadmium
19 0.01 No relaxation <0.005 <0.005
(as Cd), mg/l, max.
Selenium
20 0.01 No relaxation <0.005 <0.005
Arsenic
21 0.05 No relaxation <0.03 <0.03
Cyanide
22 0.05 No relaxation <0.01 <0.01
(as CN), mg/l, max.
Lead
23 0.05 No relaxation <0.05 <0.05
(as Pb), mg/l, max.
Zinc
24 5 15
Sl. Parameters Norms* Ganthigriha Narendrapur
No. GW7 GW8
Requirement Permissible limits
(desirable in the absence of
Date of sampling 26.04.2006 26.04.2006
Anionic Detergents
25 0.2 1 <0.1 <0.1
(as MBAS), mg/l, max.
6+
Chromium (as Cr ),
26 0.05 No relaxation 0.09 <0.01
mg/l, Max.
27 Mineral oil mg/l, Max. 0.01 0.03 <0.1 <0.1
Alkalinity ( as CaCO3),
28 200 600 526 316
mg/l
29 Aluminium (as Al ), mg/l 0.03 0.2 <0.01 <0.01
30 Boron (as B), mg/l, max. 1 5 <0.01 <0.01
* Drinking Water Specification, IS : 10500 (1991)

& Amendment no.1, January’1993
Chapter-3
Annexure-3.3
Results of Surface Water Analysis
Sl. Parameters River Lingra Kisinda Jhor before River Brahmani

No. SW1 joining Rver Brahmani d/s of Lingra river
SW2 SW3
Date of Sampling 26.04.2006 26.04.2006 26.04.2006
1. Colour, Hazen units, Max. <5 <5 <5
2. Turbidity, NTU, Max. <5 <5 <5
3. pH Value 8.1 7.9 7.7
4. Dissolved Oxygen (as O2), mg/l 5.8 5.6 6.1
5. BOD, 3 days at 27° C, mg/l 2 1 2
6. Total Hardness (as CaCO3), mg/l, Max. 80 100 124

7. Iron (as Fe), mg/l, Max. 0.25 0.59 0.28
8. Chloride (as Cl), mg/l, Max. 22 44 24
9. Fluoride (as F) mg/L, Max. 1.12 2.21 1.0
10. Dissolved Solids mg/l, Max. 178 304 254

11. Calcium (as Ca), mg/l, Max. 18 32 24
12. Magnesium (as Mg), mg/L, Max. 9 5 16
13. Copper (Cu), mg/l, Max. <0.01 <0.01 <0.01
14. Sulphate (as SO4), mg/l, Max. 7 48 14
15. Nitrate (as NO3), mg/l, Max. 0.57 1.22 1.15
Phenolic Compounds (as C6 H5OH), mg/l

16. <0.001 <0.001 <0.001
Max.
17. Mercury (as Hg), mg/l, Max. <0.0005 <0.0005 <0.0005
18. Cadmium (as Cd), mg/l, Max. <0.005 <0.005 <0.005
19. Selenium (as Se), mg/l, Max. <0.005 <0.005 <0.005

Sl. Parameters River Lingra Kisinda Jhor before River Brahmani
No. SW1 joining Rver Brahmani d/s of Lingra river
SW2 SW3
Date of Sampling 26.04.2006 26.04.2006 26.04.2006
20. Arsenic (as As), mg/l, Max. <0.03 <0.03 <0.03
21. Cyanide (as CN), mg/l, Max. <0.01 <0.01 <0.01
22. Lead (as Pb), mg/l, Max. <0.05 <0.05 <0.05
23. Anionic detergent (as MBAS) mg/l, Max. <0.1 <0.1 <0.1
6+
24. Chromium (as Cr ), mg/l, Max. <0.01 <0.01 <0.01
25. Mineral oil mg/l, Max. <0.1 <0.1 <0.1
26. Alkalinity (as CaCO3) mg/l, Max. 72 88 118
27. Aluminium (as A1) mg/l, Max. 0.01 0.01 0.02
28. Coliform organisms, MPN/100ml 600 400 900
29. Sodium Absorption Ratio 0.78 2.03 0.84

4.0 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES
4.1 General
The first step in environmental impact assessment is to list all the potentially
significant environmental impacts. These are then examined critically and the major
impacts (both negative and positive) are analyzed in detail for the EIA.
The existing plant had been planned out considering low specific consumption of
raw materials and energy and minimum impact on the environment. In order to
ensure comprehensiveness, the various aspects considered in listing of impact
during modification-cum-expansion of the plant are:
• Investigation of project components.

• Investigation of project phases.
• Investigation of Impact generating activities.
• Investigation of types of impacts.
There are various techniques available for listing of impact. These include
checklists, matrices, networks and cause effect diagrams etc. The objective of
undertaking EIA of the project under consideration at the selected site is to identify
the probable impacts on the pre-project, or the present environmental setting of the
project site surroundings. This gives a first-hand assessment of the degree of
impacts caused by the project activities from construction stage to operational stage.
From the assessment, it can be judged to what extent the potential impacts are
likely to occur and if so to what level it can be minimized by implementing suggested
environmental management plan (EMP) from the design stage itself.

4.2 Listing Matrix
The possible environmental attributes that may be affected by industrial activities

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

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

The proposed additional major production facilities of the modernization-cum-

expansion program as described in Chapter 2 are (i) augmenting Sintering, (ii) coke
making additional (iii) augmenting BFs, and (iv) Steel making in EAFs v) additional
DRI kilns etc . The supporting production units and facilities are Secondary Refining
Facilities, Pig-Casting, Slag Granulation, Continuous Casting, Billet Caster, Hot Strip
Mill, Oxygen Plant, Lime Plant, Coal Dust Injection System in BF, etc.
Each of the main such production process has got different pollution potential as
may be seen from the Table 4.1.The predominant environmental pollution would be
the air pollution due emissions of dusts and gases and water pollution due to Hot
Strip mill effluents containing toxic substance like oil.
In addition to air and water pollution, there would be generation of solid wastes such
as DRI fines, char, dust from GCP, BF slag, EAF slag, mill scales and washery
rejects and middling etc, major part of which are recycled to the process or used by
others and part may require dumping/storage on the ground for future use.
The environmental impacts of the above additional activities are given in the
following Table 4.1.
Table 4.1: Sources and types of environmental impacts
Section Feed & Fuels Operation Pollutants Recipient Form of

/Units pollution
I. Construction Stage
Construction materials - Dusts Air Air pollution
Noise
Slurry water Open drain Water pollution
Construction debris Land Land pollution
II. Operational Stage
Raw All types of solid raw Mechanical handling, Dusts Air Air pollution
Material materials sizing and conveying
Handling
Coking Coal, by-product fuel Coal carbonization Heat, Dust Air Air pollution
gas as fuel SO2, NOX
VOCs

Section Feed & Fuels Operation Pollutants Recipient Form of

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


4.5 Prediction of Impacts:

In the screening of impact the environmental attributes that may be affected
due to the proposed modification-cum-expansion of existing steel plant have
been identified. Impact prediction is a way of foretelling the environmental
consequences of the significant aspects of the proposed modification-cum-
expansion of plant. Impacts on various environmental attributes during
construction as well as operation have been discussed. The impact
assessment will focus on the proposed modification-cum-expansion and will broadly
cover the following:
¾ Estimation of physical effects for all phases including construction and

operation. Estimation by type and quantity of expected contaminants i.e.
residues, and emissions (air, water, noise, solid wastes) resulting from the
operation of the proposed expansion and modification of existing unit.
¾ Assessment of the positive and negative impacts on land use, future
development, cultural / historic resources, peoples, demographics,
infrastructure, employment, income, education etc.
¾ Indirect impacts which may arise from proposed modification-cum-expansion of
plant.
However, the anticipated environmental impacts of the proposed modification-cum-

expansion are discussed below under the category (a) Impacts during construction
and (b) Impacts during operation.

4.6 Prediction of Impacts During Construction
4.6.1 Land use

BSSL will not acquire any new land for proposed modification-cum-expansion. Most
of the units of the proposed expansion will be either higher capacity unit or
modification of the existing unit cleared during 1.5 Mtpy stage. Accordingly the
construction activity will be limited within the existing BSSL plant premises and in the
already built up area. Thus no large-scale excavation, soil erosion, loss of topsoil is
expected. The BSSL plant site is already a fairly well developed area with all sorts of
infrastructure already available. It is therefore most unexpected that influx of
construction labour is going to change present land use pattern. Further this land
use change during construction is only temporary and will persist during construction
phase only.
4.6.2 Impacts on Ambient Air Quality

The existing plant is already partially in operation and its
modification/expansion will have limited construction work i.e. limited to
specific modification in existing units as well as additional units to be put into
the place. During the limited construction phase, civil work is being carried out
to put the units in its place. The construction work leads to a generation of
fugitive dust. However the fugitive dust is not expected to spread too far. In
addition, water spraying is being undertaken to suppress dust being spread.
Due to limited construction activities, the impacts on ambient air quality will
not be permanent and will cease once the modification construction is
completed after that generation of fugitive dust will reduce drastically.

4.6.3 Impacts on Noise Levels

The present noise level is due to construction and operation of existing plant.
The production units are being chosen by criteria of environmental friendly
technology and shall generate less noise level. Noise levels during this limited
construction are likely to increase initially due to increased movement of
trucks and other diesel powered material handling equipment. This is
unavoidable and limited during day time only. Therefore, movement of trucks
and machinery will be regulated to reduce the impacts of increased noise.
The construction phase will be limited to short period and temporary, the
impacts on ambient noise levels will be insignificant and ceases once the
construction is completed.
4.6.4 Impacts on Water Environment

The water required for construction purpose will be met by extending the
existing water network of the existing plant. However, during construction, a
large volume of debris, mud etc will be generated, which during the rainy
season, can contaminate the storm water run-offs with large amounts of
suspended solids. Efforts will be made to reduce the suspended solids
content of storm water run-offs by routing the storm water drains through
catch pits. Moreover storm water run-offs will occur only during the monsoon
season which lasts for about 2-3 months in the study area. Moreover these
impacts will be temporary lasting only for the duration of the modification-
cum-expansion construction period.
It has already been indicated that the proposed expansion will be limited within an
existing plant. The plant is already having all infrastructure facilities including water
supply. The water requirement during the construction phase will be low and can be
met through the already existing water supply facilities. Thus no ground water is

expected to be extracted. Therefore, it is most unlikely that construction phase will

bring any significant modification in the ground water regime of the area. Therefore,
the construction phase of the proposed expansion will have insignificant impact on
the ground water.
4.6.5 Impacts on Ecology

The modification cum expansion of existing BSSL plant will remain within the
existing boundary of Steel plant and no new area will be acquired for
expansion. The area involved in modification-cum-expansion shall be very
small and hence the impacts on the study area as a whole will be
insignificant. Impact on ecology will be insignificant.
4.6.6 Socio-Economic Impacts

During the modification-cum-expansion limited construction work shall be
carried out in civil as well as machinery handling. The construction phase of
the project involves large deployment of manpower, both direct and indirect.
This involves employment of temporary labour, which is being engaged to
perform these tasks. This will have positive employment effect, both direct
and indirect. This will affect the economy of the study area in positive
direction as the employment shall generate income which gets routed in local
economy.
4.7 Prediction of Impacts During Operation

Generally operation of any production plant emits pollutants. Iron and Steel
industries are also no exception to that. Once the modification-cum-expansion of
existing steel plant to 3.1 Mtpy completed and total plant get operational, there
expected slight increase or marginal impacts on ambient air quality, noise levels,
water quantity and quality, ecology and positive socio-economic environment.
Environmental releases may be in the form of:

a) Emission to air
b) Waste water discharges
c) Solid waste disposal
d) Noise level etc.
These emissions, discharges and disposal may release different pollutants, which
may affect air, water, land and ecological environment directly. However, all these
are mainly primary impact. In addition to these primary impacts any industrial project
or expansion of a project has some overall impact on its surrounding 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 these primary and secondary impacts due to this proposed expansion are
being discussed and wherever required, impacts have also been quantified.
Accordingly under subsequent clauses impacts on air environment, water
environment, soil, noise, land use, and socio-economic environment due to the
proposed expansion are being elaborated.
4.7.1 Impacts on Ambient Air Quality

The principal impacts on ambient air quality due to operation of the fully operational
3.1 Mtpy plant will be due to emissions from the stacks of the various units and
emissions of fugitive dust from the iron ore and coal handling areas.
The prediction of Ground level concentrations (GLC) of pollutants emitted from the
stacks has been carried out using ISCST-3 Air Quality simulation model released by
USEPA. This model is basically a Gaussian dispersion model, which considers
multiple sources. The model accepts hourly meteorological data records, to
define the conditions of plume rise for each source and receptor combination
for each hour of input meteorological data sequentially and calculates short

term averages upto 24 hours.

The impact has been predicted over a 10 km X 10 km area with centre of the
sinter plant stack as the centre. To obtain greater resolution, the receptors
are defined with respect to 16 radial wind directions (N to NNW) and radial
distance from centre. GLC have been calculated at every 500 m grid point to
have better results.
The emissions have been computed based on the following:
a) Particulate matter (SPM) has been calculated considering emission rate of 50

mg/Nm3
b) Sulphur content of the coal has been assumed to be 0.5% as per CPCB
guidelines
c) NOx emissions from Plant have been estimated based on the assumption 75
mg/Nm3 in flue gas and SO2 emission is based on 40 % in gas phase and 60 %
in solid waste as per guideline of technology supplier Lurgi.
Details of the proposed stacks and estimated emissions are given in Table- 4.2.
Table-4.2: Stack Emission Data of 3.1 Mt Steel Plant
Sl. Description of Stack Stack Co- Stack Stack Flow Exit Temp Emission Rate Pollution
no. ordinate Height Dia (m) Rate velocity °C (g/sec) Control
(Plant Centre at (m) (Nm3/hr) (m/sec) equipme
10,10) nt
x-co- y-co- SPM SO2 NOx envisage
ord. ord. d
Sinter Plant Complex (1x177 m2)
1. SINTER PLANT –(MAIN STACK) 10000 10000 100 5.0 1020000 20.48 150 14.2 4.25 5.67 ESP
2. SINTER PLANT –Cooler ESP 10128 9850 60 3.5 412950 12.52 40 5.7 ESP
stack
3. SINTER PLANT -de-dusting 10172 10022 35 2.5 223460 13.28 40 3.1 ESP
Coke Oven Complex (2x65 Oven 4.3 ht)25:75 ratio CO gas to BF gas Stamp Charge

10,10) nt
ord. ord. d
4. Coke Oven Plant-1 11289 10172 120 4.5 105600 3.05 220 0.7 4.40 5.87
5. Coke Oven Plant-1 11322 10183 120 4.5 105600 3.05 220 0.7 4.40 5.87
Blast Furnace Complex (1x1681 m3) bag filter design norm 50 mg/Nm3
6. BF STOVE STACK(3 stove) 10589 9978 70 3.386 160250 7.02 150 1.1 2.23 2.67
7. BF Cast House-de-dusting 10672 9783 45 4.2 816000 17.18 40 11.3 3.4 - Bag Filter
8. BF Stock House-de-dusting 10539 10089 45 3.1 440000 17.01 40 6.1 - - Bag Filter
DRI Process Stacks after Waste heat Recovery Boilers(14x170000 tpy) ESP design norm 50 mg/nm3
9. DRI PROCESS STACK-1 8733 9439 76 2.17 120000 12.79 150 2.7 20.2 ESP
DRI Kilns - De-dusting stacks (ESP design norm 50 mg/Nm3)
23. DRI KILN-1 & 2-in plant de- 8736 9750 45 2.7 300000 15.77 50 4.2 - - ESP
dusting -ESP

10,10) nt
ord. ord. d
dusting -ESP
25. DRI KILN-5& 6-in plant de- 8911 9778 45 2.7 300000 15.77 50 4.2 - - ESP
dusting -ESP
dusting -ESP
dusting -ESP
dusting –ESP
dusting -ESP
SMS Complex
30. SMS-1 EAF+LF FUME 9444 9456 36.5 3.0 300000 15.15 110 4.2 Bag Filter
EXTRACTION-I
31. SMS-1 EAF+LF FUME 9766 9528 36.5 3.0 300000 15.15 110 4.2 Bag Filter
EXTRACTION -II
32. IF+LF FUME EXTRACTION -I 9578 9289 29.5 1.75 150000 22.26 110 2.1 Bag Filter
33. IF+LF FUME EXTRACTION -II 9783 9339 29.5 1.75 150000 22.26 110 2.1 Bag Filter
34. SMS-II EAF+LF FUME 10417 9522 65.0 5.82 1600000 21.47 110 13.3 Bag Filter
EXTRACTION-I
35. SMS-II EAF+LF FUME 10439 9478 65.0 5.82 1600000 21.47 110 13.3 Bag Filter
EXTRACTION -II
HOT STRIP Mill
36. RE-HEATING STACK-1 10933 9372 70 4.5 132700 6.24 530 0.9 1.8 7.37
37. RE-HEATING STACK-2 10961 9378 70 4.5 132700 6.24 530 0.9 1.8 7.37
38. RE-HEATING STACK-3 10978 9383 70 4.5 132700 6.24 530 0.9 1.8 7.37
Raw Material Preparation Plant (Bag Design 50 mg/Nm3)
39. LIME PLANT 1(100tpd Shaft) 9567 9839 40 0.75 17000 13.38 100 0.2 - - Bag Filter
40. LIME PLANT 2(500tpd shaft) 10389 9744 40 1.5 65000 12.79 100 0.9 - - Bag Filter
41. DOLO PLANT-1(500 tpd shaft) 10350 9972 40 1.5 65000 12.79 100 0.9 - - Bag Filter
Captive Power Plant(fuel Clean BF gas 5mg/Nm3)
42. BFG gas fired Boiler of CPP 10639 10056 55 2.0 140000 17.98 160 1.0 - -
* Out of 14 DRI kiln maximum 10 kiln will operate at a time

The meteorological data of the day on which the maximum GLC occurred is shown
as Table-4.3. Stability has been computed by Turner’s method and mixing height
has been obtained from literature and nearby IMD station. The predicted GLC
values have been provided at Table-4.4.
Table 4.3: Meteorological inputs (Summer 2006)
Time Wind Wind Temp. Stability Mixing height (m)

(hours) Direction speed (°K)
(m/s)
01.00 315.0 1.39 302 6 50
02.00 315.0 1.67 301 6 50
03.00 202.5 1.1 301 6 50
04.00 292.5 0.83 302 6 50
05.00 315.0 0.83 302 5 50
06.00 247.5 0.83 302 4 100
07.00 292.5 1.67 302 3 200
08.00 315.0 0.56 303 2 200
09.00 292.5 0.83 305 2 500
10.00 315.0 0.56 307 2 600
11.00 315.0 0.56 308 2 750
12.00 315.0 0.83 310 2 950
13.00 315.0 0.83 311 1 1100
14.00 315.0 0.83 313 1 1200
15.00 292.5 0.83 313 1 1400
16.00 337.5 1.67 312 2 1200
17.00 315.0 1.1 311 3 1000
18.00 315.0 1.67 310 4 800
19.00 315.0 1.1 308 6 700
20.00 315.5 1.1 302 6 500
21.00 292.5 1.1 302 6 250
22.00 292.5 0.83 302 6 200
23.00 315.0 0.83 302 6 150
24.00 202.5 1.1 302 6 100
NOTES: STABILITY CLASS 1=A, 2=B, 3=C, 4=D, 5=E AND 6=F.

Table-4.4: Predicted value of GLCs
Rank Max. 24 h. Avg. (µg/m3) of Pollutants

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

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

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

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

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

4.7.2 Impacts on Water Environment
Impacts on Water Resources
The source of water for the proposed steel plant will be the Brahmani River.
The BSSL plant authority has permission for the drawal of 100 cusecs of
water, from Brahmani River for use in steel plant (permission letter enclosed
as Annexure at the end of this chapter). The actual requirements of integrated
steel plant will be 5400 m3/h (1.5 m3/s). Drawl of 129600m3/day water from
Brahmani river will not affect the availability of water for others, as the lean
season flow rate in the Brahmani River is 1450 cusecs (1,48,105 m3/h).
The steel plant does not extract any ground water nor will do so in future.
Thus operation of the steel plant will not affect ground water availability in the
study area.
Impacts on Water Quality
As the plant water system is designed based on maximum re circulation

system and effective discharge from plant to outside will be insignificant. The
effluents likely to be generated from the proposed plant are:
• Underflow from Raw Water Clariflocculator

• Backwash Waste from Filtration Plant
• DM Plant Regeneration Waste
• Run-off water from Raw Material Storage Yards
• Waste Water from Slab Caster & Billet Caster
• Waste Water from Hot Strip Mill
• Cooling tower blow-down of various shop
• Plant Sewage & Canteen Effluents
• BOD plant effluent in coke oven complex
Sludge from Raw Water Clariflocculator and Backwash from Filtration Plant
will be led to a sludge pond for removing suspended solids. The overflow
from the sludge pond will be used for dust suppression and irrigation of green
cover. The sludge from the sludge pond will be dried and dumped in low lying
area.
In the coke oven complex, phenolic effluent shall be generated. The quantity
of effluent shall be estimated to be 40 m3/h. The effluent will be treated in
BOD plant ETP. The treated liquor shall be recycled to the quenching station,
to be used for quenching of hot coke.
Water from the BF GCP will be sent to a clarifier / thickener. The overflow
from the thickener will be reused in the Pig Casting Machine.
Run-off water from the raw material storage yard will be routed through
garland drains to catch pits to settle out suspended solids. The clear water
will be discharged into natural drainage channels.
Acidic/ Alkaline effluents will be generated at the DM Water Plant. These

effluents will be properly neutralized in neutralization pit before recycling back
for dust suppression.
Effluents from the slab caster and HSM complex are likely to contain
suspended solids and oil & grease. These effluents will be routed to settling
pits fitted with oil & grease trap. The clarified water will be reused in the plant.
Cooling Tower Blow-down and Boiler Blow-down will be utilized for slag
granulation in BF complex and dust suppression in the raw material handling

area. Blow down from the Oxygen Plant will be used in the Pig Casting
Machine. Blow-down from the Fume Extraction Units will be utilized in the
Slab Caster.
Sewage from the plant canteen will be treated in septic tanks and soak
pits.
All storm water drains from the raw materials and solid waste handling areas
will be routed through catch pits of sufficient volume to settle out suspended
solids present in the storm water run-offs.
The lists of water pollution control systems envisaged are summarized in

Table-4.5.
Table-4.5: List of Water Pollution Control Systems
Source Pollutants Control System
Raw material handling Suspended Solids Catch Pits
yard
Raw Water Treatment Suspended Solids Clarifier, Thickener, Sludge
Plant Pond
BF Gas Cleaning Plant Suspended Solids Clarifier, Thickener, Sludge
Pond
Phenolic effluent Phenols, Ammonia, BOD Plant
etc
DM Water Plant pH Neutralizing Pit
Slab Caster and Hot Suspended Solids, Settling Tanks fitted with Oil &
Strip Mills Oil & Grease Grease Trap
Cooling Tower and Temperature, Reused in the plant for dust
Boiler Blow-down Dissolved Solids suppression and slag
granulation
Canteens, Toilets BOD, Suspended Septic Tanks, Soak Pits
Solids
Thus integrated steel plant will recycle water to the maximum extent possible.
However, in abnormal condition occasionally small quantities of waste water

have to be discharged to prevent build up of excess dissolved solids in

circulating water. During the monsoon requirement of water for dust
suppression and green belt irrigation will be drastically reduced. Hence
excess water from the sludge pond will have to be discharged. This waste
water will mostly contain salts of Calcium and Magnesium and suspended
solids already present in the raw water. Moreover, the waste water quality will
be well within the stipulated norms.
4.7.3 Generation of Solid Waste
The major solid wastes expected to be generated from the various facilities of
integrated steel plant are as follows:
Table-4.3: Quantity of Solid Waste Generated in the 3.1Mtpy Steel Plant
Sr. Solid Waste Nature of Solid Waste Quantity Probable Re-use

No. (tpy)
DRI SECTION:
1. DRI fines Iron fines:33% 714000 100% will be utilize within plant in
coal fines in the form of sinter making and steel making
solids as fixed C: 9%
Ash:58%
2. Char Ash:60% 749700 100% will be sold to BEL who is
C:35% setting up CFBC based Power
H2O : 3.5% Plant within plant boundary.
VM:1.5%
3. Transfer point dust Solid dust 324655 100% will be utilized within plant in
from ESP sinter making
4. Kiln Accretion and - 42273 Dumped in low lying area and may
miscellaneous be used in clay making for various
waste purpose in steel plant
COKE OVEN COMPLEX
Coke Breeze 127000 Will be reused in sinter making


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


No. (tpy)
H2:1.6% boundary
S:0.5%
Solid waste shall be in the form of following:
• Fines collected from de-dusting system,

• Scales & scraps
• Slag from BF & EAF
Scales and skulls shall be generated as solid waste from integrated steel plant of
BSSL. These Scales and skulls are of ferrous nature and shall be recyclable. There
will be generation of scrap, which will be recycled in the plant itself in the Induction
furnace.
Slag from Blast furnace will be granulated and sold to the cement plants for slag
cement. Scrap from SMS and other areas will be recycled in the proposed steel
plant to the extent possible. Scale and debris from HSM will be recycled to the
maximum extent possible in the plant itself.
Management of SMS slag

The estimated slag generation from SMS operation shall be 445,032 tpy. The 50%
SMS slag will be used in land fill at low-lying areas and will be given for road making
purpose along with internal reuse. The remaining 50% shall be used in BF & inter
Mix as flux.
Management of Char & Washery Reject

The char is generated from DR kiln operation. The quantity and its disposal is
indicated in the table 5.2. The 100% char shall be sold to Bhushan Energy Limited

(BEL) for utilization in CFBC boilers. The coal washery shall generate 1,118,000 tpy
rejects and middling. These rejects shall be sold 100% to BEL for its use in CFBC
boilers to generate 300 MW power.
4.7.4 Impacts on Noise Levels
During normal operations of the plant ambient noise levels will increase
significantly only close to the turbines/compressor but this will be confined
only within plant boundary. However noise levels will increase greatly during
bleeding-off of excess steam. But such incidents are rare and will last only for
few minutes at a time only. The noise level within the plant boundary is
occupational noise levels and confined within shops. The level will be further
minimized when the noise reaches the plant boundary and the nearest
residential areas beyond the plant boundary, as elaborate green belt
development is envisaged for all along the boundary for attenuation of noise
and fugitive emission.
All the equipment in the steel plant will be designed/operated in such away
that the noise level shall not exceed 85 dB (A) as per the requirement of
OSHA Standard (Occupational Safety and Health Association). However, if
during operation, the noise level exceeds the OSHA norms then the
protective measures given in Environmental Management Plan will be
followed.
In addition to it, green belt development around the shops is to be done to minimise
propagation of noise to nearby areas.
4.7.5 Impacts on Ecology

The thresh-hold limit for continuous exposure of SO2 on plants is about 50 ug/m3
and that for NOx is 100 ug/m3 (Env. Engg., Chapter 7 by H. S. Pavy, D. R. Rowe,
G.T. Chobanoglous. Mc.Graw-Hill Book Co.1986). The level of air pollutants due to

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

5.0 ENVIRONMENTAL MANAGEMENT PLAN
5.1 Introduction
It has been observed in the chapter 4.0 that due to modification-cum-expansion
of integrated steel plant, there will be minor impact during construction and
operation of plant. The adverse impacts can be minimized, if suggested pollution
control measures are undertaken and implemented. To mitigate the
environmental problem, a comprehensive Environmental Management Plan
(EMP) has been formulated in this context. The EMP has been worked out based
on present environmental conditions and anticipated environmental impact
appraisal. The EMP has been made for formulation, implementation and
monitoring of environmental protection measures during and after commissioning
of the project taking into consideration the following:
• Mitigation of Adverse impacts

• Occupational safety and Health
• Training facilities
5.2 Mitigation of Adverse Impacts
5.2.1 Air Pollution Management

In the integrated steel plant the sources of air pollution will be:
• Burning of fuel (coal) in DRI, Sinter plant, Blast Furnace and coke ovens
• Air pollution in the form of fumes due to melting of iron scrap and sponge iron
in Electric Arc furnaces etc
• Fugitive dust due to handling of coal and iron ore and other raw materials etc

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

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

station.
Coke oven gas is cleaned and limited by-product is recovered and clean
gas is supplied to various users including coke oven batteries for heating.

Blast Furnace
Dust laden air will be sucked from different dust generating points by means of
suction hood, ducts and exhausted in the atmosphere after cleaning/collecting
dust in the dust collection equipment using bag filters.
For the blast furnace gas, it is proposed to use dry cyclone and wet scrubbing of
gas. Settling of particulate matter will be accomplished in water clarifiers and dust
settling chambers.
Lime calcining plant
The dust coming out from the lime kiln would be collected through bag filters and
the cleaned gas would be led into atmosphere through a tall stack. The dust
from the non point source would also be collected by DE hoods and the dust
laden gas would be cleaned by bag filters.
Electric arc furnace
The emissions from melting and refining would account to about 90 percent of
total EAF emissions. The remaining 10 per cent of emissions are generated
during charging and tapping. The primary emissions from the EAF would be
taken through a duct on the furnace roof to bag-filters.
The secondary emissions during charging and taping would be collected by a

canopy hood over the EAF and taken in the same manner to the bag-filter. Both
the emissions will be discharged into the atmosphere through a stack of suitable
height.

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

with all accessories Plain water type dust suppression system will be provided at
the all around the coal/ raw material stockpiles and coal washery. The dust
suppression systems will consist of water sprinkling systems.
In order to prevent the spread of fugitive dust, green belt of adequate width
will be developed all around the plant boundary and other locations
described later.
The sources of air pollution and the control methodologies are summarized
in Table-5.1.
Table-5.1: Sources of Air Pollutants and Control Methods

Source Pollutants Control Method
Raw Material Handling Fugitive Dust Dust Suppression System,
Yard Green Belt
DRI process gas Dust,SO2 ESP, Lime & Dolomite
Blast Furnace Stock Dust Bag Filter
House
Blast Furnace Stove SO2, NOx Burner Design, Stack of
adequate height
Blast Furnace Dust in Top Gas Gas Cleaning Plant
Lime Plant Dust, SO2, NOx Bag Filter, Stack of adequate
height
Steel Melting Shop Dust Bag Filter
Ferro-Alloys Plant Dust Bag Filter
Reheating Furnace NOx Burner Design, Stack of
adequate height
Coke ovens SO2, NOx Stack of adequate height,
gas cleaning in by-product
recovery unit
Sinter plant Dust,SO2 & NOx ESP and stack of adequate
height
Following are the list of pollution control equipment provided in the plant.
Table-5.2: LIST OF AIR POLLUTION CONTROL EQUIPMENT

Name of the unit Pollution control system
Sinter Plant Complex

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

34. IF+LF Fume Extraction -II Bag Filter

35. SMS-II EAF+LF Fume Extraction-I Bag Filter
36. SMS-II EAF+LF Fume Extraction -II Bag Filter
Hot Strip Mill
37. RE-HEATING STACK-1
38. RE-HEATING STACK-2
39 RE-HEATING STACK-3
Captive Power Plant
40. BFG gas fired Boiler of CPP
Lime & Dolo Plant
41. LIME PLANT – KILN1 Bag Filter
42. LIME PLANT – KILN2 Bag Filter
43. DOLO PLANT – KILN5 Bag Filter
Raw Material Preparation Plant
44. RMP CRUSHER Bag Filter
5.2.2 Wastewater Management

The prevention and control of water pollution aim at conserving make-up water
by recycling the wastewater after treatment. During the operation of the plant,
three major categories of wastewater, viz. blow down water from the cooling
tower, ash slurry water and sanitary waste water streams would be generated.
Wastewaters are expected to be generated from different facilities of the

proposed plant. Water Balance Diagram is given in Drg No BSSL/0/ISP/7-
1 sheet 1 of 1. Efforts are made to reuse most of the water in the plant
itself.
The wastewater likely to be generated from the integrated steel plant is:
Underflow from Raw Water Clariflocculator

Backwash Waste from Filtration Plant
DM Plant Regeneration Waste

Run-off water from Raw Material Storage Yards

Waste water from gas cleaning system in BF
Phenolic effluent in Coke oven complex
Waste Water from Hot Strip Mill
Cooling Tower Blow-down
Boiler Blow-down
Sewage & Canteen Effluents
Sludge from Raw Water Clariflocculator and Backwash from Filtration

Plant will be led to a thickener for removing suspended solids. The
overflow from the thickener will be reused in the plant water system. The
sludge from the thickener will be dried and dumped. During the monsoon
season, this treated effluent along with run-off will be discharged to nearby
natural drainage system. Since this treated effluent will contain only solids
present in the raw water drawn from Brahmani River, the discharge of this
treated effluent will not affect the quality of Brahmani River by any
appreciable degree.
Water from coal washery will be treated in thickener. Overflow from thickener
(clarified water) will be reused in the plant. The coal washery shall maintain
close circuit operation.
Water from the BF GCP will be sent to a clarifier / thickener. The overflow
from the thickener will be re-circulated. The underflow from the thickener
will be sent to a press filter and recovered cake will be recycled in sinter
plant.

Acidic and Alkaline effluents will be generated at the DM Water Plant.

These effluents will be properly neutralized and reused in the plant through
ash pond.
Effluents from the slab caster and hot strip mill complex are likely to
contain suspended solids and oil & grease. These effluents will be routed
to settling pits fitted with oil & grease trap. The clarified water will be
reused in the plant.
Cooling Tower Blow-down from various recirculation systems will be

cascaded for reuse in other qualitatively compatible systems as shown in
enclosed water balance drawing.
Thus, proposed plant will recycle water to the maximum extent possible.
However in abnormal cases periodically small quantities (50 m3/h max) of
effluents if and when required to be discharge to prevent build up of
excess dissolved solids into natural drainage channels through
stabilization in pond and will be well within the stipulated norms of quality.
Efforts will be made to harvest rainwater in the plant. Run-off water from
the office areas, shop roofs will be collected and stored for future use.
oil sewer will collect water from areas where there are possibilities of
contamination by oil (transformer yard, fuel & lubricating oil storage areas, and
workshop) and the drains from such areas will be routed through an oil-water
separator. The collected oil shall be sold to re-refiner approved by SPCB.
All storm water drains from the raw materials and solid waste handling
areas will be routed through garland drains into catch pits of sufficient

volume to settle out suspended solids present in the storm water run-offs.
The clear water will be discharged into natural drainage channels. This
type of effluent is anticipated only in monsoon season.
The sewage from the Plant, Township and Canteen waste water will be treated in
sewage Treatment Plant. The treated sewage will be diverted for irrigation of
green cover.
5.2.3 Solid Waste Management/Disposal

The principal solid waste produced by any steel plant is slag, scrap, scale and
dust. The dust from dust catcher of DRI unit, dust from SMS section will be
recycled to the extent possible in the plant itself or sold to outside parties.
SMS slag from EAF will be used in land fill at low-lying areas. Slag from Blast
furnace will be granulated and sold to the cement plants for slag cement. Scrap
from SMS and other areas will be recycled in the steel plant to the extent
possible. Scale and debris from HSM will be recycled to the maximum extent
possible in the plant itself. The solid waste generated and their probable uses are
indicated in the Table-5.2.
Table-5.2: Quantity of Solid Waste Generated in the 3.1Mtpy Steel Plant
Sr. Solid Waste Nature of Solid Waste Quantity Disposal methodology

No. (tpy)
DRI SECTION:
1. DRI fines Iron fines:33% 714000 100% will be utilize within plant in
coal fines in the form of sinter making & steel making
solids as fixed C: 9%
Ash:58%
2. Char Ash:60% 749700 100% will be sold to BEL who is
C:35% setting up CFBC based Power
H2O : 3.5% Plant within plant boundary.
VM:1.5%
3. Transfer point dust Solid dust 324655 100% will be utilized within plant in
from ESP sinter making

Sr. Solid Waste Nature of Solid Waste Quantity Disposal methodology

No. (tpy)
4. Kiln Accretion and - 42273 Dumped in low lying area and may
miscellaneous be used in clay making for various
waste purposes in steel plant
COKE OVEN COMPLEX
5. Coke Breeze 127000 Will be reused in sinter making
within steel plant
SINTER PLANT
6. Sinter dust solid 11607 Will be recycled in sinter plant
BLAST FURNACE
7. Dust from GCP Fe:50% 50430 Will be reused in sinter making

CaO:20%
SiO2:2%
Al2O3:3%
8. Granulated Slag MgO:8% 401000 Granulated and 100% sold to
Al2O3:22% cement plant
9. Usable in plant 47619 Will be recycled in SMS.
scrap
SMS SECTION:
10. Slag CaO:40-60% 445032 will be used in the land fill, Boulder
SiO2:12-18% soling of plant roads and may be
MgO:4-7% used partly in sinter making
Fe2O3:5-7% .
11. Dust FeO:70% 22888 To be reused to the sinter plant
MgO:9%
CaO:6%
12. Scales Fe:>90% 15894 100% reused in sinter plant
13. Usable Scrap 82000 100% Reused in steel making
HSM (Mill)
14. Return Scrap 38700 100% Reused in steel making
ORE CRUSHING
16. Iron Ore fines 1458600 100% reused in sinter plant
COAL WASHERY:
17. Middling from coal Ash : 45% 1118000 100% sold to Bhushan Energy
washery Carbon : 24% Limited who is setting CFBC based
O2:2.9% power plant within steel plant
H2:1.6% boundary
S:0.5%

The iron ore fines and BF GCP Sludge will be recycled in sinter plant.
Since the proposed plant envisages such a facility, the iron ore fines will
be used for sintering. The GCP Sludge will be recycled in sinter plant.
Sludge from water treatment plant and dust recovered from dust extraction
systems will be dumped in sludge pond. The slag from the Blast Furnace
will be granulated and sold to cement manufacturers. The SMS slag will be
sold to parties engaged in building roads.
Other solid wastes, which will be generated in the proposed steel plant,
include waste refractories, scrap, scales, waste lubricants etc. Waste
refractories will be sold as road building material or dumped in landfills. All
the scrap will be recycled fully. Waste lubricants will be sold to
reprocessing units. Scales will be recycled. The used batteries shall be
returned back to the manufacturer in lieu of the new batteries of equivalent
numbers.
Hazardous wastes from by product plant will be reused and balance will be
disposed / sold as per Hazardous waste rules of Indian government.
5.2.4 Noise Level Management

In integrated steel plant crusher area, furnace area, the power generating sets,
fans and pumps will be the major sources of noise.
Noise generation levels will be considered while selecting equipment. Equipment

should not generate noise more than 85 dB (A) at 1m distance. Wherever
required noisy equipment will be placed on vibration isolators or housed in a
separate enclosure or surrounded by baffles covered with noise absorbing
material. As the operator would be stationed in the control room, there is

minimum chance of exposure to high noise levels. However Personnel working in

high noise zones will be issued with personal noise protection equipment (e.g.
ear muffs, ear plugs) and their duty hours will be regulated to control noise
exposure levels. In addition green belt will be developed all around the plant
boundary and around various shops and offices to prevent the spread of
noise produced inside the plant.
5.2.5 Green Belt Development Plan

Green belt is an important sink for air pollutants. Trees also absorb noise and by
enhancing the green cover, improve the ecology and aesthetics and affect the
local micrometeorology. Trees also have major long-term impacts on soil quality
and the ground water table. By using suitable plant species, green belts can be
developed in strategic zones to provide protection from emitted pollutants and
noise.
Plant species suitable for green belts should not only must be able to
flourish in the area but must also have rapid growth rate, evergreen habit,
large crown volume and small / pendulous leaves with smooth surfaces.
All these traits are difficult to get in a single species. Therefore a
combination of these is sought while selecting trees for green belt. The
green belt should be planted close to the source or to the area to be
protected to optimize the attenuation within physical limitations.
In the proposed plant, green belt will be developed in vacant areas,

around office buildings, around stores, along the side of roads, along the
plant’s boundaries and around the waste dump area. Plant species suitable
for green belts should not only be able to flourish in the area but must also have
rapid growth rate, evergreen habit, large crown volume and small / pendulous
leaves with smooth surfaces. All these traits are difficult to get in a single

species. Therefore a combination of these is sought while selecting trees for

green belt. The green belt should be planted close to the source or to the area to
be protected to optimize the attenuation within physical limitations. A total of
approximately 33% area will be developed as green belt or green cover. Green
belt will also be planted in township. The widths of the belt will 50 m to 100 m as
per the space availability all along the boundary. Whereas, around waste dumps
site an area of about 100 acre will be under green belt with a width ranging from
30 m to 50 m as per the availability of space. A total of about 1200 - 1500 per ha
plants will be planted. The species for green belt development will be
selected in consultation with the State Forest Department. The following
species are suitable for planting in the area as recommended by Central
Pollution Control Board in their publication “Guidelines for Developing
Greenbelts” (PROBES/75/1999-2000):
A very elaborate green belt development plan has been drawn for the proposed
plant. The areas, which need special attention regarding green belt development
in the industrial area, are:
- Along Plant Boundary

- Along Road Side
- Around Various Shops
- Around Office and Other Buildings
- Stretch of Open Land
- In and Around Township

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

Druping Ashok (Polyalthia longifoila)

Mango (Mangifera indica)
Peepal (Ficus religiosa)
Arjun (Terminalia arjuna)
Jackfruit (Artocarpus heterophylla)
Palash (Butea spp)
Cassia (Cassia siamea)
Bottle brush (Callistemon lanceolatus)
Road Side Plantation
Avenue plantation should include the following species:

Gulmohar (Delonix regia
imli (Tamarindus indica)
Bargad (Ficus bengalisis)
Around Various Shops
As there will be limited space (in height) due to various over head pipelines, thus
small and medium sized species are suggested and they should be planted

depending on the vertical height and lateral space available for the plant growth.
The species selected will be from among the following:
Small Species
Ber (Zyziphus sp.)
Sharifa (Annona squamosa)
Prosopis (Prosopis sp.)
Cassia (Cassia auriculata)
Duranta (Duranta sp.)
Kamayani (Murrya exotica)
Medium Size Species

Kaner (Nerium sp.)
Subabool (Leucaena leucocephala)
Cassia (Cassia alata)
Babool (Acacia arabica)
Around Office and Other Buildings
Plantation will be done around various shops, stores and other buildings, along
the side of connecting roads. Species suggested for plantation are as follows
which are mostly ornamental plants:
Cassia (Cassia javanica)


Lagerestromea (Lagerestromea flosregennae)

Peltophorum (Peltophorum feruginium)
Gulmohar (Delonix regia)
Stretch Of Open land
In the proposed plant, green belt will be developed in vacant areas. Species
suggested for such areas are:

Pakur (Ficus racemosa)
Imli (Tamarindus indica)
Peltophorum (Peltophorum feruginium)
Bargad (Ficus bengalisis)
Mixed plantation will be done to take care of different heights and rates of growth.

In and Around Township
In the proposed township plantation will be done in following areas:
- Along the township boundary

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

Kitchen waste from plant canteen can be used as manure either after composting
or by directly burying the manure at the base of the plants.
5.3 Rainwater Harvesting
BSSL is planning to have a system of rainwater harvesting at plant in

Meramandali. Rainwater harvesting is primarily dependent on various site
characteristics such as soil properly, catchments characteristics; rainfall
characteristic, and ground water table etc.
There are artificial as well as natural rainwater harvesting system. The

recharging system can be implemented for
i) Individual units
ii) Centralized collection system
Scheme I: Collection of rainwater harvesting from individual building units and

construction of filter beds at individual building unit. Rainwater falling on other
open area is to be collected, through constructed drainage system and discharge
system and discharge to surface out-fall (by passed for rainwater harvesting)
Scheme II: Construction of rainwater filter bed at centralized place where water
from individual unit as well as storm water from open area shall be diverted
The rainwater carries suspended solids as washed out from open area. A filter
bed filters the particles thus prevent them from reaching / contaminating ground
water.

The first layer of filter bed shall be coarse sand the second layer shall be pebbles
and third layer shall be gravel. The filtrate thus collected from the bottom of filter
bed shall be piped to recharge bed.
5.4 House Keeping

Proper house keeping is an essential part of sound environmental management.
It will be rigorously seen that there is no accumulation of wastes, especially

combustible wastes (e.g. Oily rags, oil sludge, wood from packing boxes, etc.)
inside the plant area. In summer dry grasses & vegetation growing inside the
plant area will be cut and removed. All fire fighting equipment and warning
devices will be kept in perfect working conditions.
It will be seen that all personnel are aware of the implications of environmental
pollution and simple practices to avoid pollution.
5.5 Occupational Safety and Health

Maintenance of occupational safety and health is very closely related to
productivity, good employer employee relationships and good relationships
among all on board personnel.
The main factors of occupational health in steel plant are dust, heat and noise.
Following measures will be undertaken in the installation for occupational safety
and health of workers.
z Inspection and maintenance of pollution control systems will be undertaken

only after checking that the equipment has been properly shut down or with
permission of authorised officer.
z Immediate removal of waste accumulated in working areas.

z Insulation of hot surfaces.

z All safety measures will be strictly implemented. Fire fighting equipment will
be tested regularly to ensure their full serviceability. Contingency plans drawn
up to deal with accidents will be rehearsed by all personnel.
z Training of employees for use of safety appliances and first aid.
z Regular medical check up of personnel will be carried out.
5.6 Pollution Monitoring

The proposed plant’s Environmental laboratory may be equipped to monitor
meteorology, air quality, noise, water quality, emissions from stacks and solid
wastes. External laboratories may be contracted to carry out the required
monitoring work. The frequency of sampling will be as per Central and State
Pollution Control Board guidelines. Continuous on line monitoring facilities will be
provided for each major stack. An Environment Management department will be
constituted to operate and maintain all pollution control systems, organise
necessary environmental monitoring and maintain records & details of
monitoring.
5.7 Training Facilities

To achieve the objective of pollution control it is essential not only to provide
latest pollution control and monitoring systems but also provide trained
manpower to operate and maintain such systems. So the Environmental
Management department personnel will be provided with additional specialized
training to operate and maintain the equipment to be deployed on the installation.
All personnel will be trained to deal with pollution emergencies also.

5.8 Community Development Plan
BSSL is committed to community development around the steel plant. It

has an ambitious plan to adopt 10 villages for community development. A
substantial amount has been allocated for the following activities for the
social up-liftment of surrounding villages.
• An school for children of surrounding villages upto XIIth standard
• A 50 bedded community hospital for the population in surrounding
villages
• Provision of drinking water facilities in surrounding villages
• BSSL will facilitate the technical training institute such as ITI in
collaboration with state authority.
• Provision for training of women folks (sewing, stitching etc) of
surrounding villages for their economic up-liftment.
5.9 Charter on Corporate Responsibility for Environmental Protection (CREP):

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

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

Hazardous Wastes
Charge of tar sludge / ETP sludge to Coke Oven by June 2003.
Inventorization of the Hazardous Waste as per Hazardous Waste (M&H) Rules,

1989 as amended in 2000 and implementation of the Rules by Dec. 2003.
(tar sludge, acid sludge, waste lubricating oil and type fuel falls in the category of
Hazardous Waste)
Inventorisation of the hazardous waste will be done in line with the notification.
5. Water Conservation / Water Pollution
To reduce specific water consumption to 5 m3/t for long products and 8 m3/t for
flat products by December 2005.
The water conservation as per the directives of CREP, when the plant gets
stabilised and below 8 m3/t for flat products.
To operate the CO-BP effluent treatment plant efficiently to achieve the notified
effluent discharge standards. - by July 2003
The Phenolic effluent shall be treated in BOD plant and treated effluent shall be
used for coke quenching after suitable Addison of makeup water.
6. Installation of Continuous stack monitoring system & its calibration in major
stacks and setting up of the online ambient air quality monitoring stations by June
2005.
Continuous stack monitoring system & its calibration in major stacks shall be
provided. 5 nos. of permanent AAQ monitoring stations around plant is also
envisaged.
7. To operate the existing pollution control equipment efficiently and to keep

proper record of run hours, failure time and efficiency with immediate effect.
Compliance report in this regard is submitted to CPCB / SPCB every three
months.
Agreed
8. To implement the recommendations of Life Cycle Assessment (LCA) study

sponsored by MoEF by December 2003.
The issue shall be examined & shall be to be done as per the Government
directives
9. The industry will initiate the steps to adopt the following clean
technologies/measures to improve the performance of industry towards
production, energy and environment.
- Energy recovery of top Blast Furnace (BF) gas.
We are committed to adapt best available technology
- Use of Tar-free runner linings.

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

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

- To Improve overall house keeping.
Agreed
10. Sponge Iron Plants
Inventorisation of sponge iron plants to be completed by SPCBs/CPCB by June

2003 and units will be asked to install proper air pollution control equipment by
December 2003 to control primary and secondary emissions.
* As per rebuilding schedule submitted to CPCB/MoEF.
Proper air pollution control equipment shall be employed

6.0 EMP IMPLEMENTATION AND MONITORING
Various measures have been suggested in the environmental management

plan for mitigation of impacts. These have to be implemented according to
the suggestions and monitored regularly to prevent any lapse.
A large part of the sampling and measurement activity is concerned with long
term monitoring aimed at providing an early warning of any undesirable
changes or trends in the natural environment that could be associated with
the plant’s operation. A separate department has already been to look after
all environmental related matters of the plant.
Quarterly environmental audits will be carried out for expansion plant to

check for compliance with standards. This is being carried out by external
experts.
Third party environmental audits will be carried out once very year.
BSSL has already taken ISO:14001 EMS certification in many of its plant and
will implement Environmental Management System (EMS) in Meramandali
also.
The unit is taking all necessary steps to implement the measures suggested
by Central Pollution Control Board (CPCB) in the Charter on Corporate
Responsibility for Environmental Protection (CREP) for Integrated Iron and
Steel Industry.

6.1 Laboratory Facilities
It is imperative to BSSL to have a well-equipped environmental control

laboratory inside the plant premises. The Environmental control laboratory
shall apply for recognition as per EP Act 1986 and notified in Government of
India Gazette. The laboratory shall be running continuously 24 hours in three-
shift operation and carrying out all monitoring as specified in their Consent
condition.
All the personnel deployed in the laboratory have been given training by
external experts so to carry out necessary environmental monitoring as well
analysis. The equipment will be made available for carrying out
environmental monitoring shall be as follows:
Table 6.1: List of Monitoring / Analytical Equipments required with

Environmental Lab of Meramandali Steel Plant
Sl. Item Description / make/ model Quantity

No.
1. High Volume Sampler Vayubodhan APM-4-0 4
2. Respirable Dust Sampler Vayubodhan APM-451 4
3. Stack Monitoring Kit Env. Engg. Nagpur SMK-70 1
4. HVS Flow Calibrator Andersons samplers S-53 1
5. PM-10 HVS Ecotech Pvt. Ltd. 2
6. Dry Gas Meter Env. Engineers Inc. A-1 3
7. Analytical Balance The Balance Works (P) Ltd. 1
8. Digital Balance Sartorious L-22005 1
9. Anemometer Dynalab 1
10. Digital Balance Sartorious R-200 D 1
11. Personal Sampler Gillian HFS-113 A 1
12. Nephelo Turbidity meter HACH / 16800 2
13. DR-2000 Spectrophoto Meter HACH / 44800 2
14. COD Reactor HACH / 45600 2
15. Portable Dissolved Oxygen Toshniwal Process Inc. Ltd. OXI-191 2
Meter
16. PDV-2000 Digital Voltameter Chemetronics Austria PDV-2000 1
Sl. Item Description / make/ model Quantity

No.
17. Selective Iron Meter Orion Reaserch Inc. AE-940 1
18. Selective Iron Meter Orion Reaserch Inc. AE-960 1
19. Composite Sampler Sigma / 702 2
20. Visible Spectro Meter Nikal Associates Genway UK/6100 1
21. BOD Analyser HACH/2173-B 1
22. BOD Incubator Newtronic 10 GRS 1
23. Ultrasonic Flow Meter Polysonics 18408 MST-P 4
24. Vaccum Pump Charles Austerm Pumps Ltd. Capes- 1
L3C
25. Vaccum Pump Charles Austerm Pumps Ltd. Capes- 1
L2C
26. Muffle Furnace Okay 1
27. Drying Oven Scientists Own Concern – 360 2
28. Ultrasonic Cleaner Lucas Dawe B 3200 E4 1
29. Adjustable Digital Pipettes HACH (Eriuliben) 1
30. Spectrophotometer Toshniwal (BOM) Inst. Pvt. Ltd. 1
31. Digital Multimeter Philips Scientific – 8050 A 1
32. D.O Meter ORION 810 1
33. Hot Plate 1
34. Muffle Furnace Super Heating India 1
35. Electronic Balance Anamed Co AA-2200 1
36. Digital Conductivity meter Unitech U-31 C 1
37. Sound Level Meter with Bruael & Kjear – 2230 1
calibrator & Octave Pilter Set
38. CEL-275 SLM Lucas CEL-275 1
39. CEL-177 Precision Acoustic Lucas CEL 1
Calibrator
40. CEL-296 Octave Y-3 Octave 1
filter
41. CEL-238 Secondary Processor Lucas CEL 1
with Printer
42. UHER 4200 Report Monitor UHER – 4200 1
43. Electronic Balance ORTELING 1
44. On-line ambient air monitoring 2
station
45. On-line stack monitoring of major 15
stack
6.2 Meteorology
A meteorological station will be set up at a suitable location within the plant

premises. The following parameters will be recorded regularly:

9 Wind speed and direction

9 Rainfall
9 Temperature and humidity
9 Evaporation rate
6.3 Primary & Secondary Emissions Monitoring & Air Quality
Ambient air quality shall be monitored regularly in accordance with CPCB /

Orissa State Pollution Control Board (OSPCB) guidelines. Work zone air
quality shall also be monitored as per directives of OSPCB to assess the
levels of particulate matter, NOx and SO2.
Efforts will be made to install continuous Ambient Air Quality monitoring

systems in accordance with the CREP. All major stacks will be provided with
on-line monitoring system. The emissions from all the stacks shall be
monitored once a month using the manually operated stack emissions
monitoring equipment. However the frequency of monitoring may be
increased if required in accordance with the stipulations of OSPCB or other
statutory authorities.
6.3.1 Stack Emission Monitoring*
Shop Nos. of Stacks Monitoring Frequency

per month
1. Sinter Plants 3 3
2. Coke Ovens 2 2
3. Blast Furnaces 3 3
4. Refractory Material Plant 3 3

Shop Nos. of Stacks Monitoring Frequency

per month
5. Steel Melting Shop 6 6
6. Hot Strip Mill 3 3
7. DRI Units 17 17
* Parameters = TPM, SO2, NOX
6.3.2 Ambient Air Quality Monitoring*
Description Nos. of Stn Monitoring Frequency

1. AAQ Monitoring 5 Once per Week
* Parameters = SPM, SO2, NOX
6.3.3 Water Quality Monitoring*
Description Nos. of Locations Monitoring Frequency

1. Outlets 2 Once a Week
* Parameters = pH, SS, Phenol, Cyanide, COD, BOD, DO, NH3-N, Temp. O & G
6.3.4 Noise Monitoring
Description Nos. of Locations Monitoring Frequency

1 Ambient Noise 10 Once in 3 months
The suggestions given in the EMP shall be implemented by the EMD by following an
implementation schedule.

• Along with the performance and guarantee test of main plant equipment,
performance and guarantee test of pollution control equipment will be made
before taking over the expansion plant. EMD shall also be a party in preliminary
and final acceptance tests.
• A detailed maintenance schedule shall be drawn for all pollution control systems.
The maintenance shall be done strictly as per schedule and guidelines furnished
by plant manufacturer.
• Ground level concentration in ambient air, stack emission and work zone
monitoring results shall be discussed in the EMD and any variance from norms
shall be reported to the Executive Director for immediate study and rectification
action
6.4 Drainage System
The effectiveness of the drainage system depends on proper cleaning of all

drainage pipes/channels. Regular checking is being done to see that none of
the drains are clogged due to accumulation of sludge/sediments. The clogged
drains are cleaned as soon as possible, preferably the same day. The catch-
pits linked to the storm water drainage system from the raw material handling
areas are regularly checked and cleaned to ensure their effectiveness. This
checking and cleaning is rigorous during the monsoon season, especially if
heavy rains are forecast.
6.5 Water Quality
Effluents from outfall, Sewage treatment plant from Township and Plant are

monitored and tested in Environmental Control Laboratory at least once a

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

o Watering of the plants, manuring, weeding, hoeing will be carried out for
minimum 3 years
6.8 House Keeping
The EMD shall be keeping a very close monitoring of house keeping activities and
organising regular meetings of joint forum at the shop level (monthly), zonal level –
(once in two months) and apex level ( quarterly). The CED (Civil Engineering
Department) shall take care for the house keeping of shops.
6.9 Occupational Health
Routine medical examination of personnel shall be carried out as a

systematic programme at plant.
6.10 Interaction with State Pollution Control Board (SPCB)
EMD shall be in regular touch with OSPCB and send them quarterly progress report
on EMP. Any new regulations considered by State/Central Pollution Control Board
for the Industry are been taken care of.

7.0 DISASTER MANAGEMENT PLAN
An Emergency Plan has been formulated to take care of any disaster in the
existing integrated steel plant and surrounding areas and is detailed as under:
In order to prevent occurrence of any disaster, the plant will be provided with
various safety and disaster control facilities. Normally, in the steel plant, no
major disaster affecting nearby population areas are foreseen. However,
accidents inside the plant affecting workplace in vicinity cannot be ruled
out. Work-force inside the plant shall be exposed to various high pressure
system pipelines and vessels, acids and chemicals, fuel such as coal and
furnace oil and other process equipment which, if not properly operated and
maintained, can cause serious accidents affecting life and property in the vicinity
of accident site. In addition to these, numerous material handling systems, heavy
road transport, high-tension electric lines, level crossings, overhead cranes and
various other handling and transport systems always have chances of accidents.
Definition of Disaster
A situation will be called a `Disaster' if it entails any one or more of the following
factors:
i) Risks of loss of human lives - ten or more in one single situation.

ii) Loss of property as a consequence of the incident is over Rs.1 crore
and/or bears a potential to the above.
iii) A situation which goes beyond the control of the available resource of the
plant.
iv) A situation apparently may not have much loss but its long-term severity
can affect loss of life, production and property.
The types of possible disaster are given below:
Type of disasters
i) Disaster due to emergencies on account of:
- Fire
- Explosion
- Oil spillage
- Spillage of toxic chemicals
- Electrocution
ii) Disaster due to natural calamity on account of:
- Flood
- Earth quake / cyclone / Storm / Cloud burst / lightning
iii) Disaster due to external factors on account of:
- Food poisoning / water poisoning

- Sabotage
Objectives
Objectives of disaster control/management plan for existing Steel Plant are:
i) To identify type of major disasters which may occur in the plant?

ii) To collect data on type of disasters which has happened already in other
steel plants?
iii) An action plan to handle disaster.
Identification of Hazardous Process/Area
1. Furnaces area - Explosion

2. Fuel Oil tanks - fire & spillage
3. Turbine Hall – Explosion
4. Boiler Explosion
Electrical premises
1. Electrical Rooms - Fire & Electrocution

2. Transformer area - Fire & Electrocution
3. Cable Tunnel - Fire & Electrocution
Other premises
Storage facilities for coal and fuel oil -Fire/spillage
Level of Accident
If there is any disaster in any part of the plant /work place due to any reason the
area which may be affected can be classified in the following four classes.
1. Level I - Operator level

2. Level II - Local/community level
3. Level III - Regional/ national level
4. Level IV - International level

There is only level I and II class of accidents can be considered for the
steel plant.
Level I
Under this level, disasters may happen due to fire, explosion, oil spillage and
spontaneous ignition of inflammable materials.
This level has probability of occurrence affecting persons inside the plant. The
various shops, which have been mentioned as potential hazard areas, will be
affected during this level of accident.
Level II
In case of sabotage/complete failure of all automatic control/warning systems for

example in fuel oil storage area the oil kept in tanks and covered by tank bund
may leak out. However, the probability of this is very low due to adequate
security and training of persons of the plant operating such system.
Disaster Preventive Measures
If any disaster takes place it is not easy to control if contingency plans are not
available. For effective control of disaster adequate manpower, technical
know-how, alertness and internal help are necessary. It always betters to take
preventive measures to avoid any disaster. In proposed plant following
prevention measures will be taken to prevent disaster.

Plant layout:
i) Design, manufacture and construction of all plant and machinery’s and
buildings will be as per national and international codes as applicable in
specific cases and laid down by statutory authorities.
ii) Provision of adequate access ways for the movement of equipment and
personnel are kept.
iii) Minimum two numbers of gates for escape during disaster shall be
provided.
iv) Siting of fuel oil storage shall be in protected fenced area inside tank
bend.
v) Water spraying in coal storage area.
Fire Fighting
The existing plant is having a well-equipped fire-fighting group for the existing
steel plant with 5 Officers, 25 Workers trained in this field. Following fire-fighting
equipment shall be in place when the plant fully commissioned:
- Fire Tender 2 No.

- Jeep 4 Nos
- Portable Extinguishers Lot
- Foam generator Lot
- Static tanks Lot
List of Fire Extinguishers Required at Different Locations
Name of site Type

Kiln Area CO2 Foam type
Dry Chemical type

Name of site Type

IF & EAF Area CO2 Foam type
Dry Chemical type
Caster Area CO2 Foam type
Dry Chemical type
Turbo generator Area CO2 Foam type
Dry Chemical type
Cable galleries CO2 Foam type

Dry Chemical type
High voltage pannel CO2 Foam type

Dry Chemical type
Various control rooms CO2 Foam type

Dry Chemical type
Various MCC rooms CO2 Foam type

Dry Chemical type
Various pump houses CO2 Foam type

Dry Chemical type
Fuel Tank Area CO2 Foam type

Dry Chemical type
Sand Baskets
Guest Houses & offices Dry Chemical powder type

Name of site Type

Godowns Foam type
Crusher House CO2 Foam type

Dry Chemical type
However before installing fire station & safety equipment, an experienced fire
officer would be appointed who carry out an in-depth study and shall decide
about the selection of equipment.
Safety
The existing steel plant when fully commissioned will have a safety department
manned by experienced engineers and staff whose main job will be to bring
about safety consciousness amongst the work force in the plant. The safety
department will conduct regular safety awareness courses by organizing
seminars and training of the personnel among the various working levels.
Safety awareness will also be created by the various posters highlighting the safe
working practices in different shops, hazards in working area, public places and
roads etc. Safety engineers of the plant will conduct regular checks and mock
exercises on the safe working of their department and report will be given to
departmental head for corrective measures to improve the safety conditions.
Training
A department of training will also be set up to train officers. They will arrange
training on safety accident prevention, first aid, hazard control, house keeping

and environmental management. Special emphasis with mock drills in disaster

control will also be planned.
Communication
During the proposed modification-cum-expansion of steel plant there will be an

up-to-date communication facilities with telecommunication and wireless,
walkie-talkies, telecommunication and loud speakers in each shop, office and
gate to warm workers in case of an accident.
Organization to combat contingency
The contingency plan is prepared from the experiences of accidents that have
occurred in various other Steel plants. The contingency plan being a dynamic
plan will need periodical reviews and modifications with new experiences. Even
with all precautionary measures taken to avoid disaster, disaster may occur. To
tackle situations during and after disaster, a well-defined contingency plan is a
must. A Disaster Control Room (DCR) will be set up having links with all plant
control rooms. An officer will be manning the DCR. On getting information about
any accident, the officer will verify from the affected plant control room and inform
the Disaster Controller (DC) and/or other co-ordinators immediately.
The responsible officers of Disaster Control Group will assemble in the DCR and
formulate control procedures as per the contingency plans. The functions of the
various officers of the Disaster Control Group will be as follows:

Functions of Disaster controller
- To declare "Disaster Emergency" after consulting the Sr. officer available and
inform Fire Station Control Room to sound the sirens accordingly and arrange
to convey the message in public address system
- To report to DCR immediately.
- To receive messages from the communication center.
- To take decisions in consultation with the Commanding Officers of different

services and convey them to the disaster point.
- To be responsible for planning and provisions of assistance from township

and from local authorities.
- To keep higher authorities informed about the situation.
- The decision of the Disaster Controller on any matter to meet the objective of
disaster control plan will be final.
Functions of Officer In-charge:
Disaster Controller will nominate an officer whose functions will be as follows:
- To be responsible for the operation of DCR and for the dispatch of messages.
- To decide on the priority of dispatch of messages.

- To keep liaison with all activities and give up to date and accurate
appreciation of the situation.
- To be responsible for the efficient organization of the Disaster Control Room.
Functions of Commanding Officers of various services:
The Commanding Officers of various services are designated Coordinator

(services), Coordinator (Operation) and Coordinator (external services). The
following are their functions:
- To report to the Control Post immediately on hearing "Disaster Siren".
- To keep Disaster Controller posted with the up-to-date information regarding

manpower and material available concerning their respective services.
- To advise Disaster Controller on all matters arising out of disaster.
- To assist Disaster Controller for provision of material and man power

concerning his service.
- To convey message to his service teams through communication centre after

consulting Disaster Controller.
- To consult between themselves on matters related to more than one service

and to decide on the action to be taken.

Casualty services
The Commanding Officer of Casualty Services will be medical officer.
Functions
- First aid service by first aid parties on the spot.
- Ambulance service for transport of casualties from the spot to township

hospital and from township hospital to outside, if required.
Procedure for treatment
On getting a signal from the Disaster Control Room or information on telephone

or hearing siren, the Sub-Commanding Officer of the Casualty service will report
to hospital and doctor on call duty and first aid personnel will report to Disaster
Control Room. The Ambulance with the driver will report to Disaster Control
Room. First aid parties will render first aid to casualties at the place of
occurrence and those requiring further treatment would be transported to the
nearest hospital by ambulance.
In case of extra help from outside or within CMO would contact Co-ordinator
(Planning) for help in areas such as:
- Extra medical helps from neighboring hospital or main hospital.

- Evacuating the casualties.
- Essential assistance in first aid.

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

- To take immediate steps as may be necessary for the temporary support or

demolition of buildings and structures, the collapse of which is likely to
endanger life or obstruct traffic.
- To cut of supplies of water, steam & gas, electricity to damaged buildings /
structures.
Each rescue party will be provided with the following equipment:
1. Gas mask respirator

2. Fire proximity suits
3. Resuscitators
4. Petromax lamp, Torches
5. Axes/hand saw
6. Fire entry suits
7. Fire blankets
8. Ropes
9. Ladders
10. Rubber glove (Tested up to 25,000 voltage)
11. Blankets
12. Rubber shoes or Industrial shoes.
Repair services
- To take up quick repairs of the damaged machinery.

- To take up repair of damaged building roads and culverts.
- To maintain essential public utility services viz. water, electricity and sewage
system.

Fire fighting services
Fire officer will be the Commanding Officer of Fire Fighting Services. Additional
strength for fire fighting which is beyond the control of fire station will come from
security and maintenance personnel and if required form outside fire stations.
Functions
- To co-ordinate fire fighting activities

- To enforce all regulations for prevention of fire.
- To request neighboring industries and District Authority for rendering services
of their fire fighting crew under mutual aid schemes, if necessary.
Traffic control
The free movement of the fire vehicles and ambulance at the scene of
fire/emergency is very important and therefore, the security personnel on duty
must ensure that all the roads at the scene of fire/emergency are kept clear and
free from obstruction. Persons arriving by motor transport at the scene of
fire/emergency must not park their vehicles within 100 meters of fire, near fire
hydrants, at road junction and at access roads. The ignition key should be left in
the vehicles.
Training services
Functions
- To arrange training of volunteers/employees nominated by Commanding

Officers of various services.
- To arrange refresher training courses once in a year.
- To arrange mock drills, twice in a year.

- To make a list of employees trained in various specialized disasters so that
they can be easily contacted to handle a particular type of disaster. The
person concerned will immediately report to Disaster Control Room.
Faculty
Faculty will be consisted of commanding officers/sub-commanding officers and/or

their nominated officers.
Depot and Transport services
Functions:
- Dispatch of vehicle to the place of incident as per orders from the DCR.
- To get back the vehicle as soon as the work is completed.
- General administration of the depot including repair and maintenance of
vehicle.
- Storage maintenance and inspection of equipment.
- Maintenance of discipline and moral.
- Ensuring adherence to the depot duties.
- Welfare of personnel in the depot.
Vehicle repair
The Sub-Commanding Officer and his staff will promptly attend to all major
repairs of the essential vehicles under his supervision.

For carrying out minor repairs, vehicle repair party will be detained at the depot.
The party will be provided with a vehicle for quick movement.
Commanding Officer will evolve a system such that he is apprised of the

conditions of the vehicles scheduled at 1500 hrs. daily during peace time. This is
required so that the vehicles are available at a short notice.
Fuel
The Commanding Officer will contact Coordinator external services for

arrangement of fuel for vehicles during fuel crisis and stop supplying fuel to
vehicles other than those, which are in use for disaster control.
Supply services
A senior person will head supply service from stores department.
Functions:
- To be responsible for planning, organizing and procuring necessary

equipment/materials.
- To be responsible for storage of equipment/materials at accessible location
and for quick distribution on demand.
- To obtain the requirement of equipment / materials from Commanding
Officers of various services for their respective services.
- To co-ordinate with Commanding Officer of Depot and Transport Services for
transports required for distribution of equipment / materials in consultation
with DCR.

Salvage service
The salvage services will be under the charge of Committee. This committee will
be formed taking one person from stores and one from production.
Functions:
- To salvage properties from debris

- To take care of such properties
- To return the properties to respective shop in-charges.
- To co-ordinate patrolling with the help of, police and security personnel for the
safeguard of valuable properties till the same are removed to a safe place.
Welfare services
Management of proposed Steel plant will nominate one person from

administration side and he will be the Commanding Officer of welfare services.
Vacant buildings, schools complex and club will be used for housing those
rendered homeless. Emergency camps will be set up only in exceptional cases
on playing ground. For this purpose necessary material will be brought from
nearby market.
Functions:
- To provide shelters to affected persons.

- To arrange enough stock of essential commodities through co-operative
society.

- To arrange cooking of food in canteen supply to place where people are given
shelters in township. For plant people, food will be supplied within battery
area by mobile vans.
- If canteen is affected by disaster, the food will be cooked at school complex
and will be served as indicated above.
- To arrange clothing and medicines to affected persons. Doctor(s) will assist
for giving medicines.
To arrange drinking water, if supply is disrupted, with the help of District

Authorities.
Mobile canteen
One mobile canteen in a motor van/truck will be made available in the plant area.
The mobile van will be stationed in Depot.
Co-operative Society
There will be one cooperative society in township, which will be dealing in

essential commodities. The District authorities during any emergency will further
supplement the resources of this society.
Security services
Chief Security officer will be Commanding Officer, Security Services.
Functions:
- Security services will be primarily responsible for the security of the plant.
- Commandant in consultation with co-ordinator (external service) will keep a

close liaison with local police and district authorities.
- To control the vehicular traffic inside the plant.
- To help local police in patrolling the area of plant and outside the battery area,
necessary.
- To assist Fire fighting services in fighting fires.
- To assist in transporting injured persons.
- To assist local police in patrolling in township and work out adequate
arrangement for protection of property.
One jeep and one motor cycle will always be kept as reserve to cope up with
emergency demand and for immediate mobility of security personnel.
Crash shut down of Units
Section head will be the Commanding Officer for Crash Shut down of the units,
which are affected and may further aggravate disaster.
Function
To shut down the unit(s) affected and which may cause further disaster.
Public Relation Service
The Officer-in-Charge of Public Relation Services will look after this job.
Functions
- To consult DC before communication, if required with outside agencies.

- PRO will be the official spokesman for the steel plant with outside agencies.
- PRO will arrange for photography and filming of the whole disaster as
photography and filming of such incidents are of immense value for the
purpose of investigation, training and education.
.
Contingency Plan
The following contingency plan shall be followed:
Fire and Explosion
- Plant fire fighting is activated.
- Disaster Controller along with Commanding Officers takes overall charge of

the situation.
- DC will assess the situation for possible after effects of the fire in the plant
and the surrounding areas likely to get affected.
- DC will inform local authorities to send fire tenders, if necessary.
- DC will inform the people of likely affected areas through communication

system to leave the area and move to other areas earmarked, if necessary.
- DC will inform co-ordinator, external services to inform the District authorities

of the disaster and request them for help.
- To evacuate people from the affected areas outside the plant.

- To control the traffic and law and order.
- To arrange medical aid for the affected people.
- DC will arrange inspection of affected areas to get first hand knowledge of

damages occurred.
Alarm System
On receiving the message of `Disaster' from Disaster Controller, fire station

control room attendant will sound SIREN WAILING TYPE FOR 5 MINUTES. DC
will arrange to broadcast disaster message through Public Address System.
On receiving the message of "Emergency Over" from DC the fire station control
room attendant will give All Clear Signal by Sounding Siren straight for two
minutes. The features of the alarm system will be explained to one and all to
avoid panic or misunderstanding during disaster.
Actions to be taken on hearing the warning signal
On receiving the message of "Disaster" the following actions will be taken.
- All the co-ordinators will report to the Disaster Control Room even if not
contacted by the Cell :
- The Commanding Officers and Sub-Commanding Officers will report to the

place of accident.

- The Process Unit persons will remain ready in their respective units for crash
shut down on the instruction from the co-ordinator.
- The persons from other sections will report to their respective officer.
- The concerned section (Civil, Engineering Services, Mechanical, Project etc.)

will take immediate action to remove contractors personnel outside the plant
gate.
- The residents of the township will remain alert.
Disaster due to natural calamity and external factors
Most of the measures & processes shall be same as given under in-house
disaster except that the disaster controller will contact the state / district
authorities for necessary instructions to co-ordinate with them.
Chemicals/Oil spillage
The possibility of large chemical/oil spillage in the final effluent discharged in

reservoir is remote. However, DC will arrange to inform the following:
- State Pollution Control Board
- District authorities and request them to arrange patrolling of the area along
with security personnel.
- District authorities, to warn people in the affected area against fire/hazard that
may occur and against the adverse effect of using water for any purpose.
- Disaster Controller along with Commanding Officers takes overall charge of

the situation.
- DC will inform the people of likely affected areas through communication

system to leave the area and move to other safe areas earmarked.
- DC will inform co-ordinator, external services to inform the District authorities

of the disaster and request them for help.
- To evacuate people from the affected areas outside the plant. -To control the
traffic and law and order.
- To arrange medical aid for the affected people.
- DC will arrange inspection of affected areas to get first hand knowledge of

damages occurred.
Cloud burst/lightning
Cloud burst/lightning may lead to a situation, which could be minor to major

emergency. In such emergency, actions indicated under fire and explosion will be
initiated.
Food poisoning
In case of food poisoning in plant canteen the following actions will be taken:
- DC will inform the medical officer of steel plant health center for immediate
first aid.
- DC will contact District Authorities and seek their help, if necessary.
- Security Personnel and employees will help in evacuating the affected people
to various hospitals.

8.0 SOCIO-ECONOMIC IMPACT ASSESSMENT
8.1 General
Present Scenario
Socio-economic development is closely linked with the growth of industrialization. This

necessitates the development of various types of industries as the economy passes
through different stages of development. A project is a cash flow which in fact puts a
break in investment flow of a region. Such investment may be widespread impact on
the socio-economy of the area surrounding it, through multiplier and linkage effects.
At the same time possibility of some adverse impact can not be ruled out. Therefore, a
thorough socio-economic impact assessment is required for any such project /
investment. Bhusan Steel & Strips Limited has proposed to modify and expand the
existing steel plant near Angul, Orissa. The project involves substantial investment to
which the local people have strong adherence due to some obvious impact on their
socio-economic conditions. Accordingly, it is necessary to carry out a detailed socio-
economic impact assessment of the project. On this backdrop, the present study is
directed towards the following objectives:
Objective
• To assess the impact of the project on agricultural situation;

• To examine the impact of the project on pattern of demand;
• To assess the in impact of the project on consumption pattern;
• To examine the employment and income effects of the project;
• To explore the possibility of local industrialization as an offshoot of the project;
• To examine the effect of the project on education status of the people in the study

area; and
• To judge peoples' perception regarding the project.
8.2 The Study Area & Analytical Framework

In the present investigation, the study area is considered as the circle with 7 km with
centre at the project site. Major portion of the study area falls under the Dhenkanal
district while the smaller part is in Angul district. Table-8.1 depicts a synoptic view of
the basic statistics of the study area. The population of the area is around 23293 with
a density of 151 persons per square km.
Table-8.1: Estimated Population and Occupational Pattern of the Study Area

(Nos)
Item up to 0.5 kms 0.5 - 3 kms 3 - 7 kms Total
1. Population 94 3713 19486 23293

Total Including
Male 49 1912 10035 11996
Female 46 1801 9451 11297
SC 16 624 3274 3913
ST 11 434 2280 2725
2. Households 17 675 3543 4235
3. Literate 49 1913 10041 12003
4. Occupational pattern
a) Main workers 35 1366 7171 8572
i) Cultivators 13 505 2650 3168
ii) Agricultural labourers 12 486 2553 3051
iii) Workers in household 2 59 312 373
industry

Item up to 0.5 kms 0.5 - 3 kms 3 - 7 kms Total
iv) Other workers 8 316 1656 1980

b) Marginal workers 5 204 1072 1281
Total working population (4) 40 1570 8242 9853
Land use pattern of the area is given in Table-8.2. It is observed that forest cover is
quite high on around 15.4% of the land in the study area. Net Sown area constitutes
about 39% of the area. Among other categories misc. trees, permanent pastures,
barren, fallow are worth mentioning.
Table-8.2: Land use of the study area
Sl. No. Type of land Study area % of total

1 Forest land 23.7 15.4
2 Misc. trees 7.7 5.0
3 Permanent pastures 5.2 3.4
4 Culturable waste 4.5 2.9
5 Land put to non agriculture use 8.6 5.6
6 Barren 5.9 3.8
7 Current fallow 2.6 1.7
8 Other fallow 3.4 2.2
9 Net Sown Area 60.7 39.4
10 Others 31.8 20.6
Total 154.0 100.0

8.3 Analytical Framework
Sampling
The study area is divided in to three strata --- (i) within 0.5 km radius circle centering
the project site, (ii) area between 0. 5km radius circle and 3 km radius circle and (iii)
area between 3 km radius circle and 7kms radius circle. A sample of 40 respondents
is selected using two-stage stratified random sampling technique. In the first stage
villages are selected and in the second stage, the respondents are selected at random
from the selected villages.
Respondents have been interviewed with the structured questionnaire specially

designed for this study keeping in view the objectives. Major constituents of the
questionnaire are as follows:
1. Cropping pattern
2. Crop productivity
3. Cost of cultivation
4. Net return from crops
5. Household budget
6. Consumption pattern
7. Peoples' perception about the project etc.
Methodology
The major methods used as tools of analysis in this study are as given below:
1. Regression: Simple linear regression of the following type in considered

Yi = a + b Xi + Ui (Where, U is the stochastic error term having its usual properties)
The model is fitted to data applying Ordinary Least Square (OLS) to obtain
estimated demand and consumption functions.
2. Fitted regression models is used to work out
i) Elasticity of demand with respect to disposable income (e) in case of

demand functions :
e = (dy / dx) . (y/x)
ii) Marginal propensity to consume (MPC) from consumption function :
MPC = dC / Dy
3. Frequency distribution of peoples' perception, educational status, land holding

etc
8.3.1 Agriculture Situation

Agriculture is a major source from which people of the area derive their income.
However, the climatic condition and the quality of soil of the area are not suitable for
developed agriculture. Table-8.3 represents the cropping pattern in the study area.
From the table it is evident that paddy is the main crop produced. Paddy is grown on
about 67% the Gross Cropped Area (GCA). Other than paddy, maize is grown on
1.4% of the area.

Table-8.3: Cropping Pattern & Cropping Intensity

Sl No Crop Area covered in GCA (%)
1 Paddy (Kharif) 66.8
2 Maize 1.4
2 Others 31.8
TOTAL 100.0
Table-8.4 depicts productivity of crops. The productivity figure for paddy is found to be
quite low and much below state average. Productivity of maize is 0.1 qtl/ac.
Table-8.4: Crop Productivity
Sl. No. Crop Productivity (Qtl./ac.)

1 Paddy 9.5
2 Maize 0.1
Table-8.5 presents average investment in agriculture, net return and cropping

intensity. It is observed that agriculture is still profitable in this area as net return from
agriculture is positive (Rs 3230 per acre). The cropping intensity is quite low (128.5%).
This indicates backwardness of agriculture. Scanty rainfall, scarcity of irrigation water
and low quality soil permitted them to produce only a few crops
Table-8.5: Cost of Cultivation, Net Return And Cropping Intensity
Sl No Item Quantity
1 Investment in agriculture (Rs/acre) 1145
2 Net return (Rs/acre) 3230
3 Cropping intensity (%) 128.5

8.3.2 Consumption Behaviour
Table-8.6 presents the source-wise distribution of average family consumption. It is

observed that the major portion of consumption (65.8%) goes to meet the need for
food items while clothing constitute 14.0% and medical expenses 3.9% of the total
consumption.
Table-8.6: Source-Wise Distribution of Family Consumption

Total Food Education Clothing Medical Others Total
Average family consumption 21643 878 5250 2629 7357 37257
(Rs/yr)
Percentage Distribution 58.1 2.4 14.1 5.7 19.7 100.0
8.4 Anticipated Socio-Economic Impacts

The survey reveals that the respondents spend major portion of their disposable
income on food items. However, there has been a growing tendency among the
respondents, of higher expenditure allocation on non-food items although their
basket of consumption has only few items other than food. To go to the details of
their pattern of demand, income elasticity of demand is calculated by fitting demand
functions. Table-8.7 presents the results of the regression analysis conducted for
fitting the demand functions. It is observed that all the demand functions give
uniformly good fits to the data because R2 in all the cases is found to be quite high.
Moreover, as indicated by t-test, the relevant parameter of the demand functions is
found to be statistically significant at 1% level. The income elasticity of demand as
measured from the fitted functions are 0.83 and 0.86 for food and non-food items
respectively. The inelastic demand for food and non-food items indicates their strong
necessity of these items. The higher magnitude of elasticity in case of non-food
items is indicating their tendency to shift the demand in favour of non-food items as
their income increases.

Table-8.7: Demand Functions For Food And Non-Food Items

Form of the fit Item Regression parameters
ln a b R2
Dij = a * Ybj * U Food 0.336 0.834 0.9604
(Where, (17.05)*
Dij = Demand for the ith item by Non- 0.371 0.857 0.9743
jth respondent. food (21.3)*
Yj= Disposable income of the jth
respondent
Figures in ( ) indicate t - values * Significant at 1% level.
Hence, the impact of the project on the pattern of demand can be reasonably
predicted as a shift from food to non-food items i.e., a consumer behaviour which
may closely follow the Engel law. This is not a bad indication provided considerable
income is earned by them; otherwise, if the shift is a substitution of necessary food
requirements then it is not desirable in true socio-economic sense.
8.4.1 Agriculture Situation

Overall assessment of the agricultural situation of the area reveals that agriculture is
still quite backward in this area. Constraints of such backwardness as reported by the
farmers are scanty rainfall, lack of irrigation water, unproductive soil and the major one
is lack of credit. Majority of the farmers opined that unproductive land is the most
important among these constraints. Keeping this in mind, it can be concluded that
even if some irrigation facilities are provided/extended in this region, agriculture will
still continue to be traditional.
Given the persistent nature of backwardness of agriculture, it can reasonably be

argued that the project is not going to cause significant damage to it. Hence, the
project will not have much of adverse impact on the existing agricultural situation of

this area. Instead, the industrial project is likely to provide the farmers with
supplementary income, which appears to be essential for raising the standard of living
of the people of the study area.
8.4.2 Consumption Behaviour

To investigate the consumption behaviour of the respondents in detail, Marginal
Propensity to Consume (MPC) is calculated by fitting the consumption function. The
results of the regression analysis performed for fitting the consumption function are
presented in Table-8.8. It is observed that the function gave uniformly good fit to
data because R2 is high and parameters are also found to be statistically significant
at 1% level. The MPC worked out on the basis of the fitted consumption function is
0.642.
Table-8.8: Fitted Consumption Function
Form of the fit Regression parameters

a b R2
Cj = a + b Yj + Uj 5039.7 0.642 0.977
Where, (22.5)*
Cj = Consumption of the jth respondent
Y = Gross income of the jth respondent
Figures in ( ) indicate t-values * Significant at 1% level
Effort is taken here to work out the multiplier effect of investment on the people of
the study area. The calculations are done using the following model:
Let us consider that the consumption behaviour of the respondents closely follow the
following type of consumption function:


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

unskilled labour. Thus, substantial amount of employment and income are expected
to be generated for the local people. Hence, it can be ascertained that the project is
going to have significant employment and income effects.
Indirect employment
In the case of indirect employment also, the effect is quite strong and widespread.
Besides direct employment, the project is expected to generate substantial indirect
employment in other sectors. So far indirect employment is concerned, the effect is
very strong and widespread specifically, in ancillary industries, service and transport
sectors. In view of the above, it can be justifiably concluded that the present project
has tremendous positive employment and income effects.
Overall assessment of the employment and income effects indicates that the project
has strong positive direct as well as indirect impact on employment and income
generation.
8.4.4 Educational status

The existing educational status of members of the sampled households is depicted
in Table-8.9. The table revealed that about 55% of total members in the sample are
illiterate. This figure includes the non-school going children also. About 13% of the
members have education at primary level. Middle school level educated people
constitute around 14%. Persons with high school and intermediate level education
are observed to be around 9%. The study area has some highly educated persons
(i.e., Graduate, PG and technical).
As reported by the respondents during field survey, their interest towards education
has been increasing due to hope of getting employment which may come up
especially in the non-agricultural sectors in this region, as an indirect impact of this

project. The general awareness towards the importance of education is expected to

increase as a result of the new project and hence, it can be said that the project has
a strong positive impact on the level of education of the people of the study area.
Table-8.9: Educational Status of the people of the Study Area
Sl. No Level of education No (% in total)

1. Illiterate* 169 (54.9)
2. Primary 39 (12.7)
3. Middle school level 42 (13.6)
4. High schooling and intermediate 30 (9.7)
5. Graduation 17 (5.5)
6 PG 5 (1.6)
6 Technical 4 (1.9)
Total 308 (100.0)
* Includes non-school going children
8.4.5 Peoples' perception

Peoples' perception regarding a project is as important as the impact of the project.
So, it is worthwhile to examine what people perceive about the project. To fulfil this
objective, an opinion poll was conducted. The results of the poll are analysed and
furnished in Table-8.10 It is observed that 85.0% of them have identified the direct
and indirect employment opportunity due to the project. Opportunities of business
development is pointed out by about 32.5% of the respondents. 15 % of them have
identified industrialisation in the area as an advantage. Along with the growth of
industrialisation the entire area will be more urbanised. 10% of the respondents feel
increase in urbanizatin of the area.

On disadvantages, about 55% of the respondents have cited pollution as the major
factor. Around 45% of the respondents seem worried about adverse impact of the
project on health of people. The problem related to scarcity of water and displacement
of people are pointed out by around 27.0% and 23.0% of the respondents
respectively.
Table-8.10: Peoples' Perception

Perception Respondents
ADVANTAGES
1 Employment 34 (85.0)
2 Business development 13 (32.5)
3 Industrialisation 6 (15.0)
4 Urbanisation 5 (12.5)
5 Development of the area 6 (15.0)
DISADVANTAGES
1 Pollution 22 (55.0)
2 Health damage 18 (45.0)
3 Scarcity of water 11 (27.5)
4 Displacement 9 (22.5)
[ Figures in ( ) indicate % in total no. of respondents. Individuals have spelt

out more than one advantages / disadvantage ]

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

spontaneous support for the project as they foresee relatively more
advantages for the people of the study area.

9.0 ORGANISATION AND MANPOWER
Bhushan Steel & Strips Limited (BSSL) shall have Environmental Management
Division (EMD) at plant level as well as at corporate level for interaction with
statutory bodies and managing environmental issues at plant level. Executive
Director (works) of plant operation is the head of the plant level pollution control cell
with Environmental Engineer, Chemist, etc. The plant level EMD will be provided
with well-equipped laboratory for carrying out analysis of the samples of the water,
air etc. Plant EMD will carry out the monitoring of the stack emission, noise level,
analysis of the water etc. and keep the regional / local statutory body informed about
the status of pollution control with intimation to the Corporate office EMD. BSSL will
arrange professional training for personnel of EMD at plant level. The proper training
shall be provided in area of monitoring and continuous analysis of the pollutants,
legal requirement and environmental management system.
9.1 Organisational Set Up
Environmental monitoring and reporting has been designed to provide a close

watch on the surrounding natural environment and provide early warnings of
any adverse changes that may be related to some dimension of the plant’s
operations.
Organisation motto
The importance of environmental control has been recognised by BSSL and it has
taken necessary steps to identify and control pollution in the plant, respond to
impacts on its own captive population and also in the peripheral areas.

A. The above objective has been intended to be achieved through the following:
i) Improvement in the quality of raw materials.

ii) Best available technology for manufacturing operations in steel plant,
iii) Using automation & Computer control to have improvement on technology and
on working condition,
iv) Pollution Monitoring and Control,
v) Occupational health set up including regular medical monitoring of employees,
vi) A well developed safety management organisation,
vii) Preparation of Emergency/Disaster Control plan and a properly trained group to
meet the emergency situations,
viii) Green belt development inside the plant and township.
ix) Development of awareness in employees and public including student
population towards environmental preservation,
x) R & D activities in regard to specific pollution problems.
B. The following strategies are being employed to meet the above objectives:
a) All new units coming under expansion would be environmentally audited to

meet the pollution control standards.
b) As environmental management is also associated with optimum energy
utilisation & water conservation, all steps are taken to optimise the conservation
of energy and consumption of water.
c) The pollution control systems are operated and maintained as per technological
norms.
An Environmental Management Division (EMD) will co-ordinate with other

departments like Safety Management, Project Engineering, and Community
Development under Chief Town Administrator, Water Supply Department etc. and

also do the liaison work with external agencies like State & Central Pollution Control
Boards and Corporate Office.
A senior officer of the rank of Deputy General Manager (DGM), shall be the
head of the EMD. In his day to day work, he shall be assisted by
Environmental Engineers, Chemists and Laboratory Assistants. The DGM
(EMD) reports to the General Manager (EMD), who in turn reports to the
Executive Director (Works). A tentative Organisation Chart of the EMD is
given as Fig. 9.1.
9.2 Man Power
EMD is manned by adequate staff. Services of retired forest officials may be

taken for effective implementation of plantation schemes. For development
and maintenance of jobs like drainage, settling tanks etc. assistance from the
projects civil engineering department shall be taken.
9.3 Training Facilities
For the proposed project, additional training facilities will be developed for
environmental control. Specialized courses at various Research/ Educational
institutes will be organized. Training will cover the following fields:
• Awareness regarding Pollution Control and Environmental protection.

• Operation and maintenance of pollution control equipment.
• Afforestation / plantation and post care of plants.
• Field monitoring, maintenance and calibration of pollution monitoring
instruments.
• Chemical analysis of various environmental parameters at laboratory.

• Repair of pollution monitoring instruments.

• Knowledge of norms, regulations and procedures.
• Occupational health and safety.
• Risk assessment and Disaster Management Plan.
Executive Director
(Works)
General Manager
(Environmental Management Division)
Dy. General Manager

EMD(1)
Lab Chemist Field Assistant

(05 Nos.) (AAQ Monitoring Staff)
Lab Assistant (05 Nos.)
(03 Nos.) Ash Dump Area
(06 Nos.)

10.0 ENVIRONMENTAL COST & PROJECT BENEFITS
10.1 Environmental Cost Component
The project cost has been estimated to be Rs. 63300 Million (Rupees Sixty three
thousands three hundred million). The capital cost of environmental mitigation
measures is estimated to be Rs. 3481.5 Million, which includes:
Cost Of Air Pollution Control Systems : Rs. 1393.0 million

Cost of Water Pollution Control : Rs. 0870.0 million
Cost of Solid Waste Management System : Rs. 1045.0 million
(Including cost of dust storage with bund)
Green belt development : Rs. 0033.5 million
Environmental Monitoring Lab Development : Rs 0070.0 million
Social Institutional Development : Rs 0070.0 million
Since Bhushan Steel & Strips Limited will be getting part of necessary
environmental monitoring requirement carried out by an external agency, capital
cost towards part of environmental monitoring facilities and occupational health
of personnel is not required.
The estimated annual cost of environmental mitigation measures for the

proposed modification-cum-expansion units has been estimated to be Rs. 350.0
Million. The annual estimated environmental mitigation costs include:
Cost of Air Pollution Control : Rs. 140.0 million

Cost of Water Pollution Control : Rs. 087.5 million
Cost of Solid Waste Management : Rs. 087.5 million
Cost of Green Belt Maintenance : Rs. 003.5 million

Cost of Environmental Monitoring : Rs. 014.0 million

Cost Towards maintenance of
Social infrastructure : Rs. 017.5 million
TOTAL : Rs. 350.0 million
10.2 Improvement In The Physical Infrastructure
Road
Improvement and extension of the existing network is, essential to develop
remote areas, better connection between the economic centers of state, and also
cross-border transport and for personal mobility of the masses.
Rail Network
Railways provided an important mode of transportation in the public sector
spreading over the entire country. It contributes to the country’s economic
development by catering to the needs of large-scale movement of freight as well
as passenger traffic and is a major source of promoting integration among the
masses. Railway provides transport facility to people and handles freight above
600 million tons annually. The Indian railway is intended to modernize the vast
railway network, keeping both the economic and social dimensions in mind.
10.3 Improvement In The Social Infrastructure

The project investment will vastly accelerate the development and use of the
country’s irrigation potential. But even after this, two-fifths of cultivated area will
still be rain-fed.
The BSSL will launch a special programme so as to ensure each household in

the surrounding village will have full access to reliable power in the next two to

three years. The private sector has a crucial role to play in power generation and
takes on an increased role in power distribution.
In order to supplement water availability and recharge the country’s groundwater

resources, a local community-based Rainwater Harvesting Programme will be
launched to capture at least an additional 1% of local rain resources every year.
BSSL will launch Social housing schemes in the surrounding village to meet the
needs of the local poor.
10.4 Employment Potential

It generates employment both directly and also due to development of
downstream industries. During the construction period, the project is going to
create substantial employment and income. A large portion of these is likely to
trickle down to the local people. Besides this, some persons from the study area
may get employment on permanent basis for actual operation of the plant in the
form of skilled or semi-skilled, or unskilled labour. Thus, substantial amount of
employment and income are expected to be generated for the local people.
Hence, it can be ascertained that the project is going to have significant
employment and income effects. The estimated manpower requirement at the full
development stage of the integrated complex has been estimated to be 2827.
Category wise breakup of manpower is indicated in the table:

1 Managerial 29
2 Executive 310
3 Skilled 938
4 Semi-skilled 735
5 Unskilled 775


6 Clerical 40
Total : 2827
In the case of indirect employment also, the effect is quite strong and
widespread. Besides direct employment, the project is expected to generate
substantial indirect employment in other sectors. So far indirect employment is
concerned, the effect is very strong and widespread specifically, in ancillary
industries, service and transport sectors. In view of the above, it can be justifiably
concluded that the present project has tremendous positive employment and
income effects. Overall assessment of the employment and income effects
indicates that the project has strong positive direct as well as indirect impact on
employment and income generation.
10.5 Other Tangible Benefits
The other tangible benefits will be in the form of plant township hospital and
schooling facilities which will also help local population to enjoy the fruit of better
facilities in nearby.

11.0 CONSULTANT CREDENTIALS
MECON LIMITED is a Public Sector Undertaking under Ministry of Steel,

Government of India, as one of the leading design, engineering and consultancy
organizations, with extensive in house and overseas experience. MECON has
wide exposure and infrastructure for carrying out detailed design engineering,
consultancy and site services or any other technical services for various sectors
including iron ore mining and steel.
MECON’s services include the whole range of work relating to setting up of

projects in the field of infrastructure, power, metallurgy both ferrous & non-
ferrous, chemicals/ petrochemicals and allied engineering complexes including
specialized fields such as hydro engineering, sewerage scheme, sewage
treatment, industrial effluent treatment, solid waste disposal including municipal
waste disposal system, ports, defense projects, mints/ currency note presses,
environmental engineering, system engineering, etc. Because of being under
Ministry of Steel MECON has wide exposure in iron ore mining in India and
abroad. MECON was involved in the planning stage of a number of important
iron ore deposits in India.
MECON is registered with World Bank, ADB, EBRD, African Development Bank,
UNIDO, etc. MECON has collaboration agreements with the leading firms from
USA, Germany, France, Italy, erstwhile U.S.S.R etc. in various fields and
possesses process know-how & intend to make alliances & agreements to pool
up and offer the best resources as may be available for specific requirement.
MECON is the first engineering & consultancy organization in the country to be
accredited with ISO: 9001 by RW TUV of Germany in the field of design,
engineering, consultancy, contracting & supplying, inspection and project
management services.

MECON’s Engineering Resources
MECON has a large set up with about 1900 strong workforce, of which about
1600 are graduate/ postgraduate engineers and technical staff in 39 technical
disciplines. We possess our own in-house mainframe computer and host of
LANS, mini computers, PCs, latest facilities of CAD/ CAM and other design &
engineering aids. MECON is equipped with laboratories including electro-
technological laboratory (ETL), environmental laboratory and R & D laboratory
and E-Mail connectivity though VSAT of NICNET.
With head office at Ranchi; 6 regional engineering offices at Bangalore, KolKata,

New Delhi, Hyderabad, Chennai and Mumbai, 15 project site offices and liaison
offices spread all over the country including Pune, Raigad & Mehsana , MECON
can assist very effectively in executing projects.
11.1 Environmental Engineering Division of MECON
Environmental Engineering Division of MECON provides specialized services

starting from project conceptualization to commissioning of pollution control
system. The services include base line data generation, Environmental Impact
Assessment studies and formulation of Environmental Management Plan, safety
audits & disaster management plan, toxic & hazardous waste inventory &
management and solid waste disposal, industrial effluent treatment, domestic
sewage treatment & disposal system, dust extraction & dust suppression
systems and other air pollution control system.
A large number of our environmental engineers/ scientists have been trained in

UK, USA, erstwhile USSR, Canada, Japan and Germany. They have also
assimilated the latest knowledge by extensive association with various foreign

companies including WYLE Laboratories-USA, Metchem-Canada, Cremer &

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

MECON does possess a record of successfully undertaken development of clean

technology and environmental standards for Coke-oven plants and also
development of clean technology in the areas of iron ore beneficiation.
We are confident that with MECON’s established track record & long experience
in design, engineering & consultancy of various projects and extensive
experience in executing sizable environmental and mining assignments in India
and abroad, we shall be able to meaningfully contribute and supplement client
team in order to realize their endeavor successfully.

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BHUSHAN STEEL AND STRIP LIMITED

EIA / EMP FOR 3.1 MTPY INTEGRATED STEEL PLANT

EIA / EMP FOR 3.1 MTPY INTEGRATED STEEL PLANT

11.S2.Q6BK September’ 2007

Sl. Description Page No.

2. PROJECT DESCRIPTION & ANNEXURES 2 – 1 to 2 – 31

3. PRESENT ENVIRONMENTAL STATUS & ANNEXURES 3 – 1 to 3 – 22

4. ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION 4 – 1 to 4 – 28

5. ENVIRONMENTAL MANAGEMENT PLAN (EMP) 5 – 1 to 5 – 30

6. EMP IMPLEMENTATION AND MONITORING. 6 – 1 to 6 – 8

7. DISASTER MANAGEMENT PLAN (DMP) 7 – 1 to 7 – 24

8. SOCIO-ECONOMIC IMPACT ASSESSMENT 8 – 1 to 8 – 15

9. ORGANISATION AND MANPOWER 9 – 1 to 9-4

10. ENVIRONMENTAL COST & PROJECT BENEFITS 10 – 1to 10 - 4

11. CONSULTANT CREDENTIALS 11-1 to 11-4

© 2007 MECON Limited. All rights reserved (i)

Fig. Description Chapter No.

3-1 WIND ROSE DIAGRAM (3 SHEETS) 3

4-1 FLOW CHART OF IRON MAKING PROCESS 4

4-2 ISOPLETH OF SPM, SO2 & NOx 4

© 2007 MECON Limited. All rights reserved (ii)

© 2007 MECON Limited. All rights reserved 1-1

However, any industrial development process is accompanied by some

Setting up of an industry has both positive and negative impacts on the

1.2 Purpose of the Report

© 2007 MECON Limited. All rights reserved 1-2

adverse impacts and to maximise beneficial impacts. The following major

y Assess the existing status of environment.

In pursuance of Government of India Policy, under ‘The Environment (Protection)

© 2007 MECON Limited. All rights reserved 1-3

An in-depth analysis of the baseline environmental data generated by actual field

1.3 Project & Project Proponent

© 2007 MECON Limited. All rights reserved 1-4

1.4 Nature, Size, Location of the Project

The site is located between latitude 20°46’41” to 20°49’20” N and longitudes

1.5 Project Importance to the Country/Region

© 2007 MECON Limited. All rights reserved 1-5

to contribute to state as well as to national exchequer by way of taxes in the form

1.6 Scope of Study

This report shall contains various information’s on the existing environmental

© 2007 MECON Limited. All rights reserved 1-6

© 2007 MECON Limited. All rights reserved 1-7

• Environmental Management Plan(EMP)

© 2007 MECON Limited. All rights reserved 1-8

2.0 PROJECT DESCRIPTION

2.2 Type of Project

2.3 Need for the Project

© 2007 MECON Limited. All rights reserved 2-1

Domestic Market Growth Outlook

© 2007 MECON Limited. All rights reserved 2-2

2.4 Location (Maps Showing General Location, Specific Location, Project

2.5 Size or Magnitude of Operation

2.6 Schedule for Approval & Implementation

© 2007 MECON Limited. All rights reserved 2-3

Coal Washery (2.4 Mtpy)

In addition to the above main technological units, suitable supporting facilities

© 2007 MECON Limited. All rights reserved 2-4

2.7 Technology and Process Description

© 2007 MECON Limited. All rights reserved 2-5

xvii) Required services and auxiliary facilities

The total plant schedule was expected to be completed by 2005 – 06.

Proposed Modification-Cum-Expansion of Plant

• One blast furnaces of capacity 1681 m3 instead of 1250 m3 earlier proposed